mikeexplorer

It sounds like something I did in my Model train project. Several outputs are assigned to energize sections of track. With all the different train operations I wrote, it would mean pointing to that output bit many times in many subroutines which would be a mess. Its not a good idea to have an output referenced more then once in a program, So what I did was use an integer. If the value is greater then zero, energize the output. So when I want to energize a section of track, I put a non-zero number in the integer. I do put a useful number in it. Say for example I am on Ladder 23, rung 10, I will put "2310" in the integer so I know where the track was energized from. Mike  

You need a minimum of RSlogix Micro Starter, it is also the cheapest way to work with any Micrologix PLC. (That is what I use) When I was installing my copy, before I activated it it did have a trial period, but it will show as RSLogix 500. Once I activated, it "became" Micro Starter. You do have to use the software to see why the PLC faulted.  

I have been using that version for several years and it has no restrictions. (for a Micrologix 1400) and I never had any issues with it. As a test, start with a new program, ladder 2 only, and just take some inputs and energize a few outputs with each input. -----| |--------( )---    I:0/0        O:0/0 Mike  

I one time had to clear a password protected Micrologix 1000 and entered " IMLCLRMEM" for your password. Not sure if that will work for a 1200 Mike  

It has been awhile, but back a few years ago I designed a PLC controlled model train project using a Micrologix 1400 PLC as a means to learn programming. I did get stuck a few times and I got some good advice from members here and I was able to improve my skills. I did this crazy project because I wanted to be able to do projects at work to do improvements. I have had a few job changes during this time but now settled in a job where I have been able to utilize these skills to update older equipment. None of these are big projects (like designing a whole new machine) but smaller scale which I am happy with. I spent a lot of time and money on this project and I didn't want to just dismantle it and say "ok that was fun" so I made a new permanent home for the project. I had an existing around the ceiling layout in my one room, so I transferred this project to that layout.  I mounted the PLC controls on the wall, The second controls (which operate the layout manually) was mounted on a folding table. I also used a pedestal which I obtained from a previous job since they were scrapping all the equipment prior to closing. I also integrated the PLC and HMI panels into my home network so Now I can access and program the PLC and HMI panels from any computer in my house. I had a spare 4 inch panel that I purchased years ago which I used to learn how to work with HMI's and it turned out it has an ethernet port so used it for my project as a second panel for testing. When I moved the project I wasn't sure what to do with it. I ended up making it battery powered and I found a wifi bridge so now this panel works on wireless.  For those who helped me in the past when I got stuck with the programming, thank you. Mike

Me too, I like to "make a difference" at work Shortly after I started my job, this machine that drops cans of paint into a box failed. It had old pneumatic controls which we couldn't get parts for. It was also going to be replaced in a few months so I loaned them a PLC and HMI (my old Micrologix 1000 which I used as a trainer) This is why the inside isn't done very neat. The second project was to replace an old mechanical counter which was used to measure the level of liquid in several tanks. It is a unique type counter and when I contacted the company for a replacement, they wanted $5,000 ! Wow! I replaced it with a Click PLC and a small HMI for around $700. In addition, the counter would only give you a number and you had to look in a chart to determine the number of gallons in the tank. The PLC made it easy to do the calculations and display the number for the operator. I am doing other projects for work now and have several planned for the future. It is nice when I can say I like my job. Mike  

First thing is you need to define the task. What do you want the PLC controls to do? Then you need to define what inputs and outputs you need. You already mentioned thermostats so those would be inputs. Draw it up, and write down notes. Then you can start to figure out the logic and instructions needed to do the task. Mike  

You can also use RSLogix Micro starter. Its cheaper then RSLogix500 (Around $160) It will work with all Micrologix series.  

I have not seen any problems with the site  

A demonstration when things go wrong, due to a locomotive's direction control that is failing. Its a good test for the programs to sense this.    

I have been doing this project as a means to learn PLC programming. Awhile back I got stuck in a rut with doing this project and I asked some questions here. Thanks to others who pointed out some bad programming practices I was using in designing this project I was able to overcome the problems. Originally I designed it with a Micrologix 1000 PLC, but soon ran into several problems, one was the limited I/O and that it could not be expanded. Plus its a discontinued model and twice I had to repair it for bad output relays. It also had limited memory and by the time I wrote in one of the train operations, I was nearly out of memory. This is the "Second generation" project. I upgraded to a Micrologix 1400 which allowed for more I/O and Ethernet capability for the HMI. The RSlogix Micro Starter was not the expensive to purchase (about $160) so for a "home budget" it was a good way to go. I am using a C-more Micro for the HMI panel because it was not expensive. I also had on hand a smaller 4 inch panel which I discovered also has an ethernet port so I plan to use it for a second display. I originally bought this one several years ago to use with my trainer kit and basically has sat off to the side for awhile. Now I can use it. Eventually this project will be transferred to my living room. I already have an around the ceiling layout now so I designed this project to be basically the same track layout. I have a pedestal from an old take-out robot which is where the HMI panel will be mounted. This is a tour of the project with the hardware and ladders and a demonstration of routines. At the time I didn't have any written yet but I designed a menu system for the routines. It was originally an idea of the "mission" code that is on the website "contact and coil" but I later designed my own way to run routines and seamlessly hand off to another routine.    

The program for this project is large, but as shown above with the train operation routines and the menu system how one routine can hand off to another and the concept of routines that run endlessly and some routines that do an operation and end. If anyone wants to see that part of the code I will post it.   It is kind of a "mission" as described in "contact and coil" but utilizes integers to jump to the selected operation and using a flag that I call "end request" which will tell an endless running routine to end its operation at a given state. Train operations that are not endless would ignore this flag, complete its operation, then end.   I am using integers to indicate what the current running routine is, and what the "next" routine will be and another integer is set as a flag to tell the main ladder that the routine has ended so it knows to hand off to the next routine. Mike  

This is a more recent video that demonstrates the train operation routines and handing off from one to another. In this case I have actual train operations written.  

I just check mine. I have RSlogix Micro starter, version 12.00 and it does not list Micrologix 1400 C as an option. Did they recently release a C series? Last year when I was shopping for a PLC Only the A and B series was listed for the 1400. I chose the A series since I don't need the enhanced password capability for my train project. Mike  

Could you post a PDF version of the file? Mike  

I can also say that Keyence is good at sending a representative to the facility to look the application over and figure out the best solution to a problem. What TWS linked is a better solution then what I posted.   Mike  

Maybe look into something like this?   https://www.keyence.com/products/sensor/positioning/ix/  

In my experience, the inspection system had to give an explicit flag to tell the part was good. I used to work in a CD/DVD manufacturing facility and every disc was inspected. Sometimes the handling arm was out of alignment so when it placed a disc on the inspection spindle, it would use vacuum to hold it and rotate it to inspect it. If the disc bounced on the spindle it wouldn't get a vacuum confirmation and the inspection cycle did not run. There would be no outputs of results, so the handling system assumed it bad. The inspection system had discrete outputs to flag a disc good, and several outputs for bad discs depending on what kind of defect it saw. This way a graph can be shown on screen tracking what kind of defects it is seeing so adjustments to the process can be made to increase the yield.   Mike  

  Looks interesting, but for the model train project I want to stick with the HMI panel. My eventual plan is once I am "done" writing the programs for train operations I will transfer the PLC setup to my around the wall layout in my living room. I have a free standing pedestal which used to be a take out robot from an injection molding machine. The original HMI is an old Proface. It will be replaced with the C-More HMI I am currently using. The button box I am using for the project will simply be eliminated and wired to this stand.  Most of the parts used for this project were scavenged from old CD/DVD replication lines that were being scrapped. I have on hand a lot of the Proface HMI's but the cost for the software was too much, so I decided to use a C-More. I probably should put those panels up for sale on Ebay or something, someone could probably use them.   Mike  

Where I work they use a lot of AutomationDirect's Cmore HMI panels. Recently for the EA9 series they made the software free to use. I found it easy to learn and they have a lot of video tutorials to view. I am using a C-More micro panel (least expensive option) for my model train project. It has less features, but for what I need for my train project, it works. The project will also determine what HMI would suit best depending on the features needed for the project.   Mike  

I don't think the EA3 panels have a built in clock, the EA9 series does.  The suggestion above if the PLC has a clock would work fine. Mike  

With seeing the amount of I/O points on the old controller, a Micrologix 1100 could be a replacement, You can use the free version of RsLogix Micro starter lite to program it.  Mike  

Some Cmore Micro panels support the PLC you want to use via serial port. https://www.automationdirect.com/adc/shopping/catalog/hmi_(human_machine_interface)/c-more_micro_panels The EA3 series the software is free. I have two of these and they were not that expensive. Mike  

I saw the different versions. For what I need it is 5 volts to 24 volts. The LED indicator from the remote switch glows either green or red depending on the track switch position. (basically the wire is either +/- 5volts) and I want to pick that signal and make it an input to the PLC so it knows the switch is in position and not jammed. (if switch is not in either position, the wire will be zero volts)   Mike  

Thank you for posting this link, I have been having an issue with my Model train project interface and this board will solve the problem! Thank You! Mike