0:01
learn how to program a Click PLC sorting
0:03
station from scratch in this
0:05
comprehensive tutorial We'll take you
0:07
through the step-by-step process of
0:09
designing and programming a Click PLC
0:11
sorting station covering everything from
0:13
setting up the PLC to writing the code
0:15
Whether you're a beginner or an
0:17
experienced programmer this method is
0:18
ideal for anyone seeking to enhance
0:20
their PLC programming skills By the end
0:23
of this tutorial you'll have a solid
0:25
understanding of how to create a
0:26
functional sorting station using a Click
0:29
The benchwork sorting station is one of
0:31
just many machines in the machine
0:33
simulator or MS also known as easy PLC
0:37
The sorting station features a camera
0:39
that determines the color of the parts
0:41
and directs them down one of three
0:44
ramps Programming involves both
0:46
automatic and manual modes which are
0:48
controlled from a push button
0:50
control The click programming software
0:52
will be used to program this click plus
0:54
PLC Modbus TCP or Ethernet will connect
0:58
the Click to the machine simulator easy
1:00
PLC Discrete inputs and outputs will be
1:03
controlled from the machine simulator
1:05
client to the Click PLC server Using the
1:07
five-step program development process we
1:10
will demonstrate how this sewing station
1:11
is programmed So let's start and dive
1:14
into the world of industrial automation
1:16
programming Detailed information
1:18
contained in this video can be found at
1:21
acccca.ca A link has been put in the
1:23
description below If you have not
1:24
watched the other videos yet there'll be
1:26
links in the description below that will
1:27
start you at video one There'll be links
1:29
to the rest of the videos in the series
1:32
well Step one define the
1:35
task The first step in developing a
1:37
click or any PLC program is determining
1:40
what must be done Start the machine
1:42
simulator MS Select the machines button
1:45
on the main page or select machines from
1:47
the main menu at the machine simulator
1:51
All available pre-built machines for
1:52
practicing PLC programming will be
2:04
displayed Move your mouse over the bench
2:07
sorting station machine This is the
2:09
machine that we will be programming
2:11
Three items will be displayed Click the
2:14
information button on the top right of
2:15
the screen This will show you a
2:18
description of the benchwork sorting
2:27
close The sorting station simulator has
2:29
a demo mode This will allow you to
2:31
observe the machine's operation enabling
2:34
us to understand the basics of how it
2:36
functions Select the demo mode for the
2:41
machine The demonstration mode will only
2:44
show you the automatic mode When the
2:46
tray conveyor is in operation a cylinder
2:48
holds back the part allowing a camera
2:50
system to view it Once the part is
2:52
identified as either a red blue or black
2:55
part the appropriate fingers will be set
2:59
ramp The cylinder is pulled back
3:01
allowing the part to move down the tray
3:03
and be directed into the proper exit for
3:05
the color The cylinder is then extended
3:07
to allow the next part to be
3:09
identified There is a full sensor that
3:12
covers all the exit ramps This will
3:14
indicate when the part has been sent
3:15
down the exit ramp And if the sensor is
3:18
always on then the exit ramp is full and
3:23
removed Move around this 3D virtual
3:26
environment The icons at the top of the
3:28
window allow you to navigate this 3D
3:30
environment The first icon is the
3:32
default selection This will allow you to
3:34
move around without bumping into
3:36
components The next icon will
3:38
automatically show you around this
3:39
virtual environment The first person
3:42
mode will mimic a person in your 3D
3:43
learning world The third person will
3:45
show you an operator and their
3:47
relationship to the sorting station
3:49
machine Once we understand what needs to
3:51
be done we can proceed to the next step
3:53
in developing our click PLC program
4:06
Step two define the inputs and
4:09
outputs At the top of the sorting
4:11
station simulator window the view IO
4:13
will display the inputs and outputs
4:14
required for this example The outputs
4:17
are on the left hand side and the inputs
4:18
are on the right hand
4:20
side While still in demo mode you can
4:23
see the operation of the inputs and
4:26
The benchwork sorting station machine
4:28
will require 17 digital outputs and 18
4:36
inputs If you are unsure what the output
4:39
or input is doing start the sorting
4:41
station in start mode
4:56
Select the UIO at the top middle of the
4:58
sorting station simulator window We can
5:00
manually run the benchwork sorting
5:02
station without a control system such as
5:06
PLC Clicking on the outputs will allow
5:08
you to turn them on manually You can
5:11
then monitor the inputs to see their
5:13
operation The restart button at the top
5:16
of the machine simulator window resets
5:18
the scene to its starting point
5:24
The following table defines the inputs
5:26
and outputs or IO and Modbus addresses
5:28
that we will be using in the click PLC
5:33
program We can use the Click PLC
5:35
software to view the address picker and
5:38
determine the Modbus address required
5:51
Step three develop a logical sequence of
5:55
operation A flowchart or sequence table
5:57
is used to understand the process that
5:59
needs to be controlled thoroughly It
6:01
must also answer questions like the
6:03
following What happens when electrical
6:05
power and pneumatic air is
6:08
lost what happens when input and output
6:10
devices fail do we need
6:14
redundancy this step allows you to save
6:17
yourself a lot of work by understanding
6:18
everything about the operation It will
6:20
help you from having to rewrite the PLC
6:24
continuously Knowing all these answers
6:26
up front is vital in developing the PLC
6:30
program The push button control panel of
6:32
our sorting station controls both
6:34
automatic and manual movement The
6:36
operator will receive information on the
6:38
machine status from the indicator
6:40
lights Conditions must be taken into
6:42
consideration for all possibilities for
6:44
switch and push button inputs from the
6:49
This is the hardest part of the
6:50
programming development process Getting
6:52
all the conditions down for each output
6:54
based on the inputs is critical Let me
6:57
know if you agree in the comments
6:59
below Our sorting station program can be
7:02
seen as a simple conveyor operation A
7:05
part is read by a camera which sets the
7:07
color and presence of the part The
7:09
fingers are activated and confirmed A
7:12
cylinder will then allow the part to
7:13
move down the tray and into the exit
7:15
ramp The full sensor will be used in
7:17
conjunction with a timer to activate the
7:19
part destroyer and automatically clear
7:25
ramps A PLC programmer must know
7:27
everything about the sequence and
7:29
operation of the machine before
7:32
programming Ask questions or review
7:34
existing documentation to ensure you
7:36
understand the logical steps involved in
7:38
the machine's operation
7:44
Step four develop the PLC
7:48
program Writing the latter logic for our
7:50
click PLC sorting station example will
7:52
be the next step in our program
7:54
development We will use the click PLC
7:57
programming software and a click plus
7:59
PLC Call up the address picker from the
8:02
home tab Select the display modus option
8:06
to see the addresses that we will be
8:07
used for our communication
8:10
We can now enter the names of our inputs
8:13
and outputs for the machine simulator
8:17
station Detailed information on the
8:19
click PLC can be found in our click PLC
8:26
series Our program will be written in
8:28
ladder logic or ladder diagram Do not
8:31
worry that we do not document all the
8:32
names in our program This could be added
8:34
later as we need further variables in
8:42
Save and transfer a program to our click
8:45
PLC It is good practice to save often
8:47
during programming This can save you a
8:49
lot of time if the unexpected happens
8:51
such as a computer crash or a power
9:04
outage We will first program the lights
9:06
on our push button control panel This
9:08
will give the operator a visual
9:10
indication of what the program is
9:14
doing The emergency button input must be
9:17
on for any light to be activated When
9:19
the emergency button is activated the
9:21
automatic or manual lights will be
9:23
turned on depending on the setting of
9:26
switch The start and stop lights were
9:29
only associated with the automatic mode
9:31
When the automatic mode is first turned
9:33
on or when it is on and the stop input
9:35
is activated the start light will be on
9:38
and the stop light will
9:40
reset When automatic mode is selected
9:43
and the start button is pressed but not
9:45
the stop push button the stop light will
9:48
be activated and the start light will be
9:50
reset This indicates that the machine
9:54
running The stop light indicates to the
9:57
operator which button to use to stop the
10:01
In manual mode the start and stop lights
10:03
are reset Remember that the PLC will
10:06
scan left to right top to bottom The
10:08
reset from the manual will override any
10:12
condition Save and download the program
10:14
into our Click Plus PLC
10:48
We will program the automatic sequence
10:50
starting with the tray control When we
10:52
have the stop light automatic mode the
10:55
tray will start If you don't have the
10:57
sort part released and the pneumatic
10:59
cylinder is back then we will activate
11:03
part The camera control will be
11:05
activated when the start tray is on
11:23
Save and download the program
11:50
The finger control will determine which
11:52
exit part will take If the stop light is
11:55
on and the part is present then
11:57
depending on whether the blue or red
11:59
part is present this will set finger one
12:01
or two All of the parts will set the
12:04
internal bit C501 indicating that a
12:09
detected If we have detected the color
12:12
part and a trailing signal from the exit
12:14
ramp full this will reset the detected
12:17
color part indicating that the part has
12:19
been sent down one of the exit
12:21
ramps We will also reset both finger one
12:24
and two outputs and the sort part will
12:30
The sort part released will be set when
12:32
the automatic mode is enabled and the
12:33
color part is detected The finger one
12:36
and finger one advanced or finger two
12:39
and finger two advanced or black part
12:42
will be placed in series before setting
12:47
release Save and download the PLC
12:54
program The cylinder back control
12:56
release the part to be sorted If we have
12:58
a sorted part released and not timer one
13:00
then turn on pneumatic cylinder When the
13:03
part is not present and we will activate
13:05
timer one for 500 milliseconds or half a
13:08
second This will release the part for
13:11
sorting Save and download the PLC
13:16
program We will now program the ramp
13:18
full control If the ramp full input is
13:21
on for longer than 1,000 milliseconds or
13:24
1 second then timer 2 will activate the
13:28
destroyer Save and download the click
13:50
Our automatic mode for our program is
13:53
now complete We can now move on to the
13:56
control We will start with the tray
13:58
control If the manual tray light is on
14:01
then we will energize the tray The
14:03
manual light will be set and reset based
14:05
on leading edge of the advanced tray
14:07
manual push button And when the start
14:09
tray is on or off when we are not in
14:12
manual mode the light will be reset
14:16
Finger control and manual mode will turn
14:18
on the finger one light and set the move
14:21
finger to one when the finger one manual
14:23
push button is selected This will also
14:38
two When not automatic it will reset the
14:41
automatic settings for these fingers
14:46
The cylinder back control will be
14:47
activated when the in manual push button
14:50
This will also bypass the timer used for
14:52
the automatic mode The light for the
14:54
cylinder back will be activated when the
14:56
machine is in manual mode The reset push
14:59
button will turn on the light and
15:01
activate the work part destroyer This
15:03
will clear the machine exit ramps of the
15:06
parts Save and download our PLC
15:10
program Our program is now complete
15:30
We communicate with the machine
15:32
simulator using Modbus TCP Ethernet or
15:35
wireless The ports will be set with a
15:37
fixed IP address so the machine
15:38
simulator or Modbus client can find the
15:42
server Select Modbus TCP from the
15:45
communication port on the function tab
15:47
of the navigation window You can also
15:49
use the main menu setup
15:51
compport The comport setup window will
15:54
now be displayed Click on the setup
15:56
button for port one You can now set the
15:59
static IP address on the compport setup
16:02
details window Make a note of the IP
16:05
address We will need this to connect to
16:10
simulator Select Modbus TCP setup from
16:13
the main menu setup Ensure the enable
16:15
Modbus TCP server is checked for our
16:20
Ensure that the PLC is in run mode
16:22
Select status to see the active status
16:24
of our inputs and outputs on our ladder
16:29
diagram Step five test the
16:33
program We will use Modbus TCP on our
16:36
Click Plus PLC to communicate with the
16:38
easy PLC machine simulator Call up the
16:41
benchwork sorting station in start mode
16:50
The status of the machine simulator will
16:51
be at the bottom left of the screen
16:53
Currently we have no PLC connected
16:56
Select IO drivers at the top of the
16:58
screen The machine simulator IO will be
17:00
displayed Ensure we select more IO than
17:03
required for our sorting station
17:05
machine The easy PLC driver selected by
17:08
default Under the driver pulld down menu
17:11
select Modbus driver This driver
17:13
supports both Modbus TCP Ethernet and
17:19
protocols Select the configure
17:22
button We can now enter the information
17:24
for our Modbus driver Select TCP IP This
17:27
means the Ethernet port on our computer
17:30
will communicate with the Click PLC The
17:33
digital inputs from MS to the Click PLC
17:35
will be C101 to C118 This will start at
17:39
address 16484 due to the offset of one
17:43
Digital outputs from MS to the click PLC
17:47
will be C201 to C218 This will begin at
17:51
address 16584 due to the offset of one
17:57
button You will now see the inputs and
17:59
outputs specified for our Modbus driver
18:02
You can now manually send the driver
18:04
outputs to the PLC inputs and the driver
18:06
inputs to the PLC outputs
18:08
However the automatic assignment works
18:10
well and will save you time Select
18:13
automatic assignment from the driver
18:18
menu This will automatically assign the
18:21
PLC IO to the machine simulator IO
18:24
Select start driver and exit from the
18:27
menu On the bottom left side of the
18:29
window the driver communicates with the
18:33
PLC Once again ensure that the Click PLC
18:36
is in run mode We can see the operation
18:38
of our sorting station machine Try all
18:41
the manual operations from our push
18:48
panel Select UIO to know the input and
18:50
output status of machine simulator
19:08
Select the automatic
19:10
mode Select the start push button to
19:13
start the automatic sorting
19:15
machine The digital inputs and outputs
19:17
of the MS will correspond to the PLC
19:22
controller Using the data view window of
19:24
our click programming software we can
19:26
watch the inputs and outputs operate
19:30
Using a machine simulator or MS to test
19:32
the program will ensure that our program
19:34
works Troubleshooting is quickly done
19:36
without damage to any physical
19:39
hardware You can practice your
19:41
modification debug by modifying the
19:44
sorting station operation in the
19:46
way Utilize the click remote mobile app
19:49
to control the sorting
19:51
station Additional input contacts will
19:54
need to be added to the program to
19:55
control this from your phone
19:59
Add a counter for each of the exit
20:01
ramps The counter will show the number
20:04
of each color on the appropriate exit
20:05
ramp The reset will also reset these
20:10
counters Calculate the rate of parts
20:12
sorted per hour This can be calculated
20:15
in the PLC ladder logic during automatic
20:19
mode Let me know how you made out in the
20:23
below To learn more about using the five
20:26
steps to develop a PLC program click
20:29
here Click here to learn more about the
