Inst ToolsInst ToolsInst Tools
  • Ask
  • Courses
  • Videos
  • Q & A
    • Interview
      • Instrumentation
      • Electronics
      • Electrical
      • Practical Questions
    • MCQ
      • Instrumentation MCQ
      • Electrical MCQ
      • Electronics MCQ
      • Control Systems MCQ
      • Analog Electronics MCQ
      • Digital Electronics MCQ
      • Power Electronics MCQ
      • Microprocessor MCQ
      • Multiple Choice Questions
  • EE
    • Electronics
      • Electronics Q & A
      • Electronic Basics
      • Electronic Devices & Circuits
      • Electronics Animation
      • Digital Electronics
    • Electrical
      • Electrical Basics
      • Electrical Q & A
      • Power Electronics
      • Electrical Machines
      • Electrical Animation
      • Power Systems
      • Switchgear & Protection
      • Transmission & Distribution
  • Measure
    • Control Valves
    • Calibration
    • Temperature
    • Pressure
    • Flow
    • Level
    • Analyzers
    • Switches
    • Vibration
    • Solenoid Valve
  • Control
    • PLC Tutorials
    • Control Systems
    • Safety Instrumented System (SIS)
    • Communication
    • Fire & Gas System
  • More
    • Design
    • Tools
    • Animation
    • Basics
    • Formulas
    • Standards
    • TextBooks
    • Common
    • Software
    • Excel Tools
    • Erection & Commissioning
    • Process Fundamentals
    • Videos
    • Books
Search
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Reading: Automated Test Bench – Complex PLC Programming Examples
Share
Notification Show More
Font ResizerAa
Inst ToolsInst Tools
Font ResizerAa
  • Courses
  • PLC Tutorials
  • Control Systems
Search
  • Ask
  • Courses
  • Videos
  • Q & A
    • Interview
    • MCQ
  • EE
    • Electronics
    • Electrical
  • Measure
    • Control Valves
    • Calibration
    • Temperature
    • Pressure
    • Flow
    • Level
    • Analyzers
    • Switches
    • Vibration
    • Solenoid Valve
  • Control
    • PLC Tutorials
    • Control Systems
    • Safety Instrumented System (SIS)
    • Communication
    • Fire & Gas System
  • More
    • Design
    • Tools
    • Animation
    • Basics
    • Formulas
    • Standards
    • TextBooks
    • Common
    • Software
    • Excel Tools
    • Erection & Commissioning
    • Process Fundamentals
    • Videos
    • Books
Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Inst Tools > Blog > PLC Tutorials > Automated Test Bench – Complex PLC Programming Examples

Automated Test Bench – Complex PLC Programming Examples

This is a complex PLC programming example on an automated test bench to carry out 3 tests sequentially when specimen is placed on the bench.

Last updated: April 23, 2024 6:01 am
Editorial Staff
PLC Tutorials
No Comments
Share
8 Min Read
SHARE

This is a complex PLC programming example on an automated test bench to carry out 3 tests sequentially when the specimen is placed on the bench.

Contents
Automated Test BenchComplex PLC Programming ExamplesList of I/OsLadder LogicProgram DescriptionSimulation of Logic

Note: This PLC program was created for the persons to learn the PLC basics.

Automated Test Bench

Problem Statement:

Design a PLC ladder logic for the following application.

We are using one toggle switch and one sensor to control 3 Tests.

When a test specimen is placed on the bench, a series of 3 tests should run sequentially, each lasting for 10 seconds. The time delay between the two tests should be 5 seconds.

Complex PLC Programming Examples

Instrumentation Tools provides you the complex PLC example programs for practicing the ladder logics.

This PLC video explains the test bench PLC programming in a detailed explanation.

List of I/Os

Digital Inputs:

Start Button: I0.0

Sensor: I0.1

Digital Outputs:

Test 1: Q0.0

Test 2: Q0.1

Test 3: Q0.2

Ladder Logic

Automated Test Bench - Complex PLC Programming Examples

Program Description

We have used Normally Open Contacts for Start Button( I0.0) and Sensor (I0.1).

In Rung 0:

  1. Normally Open Contacts are used for the Start Button (I0.0) and Sensor (I0.1) to Turn ON the output  Test 1 (Q0.0).
  2. Normally Closed Contact is used for Memory Bit (M0) to turn OFF the output Test 1 (Q0.0).

In Rung 1:

  1. Normally Open Contacts are used for the Start Button (I0.0) and Sensor (I0.1) to Turn ON Memory Bit (M0).
  2. Timer-type TON is used to delay the turning ON time of Memory Bit (M0) for some time.

In Rung 2:

  1. Normally Open Contacts are used for the Start Button (I0.0) and Sensor (I0.1) to Turn ON the output  Test 2 (Q0.1).
  2. Normally Closed Contact is used for Test 1 (Q0.0) to turn ON the output Test 2 (Q0.1).
  3. Timer Function Block type TON is used to delay the turning ON time of the output Test 2 (Q0.1) for some time.
  4. Timer Function Block type TP is used to Turn ON the output Test 2(Q0.1) for a limited time.

In Rung 3:

  1. Normally Open Contacts are used for the Start Button (I0.0) and Sensor (I0.1) to Turn ON the output  Test 3 (Q0.2).
  2. Normally Closed Contacts are used for Test 1 (Q0.0) and Test 2 (Q0.1) to turn ON the output Test 3 (Q0.2).
  3. Timer-type TON is used to delay the turning ON time of the output Test 3 (Q0.2) for some time.
  4. Timer-type TP is used to Turn ON the output Test 3 (Q0.2) for a limited time.

Simulation of Logic

We will simulate our PLC logic and analyze the results. We may show the part of the logic instead of the complete code.

Rung 0:

When the Start Button (I0.0) is turned ON and Sensor (I0.1) gets activated (Sensor detects test), the output Test 1 (Q0.0) turns ON (Tests 1 starts) as Normally Open Contact used for Start Button (I0.0) and sensor (I0.1) allows the signal to pass through it to turn ON the output Test 1 (Q0.0).

Sequential test automation PLC

In a false state, Normally Closed Contact used for Memory Bit (M0) also passes the signal to turn ON the output Test 1 (Q0.0) and the output Test 1 (Q0.0) turns ON.

Rung 1:

PLC control for bench tests

Also, When the Start Button (I0.0) is turned ON and Sensor (I0.1) gets activated (Sensor detects test).

Memory Bit (M0) turns ON after 10 seconds as Timer Function Block type TON is used to delay the turning ON time of Memory Bit (M0) and the time is set to 10 seconds.

PLC logic for test automation

So after 10 seconds, Memory Bit (M0) will turn ON.

When Memory Bit (M0) turns ON in Rung1, Normally Closed Contact used for Memory Bit (M0) in Rung0 will be in True State and does not allow the signal to flow through it and the output Test 1 (Q0.0) in Rung0 will Turn OFF (Test 1 Ends).

Bench test automation system

Rung 2:

When Start Button (I0.0) is turned ON, Sensor (I0.1) gets activated (Sensor detects test) and the output Test 1 (Q0.0) turns OFF in Rung0 (Test 1 Ends), the output Test 2 (Q0.1) turns ON because when the output Test 1 (Q0.0) turns OFF in Rung0.

Automated test bench control

Normally Closed Contact used for Test 1 (Q0.0) in Rung2 will be in a False state and allow the signal to pass through it.

The output Test 2 (Q0.1) will turn ON but after 5 seconds (Test 2 starts after 5 seconds) as Timer Function Block type TON is used to delay the turning ON time of the output Test 2 (Q0.1) and the time is set to 5 seconds.

PLC-based test bench control

So after 5 seconds, the output Test 2 (Q0.1) will turn ON (Test 2 starts) but only for 10 seconds as we have used Timer Function Block type TP to turn ON the output Test 2 (Q0.1) only for a limited time and the time is set to 10 seconds.

So after 10 seconds, the output Test 2 (Q0.1) will turn OFF (Test 2 Ends).

Rung 3:

When Start Button (I0.0) is turned ON, Sensor (I0.1) gets activated (Sensor detects test), the output Test 1 (Q0.0) turns OFF in Rung0 (Test 1 is Ended) and the output Test 2 (Q0.1) turns OFF in Rung2 (Test 2 is Ended).

PLC ladder logic for bench test

The output Test 3 (Q0.2) turns ON because when the output Test 1 (Q0.0) turns OFF in Rung0 and the output Test 2 (Q0.1) turns OFF in Rung2, Normally Closed Contact used for Test 1 (Q0.0) and Test 2 (Q0.1) in Rung3 will be in False state.

This allows the signal to pass through it and the output Test 3 (Q0.2) will turn ON but after 5 seconds (Test 3 starts after 5 seconds) as Timer Function Block type TON is used to delay the turning ON time of the output Test 3 (Q0.2) and the time is set to 5 seconds.

PLC logic for bench test automation

So after 5 seconds, the output Test 3 (Q0.2) will turn ON (Test 3 starts) but only for 10 seconds as we have used Timer Function Block type TP to turn ON the output Test 3 (Q0.2) only for a limited time and the time is set to 10 seconds.

So after 10 seconds, the output Test 3 (Q0.2) will turn OFF (Test 3 Ends).

If you liked this article, please subscribe to our YouTube Channel for PLC and SCADA video tutorials.

You can also follow us on Facebook and Twitter to receive daily updates.

Read Next:

  • Traffic Lights PLC Program using Timers
  • Heater and Cooler PLC Exercise Problem
  • PLC Programming for Trash Compactor
  • Playground Swing PLC Logic Programming
  • PLC Programming for the Pump to fill the tank
Don't Miss Our Updates
Be the first to get exclusive content straight to your email.
We promise not to spam you. You can unsubscribe at any time.
Invalid email address
You've successfully subscribed !
Open Platform Communication (OPC)
How to use JUMP Instruction in PLC Ladder Logic?
Rockwell PLCs for Large Scale Applications
Types of PLC Memory
PLC Program for Latching and unlatching Circuit
Share This Article
Facebook Whatsapp Whatsapp LinkedIn Copy Link
Share
Leave a Comment

Leave a Reply Cancel reply

Your email address will not be published. Required fields are marked *

Stay Connected

128.3kFollowersLike
69.1kFollowersFollow
208kSubscribersSubscribe
38kFollowersFollow

Categories

Recent Comments

  • Guifty Shimica on Top Non-PLC Certification Courses for Automation Professionals
  • Guifty Shimica on Top Non-PLC Certification Courses for Automation Professionals
  • MIHARITSOA Aina Sitraka on Top Non-PLC Certification Courses for Automation Professionals
  • Vaishnavi on Free Instrumentation Course for Trainee Engineers

Related Articles

how-a-4-20ma-transmitter-works

How a 4-20mA Transmitter Works?

PLC Programmer Unknown Do's

Unknown Do’s Need to Know as a PLC Programmer

PLC Ladder Logic Simulator Mobile Apps For Android

PLC Ladder Logic Simulator Mobile Apps For Android

Modbus in Industrial Networks

How Modbus is used in Industrial Networks?

PLC Program with 2 Toggle Switches and 4 Motors

PLC Program with 2 Toggle Switches and 4 Motors

Light Tower in Industrial Automation

What is a Tower Lamp? – Light Tower in Industrial Automation

Switch NO or NC Contact

Normally-open and Normally-closed Switch Contacts

What is PLC

What is a PLC? – Programmable Logic Controller

More Articles

Two pressure transmitters

Pressure Transmitters Leg Compensation Technique

Power Electronics Objective Questions

Power Electronics Diode Circuits Questions and Answers

Vibration Probe Commissioning Checklist

Vibration Probe Commissioning Checklist

Learn SCL programming from scratch

How to Start Writing SCL Language in Siemens Tia Portal?

Digital Control Systems

Z & S Domain Relationship

What is a Rotary Actuator

Difference Between Linear Actuator and Rotary Actuator

Pneumatic Moment-balance Differential Pressure Transmitter

Pneumatic Moment-balance Differential Pressure Transmitter

Top PLC Manufacturers

PLC Brands Software Information

Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Welcome Back!

Sign in to your account

Username or Email Address
Password

Lost your password?