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Introduction to programming Allen-Bradley series of PLCs
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Implementation of an 8 Floor Control System with a PLC

Implementation of an 8 Floor Control System with a PLC
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Author: Seyedreza Fattahzadeh- copyright 2015

Binding: E-book in PDF format would be shipped in a CD ROM

Format: PDF file

Number of pages: 84

ISBN: 978-1-60585-730-5

    This book details programming a SIMATIC S7-300 PLC as an 8 Floor Elevator Control System. In other books of mine, I have talked about the basics of Programming with different models of PLCs. This book has been prepared for those who are already familiar with the basic PLC instructions, and maybe have already developed some PLC-based programs for different purposes. Therefore, this text is prepared for those who want to challenge their PLC programming knowledge to generate even more complex industrial PLC programs with enhanced features: in this case, preparing a control program for a SIMATIC S7-300 PLC to control an 8 Floor Elevator System.

    The purpose of this manual is to design and implement an eight-floor elevator control system. This project is an upgraded version of my previous one, which was published about a year ago: Programming a 4 Floor Elevator with SIMATIC S7-300 and LOGO Programmable Logic Controllers (PLC). The five most important features of this version, compared to the previous version are as follows:

    1-The upgraded version control software is more complicated than the previous one, since it has been prepared for an Elevator System with 8 stops as opposed to that with 4 stops.

    2- Two different car-traveling speeds are being used in this version to ensure smooth picking and dropping of a passenger.

    3- Permanent magnets and a hall sensor are used to detect current location of the car as opposed to the application of 5 limit switches employed to detect current position of the Elevator Car.

    4-This version has two modes of operations: Automatic and Manual. In Manual mode, an operator can move the car up/down or open/close the car's door, just by depressing four related push-buttons.

    5- The Control program of the 4 Floor System was prepared using STEP7 SIMATIC MANAGER software as  opposed to the current version, which also comes with a mostly simulation version of control software  developed using LogixPro. This second Control Software allows the developer/programmer to download even a trial version of LogixPro and use the code to master his/her programming a PLC, that the instructions being fully supported by RSLogix 500 family of PLCs. This means you can regenerate any program which is already developed with LogixPro in RSLogix 500's editor window and recompile and run it without any problem.

    Each floor is to have its own illuminated push-button to call the elevator to a demanded floor. The elevator door is to be emulated with the use of a small stepper motor that opens, and stays open, and reverses after few seconds at each floor after being called. Nowadays, HMIs, 3 phase motors, and AC motor inverters have lots of applications in PLC automation industry. In the text, I thought maybe it was not a bad idea to add those elements to my project and re-write the whole control program to include them in the system. So I used a 3 phase motor with a gear box to change the direction of the motor from CW to CCW or vice versa, I used an AC motor inverter to my system to let me 1- To get the 3 phase motor to operate from 1 phase power supply 2- to change the motor direction to either CW or CCW under PLC's control software. Bunch of figures in the text show how to do it.

    Human Machine Interfaces (HMI) are devices that let operators to check present condition of the operating machine, and if needed, impose new setting in the operation of the machine at hand. I selected a typical HMI device to add to the elevator system. The book explains how to connect the device to a typical PC to generate the screen program to show the mechanical operation of the elevator and the status of the limit switches and floor numbers and such. Just by studying the explanation of the demo program and usage of the PM Designer software, you can learn how to add a typical HMI device to your own projects.

To watch the performance of the project hardware and software at action, click following video clip!

YouTube Link

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