8 Pump Filler using Allen Bradley Micrologix 1100 PLCs

by: Joe Tavormina
for information on this project email me at:
joetavormina@yahoo.com

This design is for a control system that uses 8 small plcs networked to control
8 pumps with encoder feedback.

I have designed many control systems for filling machines in the past but not using multible processors..
http://www.geocities.com/joetavormina/4pump/

The request I have received the most is for a design using Allen Bradley PLCs.
The second highest request has been for the inclusion of an ethernet hook up.
The following design addresses both requests and more.

I am not a big fan of machine control with distributed processing, since it always leads to  inherent problems with communications
This system seems to stand up well to the many problems usally encounterd wihen synchornising  multible proccesors by means of a communications protocol.
 





The high speed of the ethernet network makes it possible to update the encoders in real time.
A web based interface is also posible since each PLC is able to host a its own web page.

The master PLC can be any PLC with an ethernet port
For this design I used an extra ML1100 for the master PLC..

The HMI for this design can be any touch screen, PC, or web interface.
I used a HMI form Maple Systems for this design.
The ML1100 plc costs about $300 each.
Each ML1100 has 10 inputs and 6 outputs.
Each ML1100 has a built in LCD screen which I used to display the live count as well the pump status.


I used this design to replace the control of an old KALISH Filler.
The customer is able to view the status of the machine from any browser on his network.