Aug 29, 2017

How To Find PPR and Maximum Frequency of Encoder

Encoder comes with a specified PPR i.e pulse per Revolution and Maximum Frequency output of the pulses given by encoder. Generally, encoders are mounted on the shaft of the conveyor, so according to the resulting RPM we should select the encoder with a proper PPR and output frequency.

How To Find PPR and Maximum Frequency of Encoder

How to Find PPR and Maximum Frequency of Encoder

The encoder is interfaced with the PLC for counting the pulses given by encoder and taking the feedback. PLC inputs also have a frequency range for the pulses which it can accept. So calculating the frequency of pules by the encoder is important in an application. Below is the formula to find the Max. The frequency of encoder in from the PPR and RPM.

Max. Frequency of encoder in Hz = (RPM / 60) * PPR

So if the encoder is mounted where the RPM = 2000 and PPR of the encoder is 360 the frequency of encoder will be 12KhZ. So we could find out that our PLC will be able to count pulses with this frequency or not.

Recommended Article: Using High Speed Counter in Omron PLC

Let us also see the difference between Single turn and Multi Turn encoders.

In single turn Encoder, the output code is repeated after every single revolution of the encoder shaft i.e we can not actually determine how many turns have encoder made 1 or 1000.

In Multi-turn Absolute encoders, the output is unique for each revolution or for every shaft positions up to 4096 revolutions and we can get to know that the numbers of rotation of Encoder.

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Apr 29, 2017

How To Set & Release Omron PLC Password

Every PLC has a feature to lock the program and Data Words inside the PLC, so that no one else can see and copy the program made by you. We do a hard job to make PLC Programs and thus also wants that no one else should take the credit of our hard work. In this article we will see "how to set and release the password in Omron PLC".

How to Put Password in Omron PLC

To set the password in Omron PLC like CPM2A, CP1E, CP1H etc., first make your program and after that in the left hand side project workspace is there. Right click on the PLC name and select Properties and Under protection tab you can set the PLC Password.

See below picture for a better Understanding.

Omron PLC Password

You can also Release the Password.

To release the password just Select PLC tab -- Protection and then click on Release password. Once you have set the password in Omron PLC for Program and memory data then no one can Upload the PLC program without knowing the password. Also, the password will always be saved in the program and you can see it if you forgot what password you have put.

Also check out the Step by step procedure for removing PLC Password.

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Feb 26, 2017

Increasing/Decreasing Speed using Buttons in JX Drive

In some of the application in industries, need of increasing and decreasing the speed using VFD drive through a single control panel using the push of Buttons is required. One of the best example of such machine is sheet laminating machine where operator can simply increase/decrease the speed using buttons. In Omron JX drive this function can be performed with ease through parameter of the drive. Here we are not talking of MODBUS communication and will use input from terminal. This feature can also be done using MODBUS communication and also with the help of POT. Subscribe to Automation-Talk by Email.

start stop control panel

Below are the important parameters which need to be set in Omron JX drive to use increasing and decreasing Speed feature using Buttons.

1. A001: Frequency reference selection:

In this parameter select 02 to use Digital operator as the input source for frequency. By default this is set to 00 (Digital Operator- Freq. Adjuster).

2. A002: Run Command Selection:

By default this is set to 02 for digital operator. Select 01 for terminal mode. By selecting this parameter, you will only able to give run command through control panel or terminal buttons.

3. C001: Multi-function input 1 selection: UP

This is the parameter which lets you use first input button, say Start button as increase button. By default this parameter value is set to 00 for Forward (FW). Change this value to 27 which will increase the frequency.

4. C002: Multi-function input 2 selection: DOWN

By default this parameter is set to 01 for reverse (REV) and we have to select 28 which will decrease the frequency. This feature is applicable while the machine is in RUN mode.

Notes the below points while using C001 and C002 parameters:

1. While the UP/DWN terminal is turned on, the acceleration/deceleration time depends on F002, F003/F202, and F203.

2. You can store a frequency set value after UP/DWN adjustment. Choose whether to store the value with C101.

3. Also, you can clear the stored frequency set value by allocating 29 (UDC) to the desired multifunction input and turning on/off the UDC terminal.

4. The UP/DOWN function is disabled when the JG operation is enabled.

5. The UP/DOWN function is enabled when the frequency reference selection (A001) is set to the Digital Operator (02).

6. The UP/DOWN function is enabled when the multi-step speed reference is enabled.

After setting the above parameter you can test this by using Start and Stop buttons. Use start button for increase and stop button for decrease. Now press and hold the increase button to increase the speed and release the button to hold the speed to that point and do same for decreasing the speed. If you have any issue in setting your button to UP and down mode (increase/decrease) then please let us know. To get the latest tutorial and program subscribe to Automation-Talk by Email.

Nov 7, 2016

PLC Programming For Counting Encoder Pulses

PLC Programming For Counting Encoder PulsesEncoder is mainly used for feedback purpose to know the position and distance measurement in Industrial applications. But before going in to the PLC Programming we should be familiar with Types of Encoder , Interfacing of Encoder with PLC.

PLC Programming For Counting Encoder Pulses / Feedback:-

Actually encoder is mounted on the shaft whose position we want to determine or want to monitor its value. Encoder have some PPR and they gives accordingly that number of pulses in one revolution.

Note:- The coupling of encoder with shaft should be done properly for accurate measurement otherwise the efficiency will decrease or it can even destroy.

PLC Logic Development:-

Now we will see the step by step detail for making the PLC Program. First of all we have to decide the condition that when should the counting start i.e when the pulses given by Encoder will be counted. Generally we want this at the auto-cycle start , So here we are considering at Auto Bit ok condition , however it can be done as per application requirement.

We here are considering the example of Omron PLC CP1H, in every PLC there is a Instruction for counting the high speed pules, In Omron it is PRV , so we will write PRV Instruction.

In PRV we have to define the port number where we have connected the Encoder and control Data. After that the value(encoder pulse value) will coming in one Data Register of PLC.

Now we have to decide as what to do this value. Let us take one example , suppose our encoder is of 360PPR i.e it will give 360 pulses in one revolution, Encoder is connected to motor shaft which is driving a conveyor and after every ever 300mm conveyor will stop and a cylinder will come down to cut.

So first we will calculate that in 1 revolution of encoder how much the conveyor moves.

If in 360 pulses conveyor moves 100 mm then we find that , for 1080 pulses of encoder conveyor moves 300mm.

Note:- Settings in the CX-Programmer.

So, after every 1080 pulses we will stop the motor and on the cylinder output and simultaneously reset the Encoder value, and continue this process. We will compare the Encoder Pulse value with the 1080 and at when they equal, motor stops, cylinder down and encoder value reset and motor again runs.

We have made the PLC Program accordingly. See the PLC Program below, we have included both the .cxp and .pdf files.

Download the PLC Program.

Also if you face any problem then you can leave us a comment. You can subscribe to get all related PLC Programs, SCADA Tutorials, HMI, VFD Installation related articles in yours inbox. Subscribe to Automation-Talk by Email for more such articles.

Sep 16, 2016

Automotive IoT Security: Staying Safe in a Connected Car

For today’s hackers, mobile apps can turn smartphones into unlocking devices for your car whether they’re authorized or not. Car sharing apps can be hacked to find users’ routes, including how much they tipped their drivers. According to a survey from the RSA Conference in March, 84% of people know that the primary means of transportation they use everyday can be hacked remotely like the above two examples. Subscribe to Automation-Talk by Email.

The public is also getting a better sense of how such attacks can happen, as shown by the 82% of RSA respondents who felt that hacking mobile apps connected to their smartphone and car was the most likely point of entry. Any third-party apps could be dangerous, but third-party stores on your car’s infotainment system are typically easier to hack than the App Store on your smartphone.

Vulnerability in Connected Cars

According to the graphic below on application protection for connected cars, the abundance of microprocessors in modern vehicles greatly expands the number of attack points a hacker could make. Whether it’s another connected car, smartphone, or even a smart traffic light, there are plenty of potentially hackable external sources that could transmit information to your own connected vehicle every day.

I’m not sure how many consumers would end up jailbreaking their own car, but some of the other tips on the graphic are worth keeping in mind before you drive, like making sure you regularly check for updates on your car’s infotainment system.

Automotive IoT Security: Staying Safe in a Connected Car

Jul 7, 2016

Monitor PLC Scan Time in Delta PLC

Sometimes it necessary and need of time to monitor PLC scan time in PLC program, so for such situations there are some special register (D) in Delta PLC which help in performing such tasks. D1000 is such a special register which is used for monitoring PLC scan time. When the scan time exceeds the set time in the monitor timer, the red ERROR LED indicator remains shining and all outputs will be “Off”. Subscribe to Automation-Talk by Email.

Monitor PLC Scan Time in Delta PLC

The initial set value of the time in the monitor timer is 200ms. If the Delta program is long or the operation is too complicated, MOV instruction can be used for changing the set value as shown in above image. The maximum set value in the monitor timer is 32,767ms. Users can add WDT instruction (API 07) into PLC program.

When CPU execution progresses to WDT instruction, the internal monitor timer is cleared as 0 and the scan time will not exceed the set value in the monitor timer. There is one more special register D1039 which is for Fixed Scan Time and will be discusses later.

May 5, 2016

Industrial Process Controllers Presentation

This is a good presentation on Industrial Process Controllers which will focus on temperature controllers and there working, different types of controllers like On-Off, Proportional & PID. The presentation will explain all these terms in detail and will tell about there working too. Subscribe to Automation-Talk by Email.

PID controller provides proportional action with two additional adjustments, integral and derivative, which helps the unit automatically compensate for changes in the system.

Recommended Article: Configure Real Time Trend In Intouch SCADA

A temperature controller gets input from temperature sensor such as a thermo-couple or RTD. It compares the actual temperature to the desired control temperature, or set point, and provides an output in the form of transistor output or relay.


Jan 31, 2016

Free PLC Softwares for Ladder Logic Programming

There are lots and lots of PLC (Programmable Logic Controller) available in the market and many PLC companies are emerging day by day with their own make and model PLC's and HMI. The best part is that they also provide free copies of their PLC software for your use. You can download the free PLC software from their website and can start learning their instructions, though the logic of all the ladder programming is same and you won't be having any issue in using this software's. Subscribe to Automation-Talk by Email.

Free PLC Softwares for Ladder Logic Programming

Even if you are not a experienced PLC programmer and still searching for job in automation industry, then you should try these free ladder logic programming software to increase your knowledge and programming skills. Why you should stick to only 1-2 brands of PLC's when you can try many different PLC's logic.

Recommended Article: Best PLC Ladder Programming Books

Big automation companies like Siemens, Allen Bradley, Omron etc. do not provide their PLC and HMI software for free, you have to buy license of their software's. So it is better to have goods hands-on some of the freely available software's.

Free PLC Software for Ladder Logic Programming

1. Delta PLC Software: Delta PLC's are very popular due to their cheap cost and easy handling. Delta automation provides its PLC software WplSoft for free. Any one can download their software without any login.

2. TRiLOGI: This is one of the best ladder logic learning software for students and any student or university can use this software free of charge by just writing an email to software company.

3. Cscape Free PLC Software: This PLC software is from Horner Automation group which deals in all-in-one controllers, remote I/O, expansion etc.

Cscape is a free PLC software with drag and drop feature. It is very easy to use and you can download this software by just creating an account with them.

Cscape Free PLC Software

This software combines graphical ladder diagram programming based on IEC-1131 with operator interface development to completely integrate the control package which is definitely a great feature.

4. Eware32: This software is from Entertron Industries Inc. and work with Entertron's ePLCs only as other software's. This software also has free simulator option so it can even work without any PLC hardware.

Eware32 Free PLC Software

5. KV-Ladder Builder : This is a PLC programming software from Keyence and is freely available at their website. You can download the software by creating account with them. This software also have a simulator mode, so you don't require actual PLC to test your ladder programs.

Recommended Article: Best Free Web Based Online SCADA Software

6. Do-more Designer Programming Software: This software is freely available and is from Automation Direct. This software work well in Windows XP, Windows 7 and Windows 8 also both 32 or 64-bit versions. When connected to internet it automatically checks for software and firmware updates.

There are lot more other free PLC software's available and you can download them from their official websites. If they are not full version at least you can get trail version for testing. I hope you enjoyed this article and it will benefit you in your programming and trying different flavors of PLC's. Please leave your feedback's and comments and also subscribe to our email subscription for free to get latest update on email.

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