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Benefit Of Converting To Rslogix 5000 From Rslogix 500; A Case Study

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2005 Annual Conference


Portland, Oregon

Publication Date

June 12, 2005

Start Date

June 12, 2005

End Date

June 15, 2005



Conference Session

Capstone and Senior Projects

Page Count


Page Numbers

10.251.1 - 10.251.12



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Paper Authors

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Peter Shull

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NOTE: The first page of text has been automatically extracted and included below in lieu of an abstract

Benefit of Converting to RSLogix 5000 from RSLogix 500

Richard P. Crum, Jayme L. Davis, and Dr. Peter J. Shull The Pennsylvania State University, Altoona Campus


In conjunction with Creative Pultrusions, Inc., a fiberglass reinforced polymer composites manufacturer in Alum Bank, PA, a senior project was designed to convert the machine operation code for their pultruders from the Rockwell Automation’s RSLogix500 software to the RSLogix5000 software. This project was a capstone design for the Electro-Mechanical Engineering Technology program at Penn State Altoona. The specific aim was to show the benefits of RSLogix5000 while improving the pultruding system at Creative Pultrusions, Inc. By streamlining the existing code, troubleshooting could become more efficient. In order to convert the code, a complete understanding of the pultrusion process was necessary along with that of both the RSLogix500 software and RSLogix5000 software. This document will discuss background information pertaining to Creative Pultrusions, Inc., RSLogix500 software and RSLogix5000 software in addition to the machine code conversion and testing processes.


In the vast world of automated manufacturing, programmable logic controllers (PLCs) are one of the most reliable and effective means of controlling any electro-mechanical process. Creative Pultrusions, Inc. is a company, which implements the use of PLCs throughout their manufacturing process. Creative Pultrusions, Inc., a high strength pultruded fiberglass reinforced polymer composites manufacturer, was the foundation of the project research. The project was to convert the existing program, which is in RSLogix500, to the latest Rockwell PLC software, the RSLogix5000.

Pultrusion Process Pultrusion is one of the many processes of producing fiberglass reinforced polymer composites. The pultrusion process starts by feeding fiberglass, woven fabrics, continuous strand mat, or carbon material through a series of creels1. This aligns and guides the material for entry into the die. As the material enters the die, it is impregnated with resin. Polyester, vinyl ester, and epoxies are typical resins that are used1. Excess resin is recycled back through the process. Once in the die, the heating process begins. The die has multiple heat zones to cure the material. Depending on the product, the set point for these zones will vary. The material is cured by an exothermic chemical reaction. There are catalysts in the resin that react once a certain temperature is reached. Heat will continue to be released by this process and allow the internal temperature of the product to exceed that of the die walls. After curing, the product is extracted from the die. The material is pulled through the pultruding machine by two hydraulic clamps. An encoder is used to monitor the length of material pultruded. When a desired length has been pulled through the machine, a saw cuts the product to length and resets the encoder. The saw can

“Proceedings of the 2005 American Society of Engineering Educators Annual Conference and Exposition 1 Copyright 2005, American society of Engineering Educators”

Shull, P. (2005, June), Benefit Of Converting To Rslogix 5000 From Rslogix 500; A Case Study Paper presented at 2005 Annual Conference, Portland, Oregon. 10.18260/1-2--15528

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