RLL Design for Sequencing Systems

Manufacturing Automation using PLCs
CHAPTER 7
RLL Design for Sequencing System
Chapter 7: RLL Design for Sequencing System

7.1 Commonly used industrial machine sequence.
7.2 Sequencing chart
7.3 Design Relay Ladder Logic for Sequencing Problems using PLCs.
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
Design RLL for Single-Path Machine Sequence Having Non-Sustain Control Signals
Design RLL for Single-Path Machine Sequence Having Sustain Control Signals
Design RLL for Multi-Path Sequencing Systems with Sustain Outputs
RLL for machine sequence with two or more alternative parallel paths
RLL for machine sequence with option of bypassing certain steps.
7.3.6
RLL for machine sequence with the option of repeating certain steps.
7.1

CHAPTER 7
RLL Design, for Sequencing System

Most manufacturing process controls are based on sequencing control systems.
Different techniques can be used to assist engineer to design the Relay Ladder
Logic based on sequencing control technique. Sequencing charts, Cascade and
Huffman methods techniques are examples, which can be used to design sequencing
control systems. The two former techniques will be illustrated in this Chapter.
7.1 Commonly used industrial machine sequence

Sequencing control system can be considered as single path or multi-path systems.
Multi-path or parallel path sequencing control system cover controlling multi-tasks
in one time, while single task is considered for single-path sequencing system. Fig.
7.1 shows a sequencing machine systems commonly used by industry [7.1].
A1
A2
A3
Ak
Ak+1
An-1
Aj-1
Bk+1
Bj-1
Ck+1
Cj-1
xp=1
.xp=0
A..
A1
A..
B1
Aj
B..
xp=0 A1
An
Aj
An+1
(a)
Aj+1
(b)
I+1
I+2
(c)
Bk
A..
Aj
I+1
I+2
(d)
.xp=1
A1
A2
A..
Aj xp=0 Aj+1
.xp=1
(e)
Fig. 7.1 Common machine sequence used by industry.

Single path machine sequence.
Parallel path machine sequence.
Parallel path machine sequence with two or more alternative
path selection.
Single path machine sequence with option bypass machine
sequence.
Single
path machine sequence with optional repeat certain steps.
7.2 Sequencing
chart
charts (also called time-motion diagrams, state diagram, or bar charts) are
useful for visualizing the operation of switching systems. They can be used to
describe the step-by-step operation of relay systems, pneumatic systems, or any
other type of switching systems.
Sequence
7.2

CHAPTER 7
To illustrate how sequence charts are constructed, consider the Relay Ladder Logic
given in Fig. 7.2. This relay ladder diagram used to actuate two double-acting
pneumatic cylinders A and B, (see Fig. 7.2). 5/2 directional-control valves with
solenoid and a return spring actuate each cylinder. The solenoids are labeled by A+
and B+, respectively, signifying that the cylinder moves in the + direction (i.e
forward or extend position) whenever the solenoid is energized. Two limit switches,
a+ and b+, are mounted to monitor when the respective cylinder reaches the
extreme + position.
-
A+
L1
REVERS
.a+
A+
a+
.b+
II
III
IV V VI
ACylinders
B+
B-
b+
R2
.a+
Limit switches
R2
L4
B+
R1
L3
L6
.a+
R1
L2
L5
START
..b+
START
R1
R1
A+
Memory relay
R2
B+
R2
A+
Solenoids
B+
Fig. 7.2 Relay ladder logic (RLL) developed using sequencing chart to control two
double acting cylinders using 5/2 solenoid valve with return spring and two limit
switches. Machine sequence START, A+,A-,B+,BThe sequencing chart corresponding to this system also is shown in Fig. 7.2. To
construct this chart, we draw horizontal lines for each of the elements taking parts
in the action, and vertical lines representing the different stages, or steps, in the
systems sequence. The horizontal axis represents time, with no fixed time scale.
Whenever a new event takes place, a new vertical line is allocated. These lines are
labeled with Roman numbers, see Fig. 7.2 Thus the time between two adjacent
vertical lines depends on when the events occur. Note, also that each cylinder is
allocated two horizontal lines, to make it possible to represent cylinder motion
between its two extreme positions. All other elements are preferably allocated only
a single line. The time period during which a given element is actuated is indicated
by a thick line stop (its horizontal line), with the beginning and end of actuation
shown by short vertical lines. Machine sensors and actuators as well as the
corresponding addresses used in PLC are listed below:
7.3

CHAPTER 7
Machine sensors & operator control buttons

Addresses
1. START push button (NO contact)
2. REVERSE push button for Emergency (NC contact)
3. Limit switch ( a+) for cylinder (A), forward position
(NO contact).
4. Limit switch ( b+) for cylinder (B), forward position.
(NC contact).
Machine actuators
Addresses
1. Solenoid direction valve drives cylinder (A) called VA.
2. Solenoid directional valve drives cylinder (B) called VB.
X001
X000
X002
X003
Y022
Y023
Machine operations
Machine operations cover three stages given as follows:
1. The system is assumed to be in its initial position before the START button has
been pressed. We assume both cylinders at their backward or retracted positions. After
pressing the START push button, solenoid (A) energized, this will hold the memory of
the valve VA; R1, which result in forward movement of cylinder (A).
2. Limit switch (a+) which is NO switch, is closed when cylinder A is expanded and
results in, breaks or reset the memory of valve VA; R1 i.e solenoid (A) de-energized.
Hence cylinder (A) moves backward or retracts. At the same time, solenoid (B) is
energized (or setting memory of the valve VB; R2) and result in cylinder (B)
movement to the forward direction.
3. Limit switch (b+), which is NC contact, is open when the cylinder (B) reaches the
forward position. This result in, solenoid (B) de-energized or breaking the valve
memory VB; R2 and cylinder (B) will move to the backward position.
Now the machine cycle is ready for next operation cycle when the operator presses
START push-button again. Push button REVERS will reset both memory VA; R1
and VB; R2 in case of Emergency, when pressed by operator which result in both
cylinders (A and B) move to backward position. Hence, the machine operation
cycle can be written as START, A+, A-, B+, B-.
PLC Relay Logic Ladder operation
Stage 1, The initial condition of the system, all the cylinders are at backward
positions and all solenoids are de-energized (off state).
Stage 2, When the START push button pressed, the internal relay R1 is energized,
which turn the NO contact of R1 in line 2 on the RLL to be closed. This result in
energizing the relay solenoid A (having address Y022) and remains energized due to
memory R1 in line 2. This will also energize the solenoid valve (A; valve VA) and
cylinder (A) will move forward or extend.
7.4

CHAPTER 7
Stage 3, when cylinder (A) reaches the extreme position, limit switch ( a+), which
has an address of X002, will allow the current flow to internal relay R2, which
energizes the solenoid valve (B), having address Y023 (i.e. VB) which results in :
Internal relay R01 will close the contact in line 6 (on RLL) and energizes
solenoid valve VB, having address of Y023, this results in forward movement of
cylinder (B).
Open the NC contact of the internal relay R1 in line 1 (on RLL), which breaks
the memory of the internal relay R1. This results in opening the contact R1 in
line 5. This will de-energize the solenoid valve VA, which results in backward
movement of the cylinder (A).
Close the contact R2 in line 4, which provide memory to internal relay R2. The
cylinder (B) will reach the forward extreme position at which limit switch (b2),
(address X003, NC type), is open. This will result in limit switch (b2) open, and
the memory of R2 will breaks in line 3, so solenoid (B) de-energized causing
cylinder (B) to move backward to its initial position.
Exercise: Modify the above example to carry out the following control sequence ;
1.
2.
3.
4.
START push button.

Cylinder (A) forward and keep it in the forward position.
Cylinder (B) forward.
All cylinders (A) & (B) backward.
Machine cycle will be ; START, A+, B+,A-,B-.
Laboratory work 7.1 : Simulates the machine cycle given in the illustrated above example
and exercise, using TOSHIBA PLCs.
7.3 Design Relay Ladder Logic for Sequencing Problems using PLCs.
One of the efficient methods to design sequencing control problems is the
CASCADE method [7.1]. This technique can be used to control the sequence of
operations of machine sequence having non-sustain control signals or sustain
control signals. To illustrate the difference between the two techniques, let us start
with the simple technique, which is the machine control sequence, having nonsustain control signals.
7.3.1 Design RLL for Single-Path Machine Sequence Having Non-Sustain
Control Signals
This technique based on dividing the machine sequence into groups, such that no
opposing output command appears in the same group. In another wards: a new
group must be started the moment it becomes necessary to shut off any output
actuated during the present group.
To describe the technique, consider the given machine sequence having three
pneumatic double acting cylinders and having a machine cycle given as follows;
START, A+, A-, B+, C+, B-, C-. Note, A+ means forward movement of cylinder A,
while A- backward movement for cylinder A. Two limit switches were located at
7.5

CHAPTER 7
the two extreme positions of the pneumatic cylinder to monitor the cylinder
position. Each limit switch is labeled by a small letter having or + sign to indicate
its extreme position. For example, a+ letter indicating that the limit switch located
at the forward extreme position, while a- letter indicating the backward extreme
position, as shown in Fig. 7.3. Each cylinder, e.g. X cylinder, is actuated using a 5/3
directional valve having two solenoids, X+ and X-, respectively, with two return
spring to provide the middle position of the directional valve. The middle position
of the directional valve will block all the 5 ports of the directional valve, as shown
in Fig. 7.3. The left and right positions of the directional valve represent the
positions of the cylinder at the two extreme positions, see Fig. 7.3. This type of
x+
+
x
-
Sol X-
+
Sol X+
Fig. 7.3, Cylinder X operation having two electric limit switches x+ and x- showing
two- solenoid valve 5/3 symbol with two-spring return.
directional valve will provide a mechanical memory for cylinder movement.
The solenoid X+ must shut off the moment solenoid X- is energized. To achieve this
requirement, the given machine sequence can be divided into three groups such that
no letter is repeated in any group and given as follows;
Machine control sequence : START, A+, A-, B+, C+, B-, C-.
Group I | Group II | Group III
The relay ladder logic divided into TWO modules called Flip-flop module and
Output module.
(1) Flip-flop module :
Each group is now allocated by one control relay (internal relay in RLL) used as RS
flip-flop (memory). These flip-flops are SET and RESET using the following
methods:
Flip-flop SET : 1st group flip-flop is SET using START signal. The 2nd and 3rd
groups flip-flops are SET using NO contact of the previous flip-flop connected in
7.6

CHAPTER 7
series with sensor signal indicating the complement of the last step of the previous
group, as shown in Fig.7.4a.
Flip-flop RESET : The reset signal of each flip-flop consists of an NC contact of the
next flip-flop. The sensor for the last program step, however, resets the last flipflop, as shown in Fig. 7.4a.
This way, only ONE flip-flop is SET at any given time or what is called ONE-HOT
CODE.
(2) Output module :
The output modules of the ladder diagram drawn with various input signals are
illustrated directly on the diagram without addressing for the meantime. The address
(Y020, Y021, .., X00, X01, ) can be added later.
Note: Two ladder lines connected in parallel (i.e. using two rungs) actuate repeating
output signals (such as A+ & A-).
Any output signal that is to appear at the beginning of a new group is produced by
an NO contact of the relay assigned to that group. All the other outputs are
produced by two contacts in series, which covers: a NO contact of the relay
assigned to its group, and the sensor signal indicating the complementation of the
previous step. The complete ladder logic diagram is shown in Fig. 7.4(a), while the
sequencing chart is given in Fig. 7.5.
7.3.2 Design RLL for Single-Path Machine Sequence Having Sustain Control
Signals
The sustained output signal mean that the control signal to be maintained from step
to step until the step does not required to be sustained. An example of sustain signal
requirement; consider the control sequence of 3 cylinders with 5/2 ways directional
valve with spring return. The 3 cylinder operations can be written with sustain
Machine control sequence : START, A+, A-, B+, C+, B-, C-.
Group I | Group II | Group III
signals as follows:
A system of this type requires sustained output signals, the previously described
method must be modified. As before, divide the system into groups so that no letter
is repeated within any group. Since A-, B-, and C- solenoids do not existing in this
problem, and obtained by switching off these solenoids. Hence, the required
motions are obtained simply by cut off the respective + solenoid in the output
module. As before, the moment a new group is activated, all the outputs of the
previous groups are automatically cut off. If it is required to maintain a certain
output into the next group, that output has to be maintained in that group. To show
7.7

CHAPTER 7
this, horizontal lines were drawn on top of the machine sequence for those sustained
control signals. For example, B+ must be maintained through part of group II, up to
group III just before B-, at this moment, B+ must be cut off, to produce stroke B-,
(see Fig. 7.4b). The sequencing chart is also shown in Fig. 7.5.
START
R02
R01
Input switches
R01
R01
a+
R03
R02
R02
R02
Flip-flop
Modules.
c+
c-
R03
R03
R01
A+
R02
A-
R02
a-
Address
Start
a+
ab+
bc+
.cSTOP(not shown)
Group memory
Flip-flop1
Flip-flop2
Flip-flop3
X00
X01
X02
X04
X05
X06
X07
X03
Address
R01
R02
R03
B+
Outputs
R03
B-
R02
b+
C+
R03
b-
C-
Output
Modules
A+
AB+
BC+
C-
Address
Y20
Y21
Y22
Y23
Y24
Y25
(a) Relay ladder logic without sustain outputs
R01
R02
A+
a-
B+
R02
b+
R03
b-
C+
Output
Modules
(b) Relay ladder logic with sustain outputs
Fig. 7.4 Relay ladder logic for machine sequence START, A+, A-, B+, C+, B-, C-. (a)
7.8
without sustain outputs, (b) with sustain outputs.

CHAPTER 7
Group I |
Group II |
Group III
I
II
III
IV
V
VI
VII
START
A+
AB+
C+
BC-
|
VIII
IX
A+
ACylds.
Solds.
Non-sus
Solds
sus
B+
BC+
C-
A+
AB+
BC+
CA
B
C
Switches
a+
ab+
bc+
cSTART
Fig. 7.5 Sequencing chart for machine cycle START,A+,A-,B+,C+,B-,C-.
7.3.3 Design RLL for Multi-Path Sequencing Systems with Sustain

Outputs
Cascade method also can be applied to multi-path machine control sequence. Fig.
7.6, schematically shows a program sequence with two (or more
than two) simultaneous parallel paths for machine sequence.
7.9

CHAPTER 7
The program proceeds as regular sequence up to the completion of step(i). At this

point, two parallel paths A and B are carried out simultaneously. Path A has j steps,
and path B has k steps; the j and k are not necessarily equal. Only after both paths
have been completed AND function, the program continue with the next single-path
step(i+1).
The corresponding relay ladder logic is also shown in Fig. (7.6). Only the key
ladder lines are indicated, with all output lines omitted for clarity. On completion
step i , (xi+ or xi depend on the problem) is actuated, setting flip-flops relay YA1 and
YB1. These flip-flops cover one or more steps each, depending on the way paths A
and B must be divided into groups. When both parallel paths are completed, sensor
signal xAj and xBk are both actuated, that will set the next flip-flop Yi+1 .
Note, the normally closed contact yA2 and yB2 (which provide RESET signals for
flip-flop YA1 and YB1, respectively) refer to the next flip-flop along the path. For
instance, if all of path (A) should belong to same group, then yA2 would become yi+1
. Similarly, contacts yAj and yBk refer to the last flip-flops of the two parallel paths. If
all of path (A) should belong to the same group, yAj would be identical with yA1.
A1
A2
B1
B2
Aj
.i+1
Bk
.yi-1
yA1
.yi
.yi
Yi
yB1
Xi
yA2 ( or yi+1 )
YA1
Xi
yB2 ( or yi+1 )
YB1
.yA1
.yi
.yB1
.yAj
yBk
XAj
XBk
yi+2
Yi+1
.yi+1
Fig 7.6 Simultaneous parallel machine sequence and keyed RLL.
7.10

CHAPTER 7
Example 7.1 Consider the following machine control sequence with two parallel paths :
A,B
START,A ,A , , A ,B ,C .
C G3
START ,G1, G2 , G .5
The machine sequence can be grouped as follows:
Developed RLL for given machine sequence assuming non-sustain control signals?
G4
The RLL for the given machine sequence is shown in Fig. 7.7
START
R02
STOP
R01
R01
R01
a+
R03
R02
R02
STOP
R02
R04
a-
Flip-flop
Modules.
R05
STOP
R03
R03
R02
a-
R05
STOP
R04
Input switches
Start
a+
ab+
bc+
.cSTOP
Address
X00
X01
X02
X04
X05
X06
X07
X03
Group memory
Flip-flop1
Flip-flop2
Flip-flop3
Flip-flop4
Flip-flop5
Address
R01
R02
R03
R04
R05
Outputs
A+
AB+
BC+
C-
Address
Y25
Y26
Y27
Y28
Y29
Y2A
R04
R03
R04
b+
c+
c-
STOP
R05
R05
R01
A+
R03
R02
A-
Output Modules
R05
R03
a+
R05
a-
R04
R05
B+
BC+
b-
C-
Fig. 7.7 RLL of two parallel paths with non-sustain control signals (for example 7.1)
7.11

CHAPTER 7
7.3.4 RLL for machine sequence with two or more alternative parallel
paths
Some of machine control sequence require two or more alternative parallel
sequence. Hence, this required to use multiple RLL sequence for each path. Any
parallel machine sequence can be enabled using selector switch/switches, or any
other external switch. For example consider Fig. (7.8), after completion of step i,
the next step is either A1 or B1 , depending on whether input signal xp has been set to
1 or 0, respectively. This xp signal can be selected manually, e.g. using selector
switch, or automatically depending on the outsider machine sequence condition.
The machine control sequence will continue along the selected parallel path. Once
either path A or B is completed, OR gate function is used, the control sequence will
continue with next step i+1.
The keyed RLL for this machine sequence is illustrated in Fig. (7.8), After step i is
completed and after switch xI is set logic 1, either flip-flop YA1 or YB1 is set,
depending on whether xp = 1 or 0, respectively. Compellation of either step Aj or Bk
sets flip-flop Yi+1 .
A RLL with alternative parallel paths is useful for operating multipurpose machines.
Programs with more than two alternative parallel paths or more can be applied in
the same manner. For example, with n different xp variables (or n switches)
required to accommodate 2n alternative paths. Using xp1 and xp2 can be used to
accommodate 4 alternative paths : 00, 01, 10 and 11.
i-1
i xp=1 A
A2
xp=0
B1
yi-1
B2
Aj-1
yA1
Aj
Bk-1
yB1
i+1
..
Bk
Yi
yi
yi
xp
xi
yA2 or yi+1
YA1
yA1
yi
xp
xi
yB2 or yi+1
YB1
yB1
yAJ
yBK
xAJ
yi+2
Yi+1
xBK
Fig. 7.8 Machine sequence, keyed RLL with two alternative parallel paths.
yi+1
7.12

CHAPTER 7
Example 7-2 Given the following alternative parallel machine sequence, group the
machine sequence using Gascade method and develop the RLL for machine sequence:
Start
R01
R01
R02
Path1
R02
R03
R01
R04
Path2
R04
xp 1;(B,B,C)
START ,A , ,A ,C .
x 0;(B ,C ,B )
p
xp 1;G ,2 G3
START,G1, ,G6
x 0;G4 ,G5
p
R02
The RLL machine sequence as follows, (see Fig.7.9):
R04
E.Stop
R01
Xp
a+
R03
E.Stop
R02
Xp
b+
R06
E.Stop
R03
Xp
a+
R05
Xp
c+
E.Stop
R06
E.Stop
R04
R05
R05
R03
c+
R05
b-
c-
E.Stop
R06
Switch
Start
E.Stop
.a+
.a.b+
.b.c+
.c.Xp
Output
address
X0
X1
X2
X3
X6
X7
X8
X9
XA
Address
A+
AB+
BC+
C-
Y22
Y23
Y24
Y25
Y26
Y27
R06
R1
A+
R6
A-
R2
B+
R4
R3
B-
Output Module
R5
R3
b-
R4
b+
R6
a-
C+
C-
Fig. 7.9 RLL for alternative machine sequence (for example 7.2).
7.13

CHAPTER 7
7.3.5 RLL for machine sequence with option of bypassing certain

steps.
Fig. 7.10, shows a program for machine sequence with the option of bypassing
certain machine sequence steps. At the completion of step i, if input control signal
xp =1, then the system goes through program steps from A1 to Aj , and continue with
step I+1. If, on the other hand, xp = 0, then the system jumps directly from step I to
I+1.
The keyed RLL for machine sequence is shown in Fig. 7.10. It can be observed that
flip-flop Yi can be reset by either yA1 or yi+1 . Flip-flop YA1 is set by the ANDing
function xp xI yI and rest by yA2 (or by yI+1 if the by passed section is all included in
one group). Flip-flop YI+1 is set by either the AND function xp xI yI or xAJ yAJ .
i-1
i xp=1
A1
A2
Aj-1
Aj
i+1
..
xp=0
.yi-1
yA1
yi+1
Yi
yi
yi
xp
xi
yA2 or yi+1
YA1
yA1
yi
yAi
xp
xi
yi+2
Yi+1
xAj
Fig. 7.10 Keyed RLL for machine sequence with option bypassing certain steps.
yi+1
Example 7.3 Develop the RLL for machine sequence with option bypassing certain
steps:
START, A+ ,
G1
Xp=1; ( B+, B-)

G2 | G3
Xp=0; by pass
, A- .
G4
The RLL for the given machine sequence is shown in Fig. (7.11).
7.14

CHAPTER 7
START
R2
R4
E.Stop
R1
R1
R1
Xp
a+
R3
Xp
b+
R4
E.Stop
R2
R2
R2
E.Stop
R3
Switch
Start
E.Stop
.a+
.a.b+
.bXp
Output
R3
R1
Xp
R3
a+
a-
E.Stop
R4
b-
A+
AB+
B-
address
X0
X1
X2
X3
X6
X7
XA
Address
Y22
Y23
Y24
Y25
R4
R1
A+
R4
A-
R2
B+
R3
B-
Fig. 7.11 The developed RLL for machine sequence with option bypassing
machine steps (for example 7.3).
7.3.6 RLL for machine sequence with the option of repeating certain
steps.
Fig. 7.12, shows a multi-path machine sequence with the option of repeating certain
steps. At the completion of step Aj , the system will continue with step i+1, provided
xp =1 . If, however, xp = 0 , then steps A1 to AJ are repeated indefinitely until xp
becomes 1. This circuit is suitable for machine sequence to be repeated until the
desired effect is achieved.
The corresponding keyed RLL for this machine sequence is illustrated in Fig. (7.12).
It can be seen that the flip-flop YA1 can be set using AND function either xi yi OR by
xp xAj yAj and reset using yA2 . Furthermore, the flip-flop yAj is reset by either yA1 OR
yI+1 , depending on weather the machine steps are repeated or not.
7.15

CHAPTER 7
Note; at least three flip-flops must be allocated for repeated machine steps. If
only one or two flip-flops were assigned for the repeated machine steps, they will
set and reset simultaneously and multifunction would occur. Even the rule to divide
the machine sequence into groups calls for only two groups to cover the repeated
steps, a third dummy group must be added. Completion of the last repeated step
sets this dummy flip-flop, and the sequence carries on from there, depending
whether xp=0 or 1.
Example 7.4 Develop the RLL for a machine sequence with option repeated certain
i-1
A1
A2
Aj-1
Aj
i+1
xp=1
xp=0
yi-1
yA1
Yi
yi
yi
xi
yAj
xp
yA2
YA1
xAj
yA1
yA1
xA1
yA3 or yAj
YA2
yA2
yAj-1
xAj-1
yi+1
yA1
YAj
yAj
yAj
xp
xAj
yi+2
Yi+1
yi+1
Fig. 7.12 Keyed RLL for machine sequence with option of repeat machine
sequence steps.
machine steps:
START , A , x p 0; repeat ( B , C , B , C ) , A .
START , G1,
G2
, G 3, G 4
G5
7.16

CHAPTER 7
The RLL for the given machine sequence shown in Fig. 7.13 (note, group G4 is
added as dummy group to include three groups, as minimum, for repeated machine
sequence steps).
START
R2
E.STOP
R1
R1
R1
R4
a+
xp
R3
E.STOP
R2
c-
R2
R2
c+
R3
b-
R4
E.STOP
R3
R3
R5
R2
E.STOP
R4
a- E.STOP
R5
R4
R4
xp
c-
Input
Start
E.Stop
.a+
.a.b+
.b.c+
.c.xp
address
X0
X1
X2
X3
X6
X7
X8
X9
XA
Output
A+
AB+
BC+
C-
address
Y21
Y22
Y23
Y24
Y25
Y26
R5
R1
A+
R5
A-
R2
B+
R3
B-
R2
R4
b+
C+
C-
Fig. 7.13 RLL for machine sequence with option of repeat machine
sequence steps (example 7.4).
PROPLEMS:
Laboratory Work 7.2 : Simulate the machine sequences for examples 7.1 to 7.4
using Toshiba PLC.
7.1) Develop the sequencing chart for the following machine cycles using
double acting cylinder having two limit switches, at the two extreme
7.17

CHAPTER 7
positions. Solve the problem assuming non-sustain control signals (5/3

double solenoids and two spring for valve center);
a) START, A+, A-, A+, A-, B+, B-.
b) START, A+, B+, B-, B+, B-, A-.
c) START, A+, A-, B+, C+, B-, C-.
d) START, A+, B+, A-, A+, B-, A-.
e) START, A+, B+, A-, B-, A+, A-.
7.2)
Group the machine cycles given in Prob. 7.1 using Cascade method then
develop the RLL?
7.3)
Resolve Problem 7.1 using sustain control signals (5/2 solenoid valve with
return spring)?
7.4)
Resolve Problem 7.2 using sustain control signals (5/2 solenoid valve with
return spring)?
7.5)
Group the following parallel path machine cycles using Cascade method,
develop the sequencing chart, and RLL using non-sustain control signals;
a)
A
START , A , A , , A ,B .
B
b)
7.6)

START , A, A, B ,C, B, A.

C

Group the following machine cycles using Cascade method and develop
the RLL for the given machine sequence having three alternative paths and
using two selector switches Xp1 and Xp2. The machine sequence given as
follows (assume non-sustain control signal for cylinders B,C and D, while
sustain control signal for
cylinder A ):
7.18

CHAPTER 7
xp1 1, x p2 1;(B , B )
or
START , A , xp1 1, x p2 0;(C ,C ) , A .

or
xp1 0, x p2 1;(D , D )
7.7)
Group the following machine cycle using Cascade method and develop the
RLL for the given machine sequence having two alternative paths and
bypass machine cycle path. The selection of machine paths and bypass path
is achieved using two selector switches Xp1 and Xp2. The machine sequence
given as follows(assuming non-sustain control signals for all cylinders):
xp1 1, xp2 1;(B , B )
or
START , A , xp1 1, xp2 0;(C ,C ) , A .

or
xp1 0, xp2 1;bypass
7.8)
Develop RLL for machine sequence with optional repeat machine steps.
The selection of repeated machine path is achieved using two selector
switches xp1 and xp2 for the machine sequence given as follows (assuming
non-sustain control signal for all cylinders):
START , A , x p1 1 & x p 2 1; repeat (until x p1 1 & x p 2 0; B , B ) , A .

7.9)
Resolve Prob. 7.8 by adding alternative path of machine sequence as

illustrated below:
7.19

CHAPTER 7
xp1 1 & xp2 1; repeat (until x p1 1 & x p2 0; B , B )
START , A , or
xp 0 & x p2 1; (C ,C )
1
, A .
REFERENCES:
[7.1] : David W. Pessen, Industrial Automation, Circuit Design & Components
, A Wiley-Interscience Publication, John Wiley & Sons, 1989.
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RLL Design for Sequencing Systems

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RLL Design for Sequencing Systems

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Manufacturing Automation using PLCs