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Development of a Four-Story Elevator System for Teaching Motion Control Concept with Programmable Logic Controller

Abstract

The motion control and the programmable logic controller (PLC) are essential sub-modules in the industry automation systems. The integration of motion control teaching components into a course has been successful for the past two years. Practicing programming with a PLC trainer provides a limited range of real world experiences which usually involves various motion control components. Therefore, various assignments using input/output (I/O) devices could be given to students to exercise development of ladder logic diagrams. But more dynamic applications with motion control components are necessary to train and prepare students for the real world. The development of the PLC controlled four-story elevator is the final project assignment for students in the advanced PLC course. This final project requires the following tasks: the development of interfacing software for the human machine interface (HMI) terminal, the design of a hoist using a stepper motor, the implementation of a position-sensing mechanism, the completion of a ladder logic diagram for entire elevator control and the development of a miniature four-story frame that will enclose a carriage. In this paper, various PLC-based motion control topics, which are necessary to complete the final project, are introduced and the implementation details of the PLC controlled four-story elevator is discussed.

Introduction

This paper introduces the recently applied motion control project – a PLC-controlled four-story elevator system – to the advanced PLC course. Penn State Berks offers a year-long PLC course for both EET (Electrical Engineering Technology) and EMET (Electro-Mechanical Engineering Technology) students. The fundamentals of the programmable logic controls (EET275) are taught in the spring semester and the advanced topics (EMET430) are covered in the fall semester.

The advanced course was designed to enable students to exercise many skills that they can directly apply to solve real world problems. In order to practice the various skills that students acquired through classes and lab exercises, the development of a PLC-controlled four-story elevator system was assigned to the students as the final project.

At the beginning of the advanced course, students learn about the PanelView operator terminal and the PanelBuilder software to design control panel applications for the PV550 terminal1, 2. The lab assignments are based on the user manuals from the manufacturer and customized descriptive problems. Four major motor types – induction motor, brushed and brushless dc motors, and stepper motor – are introduced. The characteristics of these motors and application methods are emphasized in the classes and labs.

Programming with an industrial control trainer (ICT) from Bytronic Inc. is the second exercise. The purpose of this exercise is to become familiar with various motion control components such as the permanent magnet dc motor (PMDC) and linear and rotary solenoids3. The experiments with the proximity sensors, both capacitive and inductive types, and the photo sensors are also

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Lee, S. (2010, June), Development Of A Four Story Elevator System For Teaching Motion Control Concept With Programmable Logic Controller Paper presented at 2010 Annual Conference & Exposition, Louisville, Kentucky. 10.18260/1-2--15636