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Custom made servo motor using hall effect sensor. The problem is that there is asymmetry with the servo going 90-0 vs 0-90. I don't know why that is. What may cause the asymmetry. I'm only using Kp and very basic and simple PID. Calculating the shortest distance between the angles. And moving the motor using the output. If you look at the slope of the curves. When its going 90-0 or from any angle to 0 it works smoothly. As you can see it looks like a typical PID but when going 0-90 it looks inverse.

Hello,

I work as an intern in a company and they gave a S7-1200 to play. It is used and it's state is unkown(we don't know if it works at all).

Run/Stop led alternating
Error led always on
Maint led flashing

As I searched online the plc is probably faulty.
I am trying to connect it to TIA PORTAL via ethernet but I a cannot find it in Tia.
I have connect the PLC on a switch we have in the office. S7 Link led is green and Rx/Tx flashing.
Should I connect the PLC on my computer directly or the PLC is completely faulty?

Thank you in advance.

I know this isnt entirely to do with PLC's but is connected to a safety controller so hopefully this falls within th scope of this forum.
We have an existing production line in our factory that health and safety has deemed needs a new emergency stop button fitting to. It appears to be that it just needs putting into the existing two channel series circuit somewhere in the middle. The engineering manager has asked the controls team to sort it out but not having much in the way of experience with safety systems is this OK?

I have a question for all you guys. I usually troubleshoot machinery that is automated and have programmed from scratch for small machines. Just today I troubleshooted a basic issue for a diverter valve on a 8 silo system. Holy smokes ! The ladder diagram was HUGE. It was a contrologix rack and it was my first time dealing with contrologix. I usually work with compactlogix. (I know they’re practically identical in certain things) I got it up and running in no time because the code for the valve was basic. I started scrolling to other routines and i saw a lot of recipe management and super huge code that didn’t even fit in my screen 😵‍💫

Obviously I never saw this code. There was no comments. Some things were labeled. How do you guys figure complex code out ? I now i’m at home trying to reverse engineer how this works but holy crap I never seen a program this big before. How do you guys not get scared when seeing sh*** like this. This triggered my imposter syndrome forsure. 😭

Anyways, thanks in advance.

Hi everyone I had a question about Allen Bradley software's and what each program is intended for. This is what I believe to be true, but I want to make sure I'm not missing anything.

Factory Talk Linx - creates connection between PLC/HMI to Computer

Studio 5000 View Designer- Allows for creation of new HMI Programs

Studio 5000- PLC Programming software

RsLogix 500- For SLC plcs

Connected components workbench- Drive Programming and Micro series PLC/ Panel View 800 programming

Am I missing anything to be able to create and edit new HMI programs and create/edit PLC programs on modern day controllers. Thanks for the help.

Hey guys. I'm trying to add a login event log to a HMI program that we use to shuffle boxes around to different sorters. The idea is to password protect the screen and whenever it's entered it creates a log entry into a file. This is so we can hand over some of the responsibility to operations but this way if something happens we can find out when a change was made to the program. Does anybody here have any links to how I would create something like this. I'm using C-More 6.78 for the program

I work for a smaller SI company. We have been mainly project work since 2020 but have a new client that would like us to provide an hourly T&M rate for service calls. The last rate sheet we have was updated in 2022. Ive inherited the task of updating the sheet an I am wondering what what others are using as an hourly rate. New clients was $138 /hr and some discounts for older clients. Are we too low?

If you've taken the new Ignition Core exam what has been your experience? How long did it take you to study, take the test, and how difficult did you find it?

https://preview.redd.it/cwn3hc592rcd1.png?width=986&format=png&auto=webp&s=10a6bb23e26923ade7101b61e2a85af7c09b8759

https://training.inductiveautomation.com/core-certification/

I have attached a SM334 Module to my IM153-2 and AI 8x16 HART Module via a Backplane connector (which is connected to a CPU 317-2 PN/DP via Profibus DP). When I try to connect a known working 4-20 mA sensor to the input module, the sensor doesn't turn on and I don't receive any signal back. But when I connect the sensor to the AI module beside it, it turns on and I do receive a signal from the Pressure Transmitter.

Does anyone know why I can't get a signal back from this module?

Couple Notes:

1. I am testing the AI side first to make sure the module works; I am using the module for the AO functionality, not the AI Module functionality.

2. The Processing Image Input and Output sizes are set to 512.

3. The AI Addresses are 256...271 for the HART module and 272...279 for the AI4/AO2 Module.

4. The Module is being detected via the backplane connector, so I am not receiving any hardware configuration errors.

I have a G7 setup to get its run source and reference from the option PCB card. I’ve got a job button wired to the S7 terminal and have h1-05 set to FJog. It will not jog when hitting the button. The drive is seeing it when I bring up the u1-10(I think?) to monitor the inputs. What am I missing here? I want to maintain the run source and reference over Ethernet but want a local jog button. TIA

Hi all, we want to start using industrial robots. Right now for palletizing. Which brand do you use or would you not recommend?

Hello guys, I am using a Siemens S7-1214C with Pid_Temp. The application of this Pid is to keep a certain temperature through a valve that can blend cold and hot air. 0..10V output from PLC. I have a burner with a fixed setpoint that generates heat. I already did a fine optimization on this Pid and now it works well, but I would like to know if I can increase this optimization. Regards.

I'm currently working on a project that would enable remote operation of a cell from a mobile device that's connected to an OPC UA server within a S7-1500 PLC. I would say I'm on the inexperienced side of programming PLCs and have never built a heartbeat connection to a PLC before but in the interest of safety I believe it would be beneficial to have the cell E-stop when the connection to the mobile device is terminated/can't be reached. Any tips to go about this process of setting up this interlocking communication to prevent the cell from continuing to run if a connection to a device that starts the operation is terminated.

p.s. I still want to be able to run the cell from the HMI when no connection to a external device is made (which is already possible)

By locked down I mean no access to diagnostics, no attempt to explain flow of logic or systems states - basic controls only eg on/off, set temp.etc

This i saw on a big site with a lot of systems. Some custom, some bought. Staff on site are all electricians it would seem. Big facility - 500 staff overall. No access to a single PLC

Please give me your thoughts or if you have ever tried this. I need one more DO on a LynxSpring BZ122-LX and it has 2 spare AOs. So I was thinking of putting a 5V relay to convert it. Seems like it would work as long as the current isn't too high for the output. I'd just be concerned that the relay may bounce if you provided a 3-4V signal. ???

I was also looking into something that I can't seem to find. A sort of relay that activates when a certain voltage is achieved. Something that does the same thing as a comparator but has a dry relay contact as an output. Let me know if you know of such a thing.

Edit: Thanks for everyone's input. I've came to the conclusion that:

1: A coil relay is a very bad idea.

2: A SS relay is probably not that great either.

3: You could use something like this limit alarm if there were no other option, but it may be just as expensive in the end as getting another PLC card or whatever.

Hi,

I'm using studio 5000 with emulator.
I built a very simple program, XIC Contact should energized OTE, one simple rung.
For some reason, the XIC is not energized my OTE.
The program is in run mode, no errors or warnings.
I called the routine in the main routine with JSR.
The tags are used only in this routine, those actually the only tags in the program.
Usually I don't work with emulator, I checked and the configuration is exactly how it should be.
What should I check?

User u/5hall0p suggested this as a program to make as a good way to practice PLC programming. I've just recently got TIA Portal, and am still finding out about it and have a lot to learn.

This was the description he provided:

The garage door opener is a good one. Press the button when closed, it opens. Press the button when open, it closes. Press the button mid way it stops. Press it again it goes in the opposite direction. Safety eye gets blocked while closing, stop, reverse, open, then flash light. Light is on whenever action is initiated and stays on for a time delay afterwards.

Please note that I just assigned everything as 'global memory' bits, which I've found lets me operate everything in PLCSIM. The reason their addresses are mixed up is I have other routines with different tags that I'm working on at the same time also. Also I wanted to try doing it with just a single button that made the door open, close and stop, which is the case with a lot of garage doors I've seen.

Feel free to give any feedback on how it could be improved based on the screenshots. Note that I simulated it in PLCSIM and it operates as per the description. One issue I had was that the sequence was jumping through the steps until I added the 2 second time delay to each step. The downside of this is the button does nothing for the first 2 seconds that the door is stationary. Not sure if this is acceptable in a real-life scenario, but it allows the code to work for now, but maybe there's a better way to do this?

Thanks

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Hello guys, so my supervisor at my internship company asked me to lookup a bunch of standards, and gave me a timeline of 10 days, but i don't know what are the necessary informations that i should know, like i dont know what i should focus on and i need your help if you re familiar with them, the standards are: Namur Enisa SANS institute Nist 800-82 Reference architecture. Please if you can give me some pointers on how to read those and what should be the take away from them. For context it's like the prerequisites for a mega project the team is working on. THANK'S FELLAS.

Hello,

I am trying to set a communication between ABB plc PM573 and a python program via modbus TCP. I am using pyModbusTCP as my library. The main problem is the communication is failing if ı don't connect the plc from Automation Builder. I mean ı can't read any register information or etc if the PLC is not connected from Automation Builder but when i ping the IP i can get the signal.

Is there anyone who knows how to connect it ? I am guessing there should be a initilazing request or some setting maybe...

We have a siemens s7-1500 and we try to do the safety program with profisafe I/O modules
when we dont have a program in plc, the modules work fine, but when we do the safety blocks both modules show us SF LED and the output module is locked in 5V, then the input module give us 24V like its an output module and the whole block is blocked in safe mode

What's your favorite customer...not lie, but moment of wishful thinking? Like, something they say they don't need at the beginning of the job, but turns out it's critical to their process? Or the opposite. They say they need something and end up not using it.

Forgive the ignorance here. PLCs are a bit foreign to me.

What is the advantage of a standard PLC that clicks together over field/remote IO?

Background: I work in Test Engineering and we have a new manager. He is wanting to bring more PLCs into our test solutions over custom boards. I normally do the board designs and firmware in the test department so this is becoming my job to learn. Which is fine, I like new challenges. It's just kinda weird because he is mandating PLCs yet has no recommendations of what to actually do in a way that seems like he never used one. I'm not entirely sure our new manager knows what we even here but oh well he is the boss.

I dipped my toes in and everything I used on this project modbus TCP. It was all field io type stuff even though I have it all on 1 din rail. I just had no clue where to start with one of the click together type PLCs. I will be honest I used an Arduino OPTA so I can do a more traditional coding style than ladder logic.

So back to question what is the advantage of snapping it all together over what I did? I'm honestly open minded on this because I know I don't know anything here about PLCs. Any recommendations on a snap together type PLC for future projects?

Thanks!

This might seem like a weird question for a PLC sub, but I'm curious if any of you used LEGO technics as a demo platform for a PLC lab.

My idea is to make a motorized conveyer belt or something like that and have the motor controlled by a PLC. I have electronics experience so interfacing the two should be easy

Curious if someone else has done this, and what your experiences were

I work as technician without a degree. I have done some part-time night school, but found that doing calculus late at night was negatively affecting job performance, and I am making a pretty penny and don't want to screw that up. Basically, I have been some kind of "troubleshoot and fix it" guy since I started working full-time, 12 years ago. Got into industrial controls kinda sorta in 2016, got into it for real about 3 years ago.

I am looking for pointers on possible certifications or training to pursue that might land me a starting position editing logic, instead of just chasing faults. Life isn't bad by any means, but I am eager to learn more.

I have a basic resume, plus a detailed list of specific hardware I have messed with.

Resume

https://docs.google.com/document/d/1JOjTUNOZ2vH-kQ_wLNex86D4yX4-L3XJphWtInVxdxI/edit?usp=sharing

Detail

https://docs.google.com/document/d/1VTKohPDdWIp_8TG3OJqkPY3pnYaHd5HJkZJdmAVztGI/edit?usp=sharing

Long time lurker, first time poster.

I am working on reducing component costs of a design, and found this 3 phase current sensor from ATO for $161.

https://www.ato.com/3-phase-ac-current-transducer-1a-to-80a

The design currently uses this current sensor from Automation Direct for $429.
https://www.automationdirect.com/adc/shopping/catalog/sensors_-z-_encoders/current_-a-_voltage_sensors_(ac_-a-_dc)/3-phase_ac_current_transducers/3actr200-42-24-f

Both components meet the needs of the design (at least according to their datasheets). My question is:

Has anyone used ATO before? If so, what was your experience?

They seem to be a cheap brand (which I'm okay with), but I don't want to waste my time if this company is shipping products with major QC issues.

Paul Lynn's PLC Dojo is still good to start learn about plc? i'm from brazil but we dont have any good content about it here.

Doing his 5 courses will I have good knowledge to work in the area?

Hello guys, did it ever happen to you that opening program from target PLC in TC2 either interrupted the program execution or communication between something? (Like HMI or hardware with ehernet communication). Never happened to me before but at friday we've been testing new function for robotic cell. We've been testing similiar thing day before and it was all good so they didn't even bother with waiting for me and started the test. Then I had to rush in and make fast connection and download from PLC to be able to see what's happening inside it. Then it happend that once robot finished it's job it started the program all-over again and crashed because of it. We've repaired the robot's tool which broke and it's all good but I can't figure out why did it happen. I've been staring into the code for the whole weekend and there is just no way that it happened via natural execution.. it was either bug in robot's controller program or the download made some mysterious thing inside the PLC which allowed the program recycling. I've never seen it before but I need to be 100% sure if that might have been the cause. Thank you all for replying.