Hi everyone, today we are going to be looking at the Robot Packing PLC program development
The Machine Simulator, or MS, is a valuable component of the EasyPLC software suite
It offers a range of built-in machines including the Robot Packing machine, which effectively
demonstrates various programming techniques. We will use the CLICK PLC programming software to showcase a sequencer application for this example
In this scenario, the robot is tasked with collecting five bags and loading them onto
a cardboard box. A logical sequence of steps will be implemented to accomplish this, with the counter controlling
the progression. This fundamental approach to programming sequencers applies to all PLCs
To program the EasyPLC Robot Packaging Machine Simulator, we will use the free CLICK programming
software and a CLICK PLUS PLC. Interference between the software and the PLC will be established using Modbus TCP or Ethernet
The program sequencer offers a convenient and effective means of controlling the automation system
We will follow the five program development steps to guide you through the process
These steps will provide a clear and structured approach to programming the sequencer
With that said, let's dive right in and begin our journey into the world of Robot Packing
PLC program development. Detailed information contained in this video can be found at accautomation.ca
A link has been put in the description below. If you have not watched the other videos yet, there will be links in the description below
that will start you with video 1. There will be links to the rest of the videos in the series as well
Step 1. Define the Task The first step of a CLICK or any PLC program development is to determine what must be done
Start the EasyPLC Machine Simulator or MS. Click the Start button on the main page or select Machines from the main menu at the
Machine Simulator window. All of the available machines will now be displayed
Click on the 30 Packing Auto. This is the example we will be programming
To the left of the screen, information will be displayed on how the robot packing machine
needs to function. A conveyor belt supplies bags containing food that must be packed into cardboard boxes
Another belt supplies the cardboard boxes to fill the food bags. The objective is to manipulate the automatic packaging system to fill each cardboard box
with 5 food bags. The packing robot has two working modes, continuous loading or loading in different positions
In the continuous work mode, the PLC must indicate a lowering speed to match the rate
of supply of food bags. In the position mark mode, once each bag has been loaded, the PLC must indicate new loading
positions to the robot so that it lowers and a new bag can be loaded
Use the two photo cells installed on the bag conveyor to give the appropriate instructions
to the packing robot. Once the 5 bags have been loaded, the bag conveyor must be stopped and the robot clamping
system must be closed so that the bags do not fall when they are inserted into the cardboard box
At the same time, the PLC must manage the cardboard box conveyor to position it correctly
in the loading position, stopping the advance with the stop cylinder rod and using a pneumatic
blocker so that the box does not move during the loading operation
Once loaded, release the box to load a new empty one. The robot packing machine simulator has a demo mode for this built-in machine
This will allow you to watch the operation of the robot packer. Select the demo mode for the packing auto robot
The demo mode will show you the basics of the robot packing operation
Move around this 3D virtual environment. The icons on the top of the window will allow you to move around this 3D environment
The first icon is the default selection. This will enable you to move around without bumping into components
The last icon will automatically show you around this virtual environment. The first mode will mimic a person in your 3D learning world
The third person will show you an operator and their relationship to the auto packing machine
Once we understand what must be done, we can move on to the next step in developing the
CLICK PLC program. Step 2. Define the inputs and outputs
At the bottom of the machine simulator window, the VUIO will display the inputs and outputs
required for this robot packing example. While still in demo mode, we can see the operation of the inputs and outputs
The EasyPLC-30 packing auto will require 12 digital outputs and 13 digital inputs
If you are unsure of what an input or output is doing, start the robot packing machine
in start mode
Select the VUIO at the bottom middle of the auto packing machine simulator window
You can manually run the auto packer without any control or PLC connected
Clicking on the outputs will allow you to turn them on manually. You can then monitor the inputs to see their operation
The reset button at the bottom of the machine simulator window will reset the machine back
to the start. Step 3. Develop a logical sequence of operation. A flowchart or sequence table is used to understand the process that must be controlled thoroughly
It must also answer questions like what happens when electrical power or pneumatic air is lost
What happens when inputs and output devices fail? Do we need redundancy
This step is where you will spend most of your time. Understanding everything about the operation will save you time
It will help prevent you from continuously rewriting the PLC program logic
Knowing all these answers up front is vital in developing the PLC program
Our CLICK PLC robot packing example will break down into two basic parts
The conveyor controlling the empty box and the robot collecting the bags
When the start button is selected, the box conveyor will make a box and position it for
the robot to fill the bags. When the box is filled with the bags, it is sent down the conveyor belt and another box
is positioned for the robot. Our sequence table for the robot will show the input signals to the left side and the
output signals to the right. The value of the counter is shown with each step
Each step will show the conditions that need to occur for the next step to operate
A PLC programmer must know everything about the sequence and operation of the machine
before programming. Ask questions or view existing documentation to ensure you know the logical steps to the
machine's operation. Step 4. Develop the CLICK PLC program
The next step in our program development will be writing the ladder logic code for the CLICK
PLC example. We will use the free CLICK programming software with the CLICK PLUS PLC
The CLICK series will install the program, communicate to the controller instruction and address the controller
Using the address picker, enter as many address names as you can think of that you will use
in the program. As you write the program, we can always go back and document the additional addresses
To access the address picker, select it from the main menu, Program, Address Picker
This can also be accessed in the navigation window in the Program tab under the Ladder
Program heading. The first rung will start and stop the robot packing machine by turning on the internal
bit C1. This bit will then be used as a condition in the entire program
The next two rungs are part of the control for the boxes on the conveyor
If the robot packing machine bit is on and we do not have a photocell 3 signal, activate
the cylinder stop. This resets when the box is full. A timer ensures that the box is stopped by the cylinder rod
This creates a half second delay after the photocell 3 signal is seen
The box conveyor will stop after this. The conveyor will start again when the box is full and the cylinder stop has returned
The pneumatic push ensures the empty box remains still when the robot fills it
This is engaged after the timer expires to ensure the box is positioned correctly
Timer 2 is activated when the box is full and the cylinder stop is back. It is a half second timer
The box full bit is set from the counter sequencer. Timer 16 will activate the box once it is complete
Timer 3 is used to reset the full box bit. This happens 1.5 seconds after photocell 3 no longer sees the signal
A counter is used to control the sequence of the robot. The previous step and table give us conditions for each counter increment
We compare the counter or accumulator to set the outputs
In the case of the robot home output signal, the counter will be greater than or equal
to 0 and less than or equal to 9. It will also be on when it is greater than or equal to 11
We can see this by looking at the sequence table. The work part creator will create the bags along the conveyor belt
This will occur when the counter equals 0, 2, 4, 6 or 8
Robot 1 load position will activate when the counter is 1. A timer ensures that the position is reached before the next step
Robot 2, 3 and 4 load positions will activate at the appropriate counter value
Individual timers ensure that the position is reached before the next step
The closed grip on the robot activates when the counter is equal to 9 and 10
This holds the bags so that they do not fall when moving to the box
When the counter equals 10, the robot is sent to the unload position
A timer ensures that the position is reached before the next step
The robot home reset timer ensures that the home position is reached before starting the
robot sequence over again. This is the end of the ladder logic for our packaging robot program
Select the COM port under the Setup selection on the main menu
Available ports on the CLICK PLC are displayed. Using Modbus TCP Ethernet, we can set up either the WLAN, Wireless Local Area Network, or
Port 1 Ethernet. Select Setup for Port 1. Note that if you want to go directly to the COM port setting details window, select COM
Port 3 Setup under the CPU Configuration on the Function tab of the main navigation window
A static IP address is used for our CLICK PLC. This ensures that the IP address on the network can always be found
Note the IP address we are using. This will be later used for the EasyPLC Robot Packing Machine Simulator connection
Under the Setup menu on the main screen, you will also see Modbus TCP
This will show us the default parameters for our Ethernet port and allow us to enable the
Modbus TCP server. This is enabled by default on the controller. We will leave everything as their default values
Our CLICK PLC is now set to communicate to the EasyPLC Machine Simulator Modbus TCP client
Download the CLICK Ladder program to the CLICK PLC. Ensure that the PLC is in Run mode
Step 5. Test the program. We will use Modbus TCP on our CLICK PLUS PLC to communicate with the EasyPLC Machine Simulator
Call up the Robot Packing Machine Simulator in Start mode. The status of the machine simulator will be at the bottom of the screen
Currently, we have no PLC connected. Select I0 drivers on the bottom middle of the screen
The Machine Simulator I0 number will be displayed. Ensure we select more I0 than the number required for a Robot Packing Machine
The EasyPLC driver is selected by default. Under the Driver pull-down menu, select Modbus Driver
This driver will communicate Modbus TCP or Ethernet and Modbus RTU serial
Select the Configure button. We can now enter the information for our Modbus driver
Select TCP IP. This means the Ethernet port on the computer will communicate with the CLICK PLC
Digital inputs from MS to the CLICK PLC will be C101 to C112
This will start at address 16484 due to the offset of 1
Digital outputs from MS to the CLICK PLC will be C201 to C213
This will begin at address 16584 due to the offset of 1
Select the OK button. You will now see the inputs and outputs specified for the Modbus driver
We can now manually assign the driver outputs to the PLC inputs and the driver inputs to
the PLC outputs. However, the automatic assignment works well and will save you time
Select Automatic Assignment from the Driver option in the main menu. This will automatically assign the PLC I.O. to the Machine Simulator I.O
Select Start Driver and exit from the main menu. On the bottom left side of the window, the driver communicates to the CLICK PLC with
a green light. Select View I.O. to know the input and output status of the Machine Simulator
Ensure that the CLICK PLC is in Run mode. We can see the operation of a robot packing machine
Select the Start button on the control panel and ensure the Emergency Stop is not on
The digital inputs and outputs of the MS will correspond to the PLC controller
Using the Data View window of the CLICK programming software, we can also watch the inputs and outputs operation
Using Machine Simulator or MS to test the program will assure that your program works
Troubleshooting is quickly done without damage to any physical hardware
You can practice your modification and debug by modifying the robot packing operation in
the following way. Add a stack light to indicate the operation of the robot packing machine
Add a Jog button to the control panel to sequence through the steps
Calculate the rate of full boxes coming out of the robot packing machine in boxes per hour
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