Using a PLC to transform the electrical system of a machine tool significantly simplifies the wiring and improves overall efficiency. The design approach involves connecting each electrical component directly to the input and output ports of the PLC. The relationships between these components and their operational states are defined by a logic program, eliminating the need for traditional series or parallel connections. This results in a more straightforward wiring layout and makes the system easier to maintain and modify.
First, the connection between electrical components and the PLC hardware is established. Control circuit elements such as switches, buttons, relay contacts, and contactor auxiliary contacts are connected to the PLC's input ports. Each contact is assigned a specific port number, and multiple contacts from a single component usually only require one input port. On the other hand, energy-consuming devices like relay coils, contactor coils, solenoid valves, indicator lights, and illumination lamps are connected to the output ports. An input/output port assignment table is then created, with each port serving as a key logical variable in the control program.
Next, a logic program is written to define the conditions under which each output port is powered on or off. This program must be developed based on the machine tool's control requirements and the original relay control logic. As the PLC runs, it continuously reads the status of all input ports, processes the data according to the logic program, and controls the output ports accordingly. This allows the connected coils to be energized or de-energized, thereby controlling motors, hydraulic systems, and other electrical components. In effect, the complex wiring of the original system is replaced by well-defined logic programs.
This method enables the complete fulfillment of the machine tool's control needs. By leveraging the capabilities of the PLC, it's possible to implement self-diagnosis features through additional logic programming or by adding a minimal number of components. This not only enhances the reliability and efficiency of the machine tool but also improves its maintainability and reduces the risk of future failures. Overall, integrating a PLC into the control system offers significant advantages in both performance and long-term operation.
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