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Inst Tools > Blog > PLC Tutorials > PLC Programming for Sequential Batch Mixing System

PLC Programming for Sequential Batch Mixing System

This article discusses Sequential Batch Mixing systems with weighing functions using the Omron PLC programming for process control.

Last updated: September 26, 2024 5:52 am
Editorial Staff
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This article discusses Sequential Batch Mixing systems with weighing functions using the Omron PLC programming for process control applications.

Contents
Sequential Batch Mixing SystemProject IOPLC Programming

Sequential Batch Mixing System

The PLC system has 2 buttons, the START_SYSTEM (0.00) button is used to Turn On the system, and the STOP_SYSTEM (0.01) button is used to Turn Off the system.

Before the PLC system is started, the “Set Value” in the memory words SV_LIQUID_PREMIX (D1) and SV_LIQUID_MIXER (D3) needs to be Set. This is used as the maximum liquid content value in the PREMIX and MIXER tanks.

When the START_SYSTEM (0.00) button is pressed, the Output VALVE_INPUT_PREMIX (100.00) will OPEN to carry out the liquid filling process in the PREMIX tank. The Output VALVE_INPUT_PREMIX (100.00) will CLOSE when the value in the memory word PV_LIQUID_PREMIX (D0) is equal to SV_LIQUID_PREMIX (D1).

When the value in the memory word PV_LIQUID_PREMIX (D0) is equal to SV_LIQUID_PREMIX (D1), then the Output MIXING_PREMIX (100.01) will be ON for 10 seconds to carry out Mixing process in the PREMIX tank.

After the Mixing Process in the PREMIX tank is completed, the Output VALVE_INPUT_MIXER (100.02) and VALVE_OUTPUT_PREMIX (100.03) will OPEN to drain the liquid from the PREMIX tank to the MIXER tank.

The Output VALVE_INPUT_MIXER (100.02) will CLOSE when the value in the memory word PV_LIQUID_MIXER (D2) is equal to SV_LIQUID_MIXER (D3).

The Output VALVE_OUTPUT_PREMIX (100.03) will CLOSE when the value in the memory word PV_LIQUID_PREMIX (D0) is zero “0”, this indicates the PREMIX tank is empty.

When the value in the memory word PV_LIQUID_MIXER (D2) is equal to SV_LIQUID_MIXER (D3), then the Output MIXING_MIXER(100.04) will be ON for 20 seconds to carry out the Mixing process in the MIXER tank.

After the Mixing process in the MIXER tank is completed, the Output VALVE_OUTPUT_MIXER (100.05) will OPEN to empty the liquid in the MIXER tank. The Output VALVE_OUTPUT_MIXER (100.05) will CLOSE when the value in the memory word PV_LIQUID_MIXER (D2) is zero “0”, this indicates the MIXER tank is empty.

When the MIXER tank is empty, the system will be OFF and will Run again when the START_SYSTEM (0.00) button is Pressed.

Mixing Batch PLC Program Sequenced With The Weighing Function

Project IO

CommentInput (I)Output (Q)Memory BitsMemory WordTimers
START_SYSTEM0.00    
STOP_SYSTEM0.01    
VALVE_INPUT_PREMIX 100.00   
MIXING_PREMIX 100.01   
VALVE_OUTPUT_PREMIX 100.03   
VALVE_INPUT_MIXER 100.02   
MIXING_MIXER 100.04   
VALVE_OUTPUT_MIXER 100.05   
SYSTEM_ON  W0.00  
VALVE_INPUT_MIXER_CUTOFF  W0.01  
VALVE_OUTPUT_PREMIX_CUTOFF  W0.02  
VALVE_OUTPUT_MIXER_CUTOFF  W0.03  
TIMER_PREMIX    T0000
TIMER_MIXER    T0001
PV_LIQUID_PREMIX   D0 
SV_LIQUID_PREMIX   D1 
PV_LIQUID_MIXER   D2 
SV_LIQUID_MIXER   D3 

PLC Programming

RUNG 0 (START_SYSTEM)

In this Rung, when the START_SYSTEM (0.00) button is pressed, the memory bit SYSTEM_ON (W0.00) changes to an ON state. Because it uses “latching” the memory bit SYSTEM_ON (W0.00) remains ON even though START_SYSTEM (0.00) button has been Released.

The memory bit SYSTEM_ON (W0.00) will be OFF if the STOP_SYSTEM (0.01) button is Pressed or when NC contact of the memory bit VALVE_OUTPUT_MIXER_CUTOFF (W0.03) is HIGH.

PLC Programming for Sequential Batch Mixing System

RUNG 1 (VALVE INPUT PREMIX)

In this Rung, the Output VALVE_INPUT_PREMIX (100.00) will be OPEN when NO contact of the memory bit SYSTEM_ON (W0.00) is HIGH and the value in memory word PV_LIQUID_PREMIX (D0) is less than SV_LIQUID_PREMIX( D1).

The Output VALVE_INPUT_PREMIX (100.00) will CLOSE when value in the memory word PV_LIQUID_PREMIX (D0) is greater than SV_LIQUID_PREMIX (D1) or the NC contacts of VALVE_OUTPUT_PREMIX (100.02) and MIXING_MIXER (100.04) are HIGH.

RUNG 2 (MIXING PREMIX)

When NO contact of the memory bit SYSTEM_ON (W0.00) is HIGH and the value in the memory word PV_LIQUID_PREMIX (D0) is equal to SV_LIQUID_PREMIX (D1), then the Output MIXING_PREMIX (100.01) will be ON and the Timer TIMER_PREMIX (T0000) starts counting up to 10 seconds. The Output MIXING_PREMIX (100.01) will be OFF when the TIMER_PREMIX (T0000) Timer reaches the “Set value”.

PLC sequential control logic

RUNG 3 (MIXER INPUT VALVE)

When NO contacts of the memory bit SYSTEM_ON (W0.00) and TIMER_PREMIX (T0000) are HIGH, the Output VALVE_INPUT_MIXER (100.02) will be OPEN.

When the value in the memory word PV_LIQUID_MIXER (D2) is equal to SV_LIQUID_MIXER (D3) and the memory bit VALVE_INPUT_MIXER_CUTOFF (W0.01) is ON, then the Output VALVE_INPUT_MIXER (100.02) becomes CLOSE because of the “Interlock” of the memory bit VALVE_INPUT_MIXER_CUTOFF (W0.01).

RUNG 4 (VALVE OUTPUT PREMIX)

When NO contacts of the memory bit SYSTEM_ON (W0.00) and VALVE_INPUT_MIXER (100.02) are HIGH, the Output VALVE_OUTPUT_PREMIX (100.03) will be OPEN.

When the memory word PV_LIQUID_PREMIX (D0) is equal to zero “0” and the memory bit VALVE_OUTPUT_PREMIX_CUTOFF (W0.02) is ON, then the Output VALVE_OUTPUT_PREMIX (100.03) becomes CLOSE because of the “Interlock” of the memory bit VALVE_OUTPUT_PREMIX_CUTOFF (W0.02).

PLC sequential batch mixing logic with timers

RUNG 5 (MIXING MIXER)

When NO contact of the memory bit SYSTEM_ON (W0.00) is HIGH and the value in the memory word PV_LIQUID_MIXER (D2) is equal to SV_LIQUID_MIXER (D3), then the Output MIXING_MIXER (100.04) will be ON and the Timer TIMER_MIXER (T0001) starts counting up to 20 seconds.

The Output MIXING_MIXER (100.04) will be OFF when the TIMER_MIXER (T0001) Timer reaches “Set value”.

Sequential batch control PLC program

RUNG 6 (MIXER OUTPUT VALVE)

When NO contact of the memory bit SYSTEM_ON (W0.00) and TIMER_MIXER (T0001) is HIGH, the Output VALVE_OUTPUT_MIXER (100.05) will be OPEN.

When the memory word PV_LIQUID_MIXER (D2) is equal to zero “0” and the memory bit VALVE_OUTPUT_MIXER_CUTOFF (W0.03) is ON, then the Output Output VALVE_OUTPUT_MIXER (100.05) becomes CLOSE because of the “Interlock” of the memory bit VALVE_OUTPUT_MIXER_CUTOFF (W0.03).

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