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DL105 Applications
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Application: DL105, encoder and contactors work together for simple, low-cost automatic gate operator Products used: DL105 PLC, encoder, contactors Description: Due to security issues, we decided to install an automatic gate operator at our facilities on the East Side of Detroit. After a lot of searching, our maintenance man reported to me that he found the quality of the big name gate operators to be less than what he expected for the cost. He than suggested that we make our own. We purchased a DL105, two contactors with an interlock, and a quadrature encoder from AutomationDirect. The drive is a used ½ hp 3-phase gear motor from an old elevator door operator. The remote control is provided via a Genie garage door module. We installed everything in a NEMA 4/12 box. The encoder, mounted on an idler shaft, provides position, stall protection, and direction confirmation. No mechanical limit switches, belts, relays, etc. are necessary The PLC allowed us to program in features that are not available in commercial operators. Every time I drive through that gate I’m amazed. This unit has been totally trouble free for three years, in all kinds of Michigan weather, with temperatures well outside of the recommended range of the PLC and encoder. A counter in the program indicates an average of about 30 cycles a day; that’s about 25,000 cycles so far with no Failures. We have built far more sophisticated controllers for elevators using the DL205, but the simplicity and reliability of the gate operator makes this my favorite project. Submitted by: |
Application: DL105 CPU helps locate parts and dispense adhesive in adhesive dispenser system Products used: DL105 CPU, EZTouch panel Description: A customer needed an automatic fixture to locate a part beneath his adhesive dispenser, lift the workpiece to the appropriate height, and rotate it beneath the dispense needle to lay a bead of adhesive on the part. After designing the mechanical aspects of the machine, I used a DL105 CPU to drive a stepper motor for part rotation. The discrete outputs were used to drive solenoid valves to control the pneumatic slides, and to turn the dispenser on and off. The touch panel was used to generate manual controls for setup, to enter the number of rotations the part had to make, the rotational speed, and to generate error reports. I also used AutomationDirect’s prox sensors to verify fixture location. Your excellent pricing made this a very profitable project for my firm. Thanks again for the quality products at low prices. Submitted by: |
Application: DL105 and DirectView 1000 operator interface count and package plastic drinking straws Products used: DL105 and DirectView1000 Description: Drinking straws are made using a continuous extrusion, cutting and wrapping process that shoots a machine gun-like barrage onto a conveyor belt, all laying neatly parallel to one another, perpendicular to the belt. The customer needed several low cost counting, queuing and loading systems. The DL105 and DirectView 1000 combination was the perfect solution. The PLC counts the output of each of two straw wrappers by sensing a point on a revolving wheel within the wrappers, and uses discrete CMOS logic to OR the outputs, effectively adding the two signals. When it reaches the desired package count, a brush flips down and starts bunching product while those that have passed are loaded into a bucket conveyor, awaiting the bagging machine. The PLC steps the conveyor queue, pushes the straws into the bagger and, if necessary, dumps the product into an overflow bin if the bagger isn’t ready. The DirectView operator interface allows the operator to easily control the package size. Additionally, we added maintenance troubleshooting help and management statistics to the display, a surprise function they really valued. The AutomationDirect design tools simplified the design process. I prototyped at my desk using a 1.8GHz desktop PC - the big display and high-speed printer really helped. I debugged the system out on the factory floor using an old 233Mhz laptop -- more than enough to see what was going on. Great tools and great support. - thanks. Submitted by: |
| Application: DL105 gets conveyors ready to roll Products Used: DL105, Hitachi L100 Drive, and EZTouch mono 6" Description: A customer needed a machine to cut axial slots in rubber coated conveyor rollers. The number of slots required would vary from 20 to 300, and the slot spacing had to be very even and accurate. Using the pulse output features of the DL105 and a low cost stepper motor and driver, I built a system that would automatically index the roller on a spindle, then create axial slots with a high speed router and saw blade, with X and Y motion accomplished by air cylinders. The EZTouch allows the operator to perform all manual motions for setup, as well as displaying a part counter, cut counter, and fault reporting. The Hitachi drive allows excellent speed control of the router head. Via some simple software, all the operator needs to enter is the amount of slots desired, and the machine does the math and creates very evenly indexed cuts. Stepper motor speed is also adjustable via the touch panel. Submitted by: |
| Application: DL105 controls portable saw mills Products Used: DL-105DR-D, DL-105DR, OP-1500 Description: We use the DL-105DR-D, DL-105DR , OP1500 interface panel and an optical encoder to control portable saw mills. The PLC takes preset values entered by the operator and sets the head vertically to within .020" of the desired value. The total weight of the head is approximately 1500 LBS, moving at 1ft/sec or greater. These machines are subjected to every environment on earth. The PLC and interface are mounted directly to the head, which is powered by a 4-cylinder diesel engine. This combination allows the operator to increase production speed and reduce waste; it also allows us the ability to customize functions with ease. In addition, the removable terminals allow the customer to perform field repairs and upgrades with minimal downtime. The reliability and ease of use coupled with the low cost make this option a customer favorite. Submitted by: |