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11. FLOWCHART BASED DESIGN

Topics: Describing process control using flowcharts Conversion of flowcharts to ladder logic Objectives: Ba able to describe a process with a flowchart. Be able to convert a flowchart to ladder logic.

11.1 INTRODUCTION
A flowchart is ideal for a process that has sequential process steps. The steps will be executed in a simple order that may change as the result of some simple decisions. The symbols used for flowcharts are shown in Figure 126. These blocks are connected using arrows to indicate the sequence of the steps. The different blocks imply different types of program actions. Programs always need a start block, but PLC programs rarely stop so the stop block is rarely used. Other important blocks include operations and decisions. The other functions may be used but are not necessary for most PLC applications. Start/Stop Operation

Decision

I/O

Disk/Storage

Subroutine

Figure 126

Flowchart Symbols

A flowchart is shown in Figure 127 for a control system for a large water tank. When a start button is pushed the tank will start to fill, and the flow out will be stopped. When full, or the stop button is pushed the outlet will open up, and the flow in will be stopped. In the flowchart the general flow of execution starts at the top. The first operation is to open the outlet valve and close the inlet valve. Next, a single decision block is used to wait for a button to be pushed. when the button is pushed the yes branch

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is followed and the inlet valve is opened, and the outlet valve is closed. Then the flow chart goes into a loop that uses two decision blocks to wait until the tank is full, or the stop button is pushed. If either case occurs the inlet valve is closed and the outlet valve is opened. The system then goes back to wait for the start button to be pushed again. When the controller is on the program should always be running, so only a start block is needed. Many beginners will neglect to put in checks for stop buttons.

START Open outlet valve Close inlet valve

start button pushed?

no

yes Open inlet valve Close outlet valve

yes Is tank full? no

Open outlet valve Close inlet valve

stop button pushed? no

yes

Figure 127

A Flowchart for a Tank Filler

The general method for constructing flowcharts is: 1. Understand the process. 2. Determine the major actions, these are drawn as blocks.

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3. Determine the sequences of operations, these are drawn with arrows. 4. When the sequence may change use decision blocks for branching. Once a flowchart has been created ladder logic can be written. There are two basic techniques that can be used, the first presented uses blocks of ladder logic code. The second uses normal ladder logic.

11.2 BLOCK LOGIC

The first step is to name each block in the flowchart, as shown in Figure 128. Each of the numbered steps will then be converted to ladder logic

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STEP 1: Add labels to each block in the flowchart START F1 Open outlet valve Close inlet valve

F2 start button pushed? no

F3

yes Open inlet valve Close outlet valve F6

F4

yes Is tank full? no

Open outlet valve Close inlet valve

F5 stop button pushed? no yes

Figure 128

Labeling Blocks in the Flowchart

Each block in the flowchart will be converted to a block of ladder logic. To do this we will use the MCR (Master Control Relay) instruction (it will be discussed in more detail later.) The instruction is shown in Figure 129, and will appear as a matched pair of outputs labelled MCR. If the first MCR line is true then the ladder logic on the following lines will be scanned as normal to the second MCR. If the first line is false the lines to the next MCR block will all be forced off. If a normal output is used inside an MCR block, it may be forced off. Therefore latches will be used in this method.

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Note: We will use MCR instructions to implement some of the state based programs. This allows us to switch off part of the ladder logic. The one significant note to remember is that any normal outputs (not latches and timers) will be FORCED OFF. Unless this is what you want, put the normal outputs outside MCR blocks.

A MCR If A is true then the MCR will cause the ladder in between to be executed. If A is false the outputs are forced off. MCR

Figure 129

The MCR Function

The first part of the ladder logic required will reset the logic to an initial condition, as shown in Figure 130. The line will only be true for the first scan of the PLC, and at that time it will turn on the flowchart block F1 which is the reset all values off operation. All other operations will be turned off.

STEP 2: Write ladder logic to force the PLC into the first state first scan L F1

F2

F3 F4

F5

F6

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Figure 130

Initial Reset of States

The ladder logic for the first state is shown in Figure 131. When F1 is true the logic between the MCR lines will be scanned, if F1 is false the logic will be ignored. This logic turns on the outlet valve and turns off the inlet valve. It then turns off operation F1, and turns on the next operation F2.

STEP 3: Write ladder logic for each function in the flowchart F1 MCR outlet

inlet F1

F2

MCR

Figure 131

Ladder Logic for the Operation F1

The ladder logic for operation F2 is simple, and when the start button is pushed, it will turn off F2 and turn on F3. The ladder logic for operation F3 opens the inlet valve and moves to operation F4.

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F2 MCR start U F2

F3

MCR F3 MCR outlet

inlet F3

F4

MCR

Figure 132

Ladder Logic for Flowchart Operations F2 and F3

The ladder logic for operation F4 turns off F4, and if the tank is full it turns on F6, otherwise F5 is turned on. The ladder logic for operation F5 is very similar.

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F4 MCR F4

U tank full L tank full L

F6

F5

MCR F5 MCR F5

U stop L stop L

F6

F4

MCR

Figure 133

Ladder Logic for Operations F4 and F5

The ladder logic for operation F6 turns the outlet valve on and turns off the inlet valve. It then ends operation F6 and returns to operation F2.

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F6 MCR outlet

inlet F6

F2

MCR

Figure 134

Ladder Logic for Operation F6

11.3 SEQUENCE BITS

In general there is a preference for methods that do not use MCR statements or latches. The flowchart used in the previous example can be implemented without these instructions using the following method. The first step to this process is shown in Figure 135. As before each of the blocks in the flowchart are labelled, but now the connecting arrows (transitions) in the diagram must also be labelled. These transitions indicate when another function block will be activated.

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START T1 F1 Open outlet valve Close inlet valve T2 no

F2

is the NO start button pushed? yes T3 Open inlet valve Close outlet valve T4

F3

F6 F4 Is tank full? yes no T5 F5 is the NC stop button pushed? no yes T6 Open outlet valve Close inlet valve

Figure 135

Label the Flowchart Blocks and Arrows

The first section of ladder logic is shown in Figure 136. This indicates when the transitions between functions should occur. All of the logic for the transitions should be kept together, and appear before the state logic that follows in Figure 137.

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FS F1 F6 F2 F2 F3 F5 F4 F4 F5 stop full full stop start start

T1 T2

T3 T4

T5 T6

Figure 136

The Transition Logic

The logic shown in Figure 137 will keep a function on, or switch to the next function. Consider the first ladder rung for F1, it will be turned on by transition T1 and once function F1 is on it will keep itself on, unless T2 occurs shutting it off. If T2 has occurred the next line of ladder logic will turn on F2. The function logic is followed by output logic that relates output values to the active functions.

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F1 T1 F2 T2 F3 T3 F4 T4 F5 T5 F6 T6

T2

F1

T3

F2

T4

F3

T5

T6

F4

T4

T6

F5

T2

F6

F1 F2 F6 F3 F4 F5

outlet

inlet

Figure 137

The Function Logic and Outputs

11.4 SUMMARY
Flowcharts are suited to processes with a single flow of execution. Flowcharts are suited to processes with clear sequences of operation.

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11.5 PRACTICE PROBLEMS

1. Convert the following flow chart to ladder logic. start

A on

is B on? no A off

yes

no

is C on? yes

2. Draw a flow chart for cutting the grass, then develop ladder logic for three of the actions/decisions. 3. Design a garage door controller using a flowchart. The behavior of the garage door controller is as follows, - there is a single button in the garage, and a single button remote control. - when the button is pushed the door will move up or down. - if the button is pushed once while moving, the door will stop, a second push will start motion again in the opposite direction. - there are top/bottom limit switches to stop the motion of the door. - there is a light beam across the bottom of the door. If the beam is cut while the door is closing the door will stop and reverse. - there is a garage light that will be on for 5 minutes after the door opens or closes.

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11.6 ASSIGNMENT PROBLEMS

1. Develop ladder logic for the flowchart below. Start Turn A on

Is B on? yes Turn A off

no

Is C on? no

yes

2. Use a flow chart to design a parking gate controller. keycard entry light - the gate will be raised by one output and lowered by another. If the gate gets stuck an over current detector will make a PLC input true. If this is the case the gate should reverse and the light should be turned on indefinitely. - if a valid keycard is entered a PLC input will be true. The gate is to rise and stay open for 10 seconds. - when a car is over the car detector a PLC input will go true. The gate is to open while this detector is active. If it is active for more that 30 seconds the light should also turn on until the gate closes.

gate

cars enter/leave

car detector

3. A welding station is controlled by a PLC. On the outside is a safety cage that must be closed while the cell is active. A belt moves the parts into the welding station and back out. An inductive proximity sensor detects when a part is in place for welding, and the belt is stopped. To weld, an actuator is turned on for 3 seconds. As normal the cell has start and stop push buttons.

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a) Draw a flow chart b) Implement the chart in ladder logic

Inputs DOOR OPEN (NC) START (NO) STOP (NC) PART PRESENT 4. Convert the following flowchart to ladder logic.

Outputs CONVEYOR ON WELD

Start

Turn off motor no

start pushed yes Turn on motor

stop pushed yes

no

5. A machine is being designed to wrap boxes of chocolate. The boxes arrive at the machine on a conveyor belt. The list below shows the process steps in sequence. 1. The box arrives and is detected by an optical sensor (P), after this the conveyor is stopped (C) and the box is clamped in place (H). 2. A wrapping mechanism (W) is turned on for 2 seconds. 3. A sticker cylinder (S) is turned on for 1 second to put consumer labelling on the box. 4. The clamp (H) is turned off and the conveyor (C) is turned on. 5. After the box leaves the system returns to an idle state. Develop ladder logic for the system using a flowchart. Dont forget to include regular start and stop inputs.

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