CompactLogix PLC Application: Tray Stacker

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⌚Timestamps:
00:00 - Intro
01:00 - Tray stacker
02:12 - I/O modules and devices
03:11 - Variable Frequency Drives
03:58 - Servo drives
04:52 - HMI
05:48 - Safety devices
06:23 - Conclusion
In today’s video, we will learn about Allen Bradley CompactLogix PLCs by looking at a typical application of a CompactLogix PLC. Along the way, we will see how a CompactLogix system can be used to control a mid-sized machine and what components make up a CompactLogix system.
In this video, we’ll see how a CompactLogix system can be used to control a tray stacker machine.
The tray stacker has three conveyors that are used to transport trays through the machine.
When trays are stopped on the middle conveyor, an arm is lowered and a set of actuators are used to grab the tray. Once the tray is secure, the arm lifts the tray from the conveyor to make room for the next tray.
The arm is lowered to place any currently stacked trays in the new tray and then grab the bottom tray.
This process is repeated to build a stack of trays. Once a stack is complete, it is transported out of the machine using the conveyor belts.
Now that we know what the machine does, let’s take a look and see how a CompactLogix PLC system could be used to control this machine.
The control system for this machine is made up of a CompactLogix PLC, which controls the machine. The CompactLogix PLC is connected to several other devices to monitor and control the machine.
A CompactLogix controller can be extended with I/O modules to interface with these devices. The most common types of I/O modules are digital input and digital output modules.
The sensors in the application are wired to input modules and tell the PLC important information about the process like if a button is pressed or if a tray is in position on the conveyor.
The actuators in this application are wired to output modules.
Variable frequency drives are devices that are used to control motors. In this application, PowerFlex variable frequency drives are used to control the motors because they are designed to be integrated easily into CompactLogix systems.
Variable frequency drives are used when you want to control the speed of a motor and servo drives are used when you want to control the position of a motor.
In this application, the lifting arm has to move to a precise position to lift the stack of trays from the conveyor belt. For this positioning application, an Allen Bradley Kinetix servo drive is used.
The machine is equipped with a Human Machine Interface, also known as an HMI. In this case, a PanelView 5000 HMI is used and communicates with the PLC over an EtherNet/IP network.
This device is a touchscreen terminal that lets an operator see the status of the machine and send commands to the PLC. Some common commands may be reset to reset a fault, start to start running the machine, and stop to stop the machine.
Finally, safety devices are used to ensure that the machine can stop safely in case of an emergency.
Although there are safety-rated CompactLogix PLCs available, mid-sized machines like this one often use hardwired safety equipment.
With hardwired safety, the PLC doesn’t control the safety logic. Instead, safety devices like emergency stops and safety light curtains are connected to safety relays which inhibit movement of the machine when a safety event has occurred.
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variable frequency drives: www.realpars.com/blog/variabl...
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What is an HMI? : www.realpars.com/blog/what-is...
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[@widescreen247]

Very similar process we have for our stacker in the sawmill i work at. Instead of having a servo drive, we have hydraulic servo valves and a linear transducers in the pistons to determine feedback , which going back to a hyd02 card Love watching your videos btw, its making me a better maintenence electrician

[@realpars]

Thank you! Happy to hear that.

[@tameem878]

Amazing and informative video, thanks for the effort and please continue with the PLC and automation series, I salute the hard work done to clarify how the entire system works.

[@realpars]

Thank you very much! Happy learning

[@luisfructuoso818]

​@@realpars how do you create this Incredibles animations. I am automation teacher.

[@KevinNguyen-tw5ml]

Thank you so much !

[@realpars]

Our pleasure!

[@samratsantosh5659]

Thanks 🙏

[@realpars]

You're very welcome!