COLLEGE OF SCIENCE OF TECHNOLOGY

MEE PRODUCTION

REG NO: 222016656

NAMES: RUGERO KESLINE
DATE: 24TH/03/2025

LECTURE: TECHNICAL SKILLS

LECTURER: HITIYISE EMMANUEL

ASSIGNEMENT 1
1. For industrial automation, explain what Instruction list is and how it can be used for PLCs
programming, consider 3 different types/brand of PLCs

A. Definition of Instruction List (IL)

Instruction List (IL) is a low-level, text-based programming language used in Programmable
Logic Controllers (PLCs) for industrial automation. It follows a structured, sequential format
where each instruction represents a specific operation executed by the PLC. IL is part of the
IEC 61131-3 standard, which defines five PLC programming languages, and is known for its
efficiency in executing commands with minimal memory usage. Unlike graphical languages like
Ladder Logic (LAD) and Function Block Diagram (FBD), IL is closer to assembly language,
making it highly efficient for applications requiring speed and precision.
In IL, each line consists of a mnemonic instruction such as LD (Load), ST (Store), AND, OR, or
JMP (Jump), followed by operands like inputs, outputs, or memory registers. This structure
allows PLCs to execute logical operations, process control sequences, and manage industrial
automation tasks. IL is particularly useful in situations where direct register access, compact
coding, and high-speed execution are required.

B. How IL is Used in PLC Programming

IL is used to program PLCs for a wide range of industrial applications, including logic
processing, motion control, safety automation, and data handling. Since IL operates with a
strict top-to-bottom execution flow, it is especially useful in high-speed automation where
decisions need to be made in real-time. Some key areas where IL is applied include:
1. Logic Control and Decision Making
IL is commonly used in machine automation where conditions must be met before an action
takes place. For example, in an automated conveyor system, IL can ensure that a belt only
moves when a sensor detects a package. IL allows complex logic conditions using AND, OR,
and XOR operations, making it effective for controlling valves, motors, and actuators.
2. Process Control and Timing Operations
IL supports timers and counters, which are essential for regulating industrial processes such as
heating, mixing, and flow control. IL programs can include delay functions, repetitive cycles,
and pulse signals to coordinate machine sequences. It is widely used in chemical processing,
food production, and packaging lines where precise timing is critical.
3. Motion Control and Robotics
IL is often applied in robotic arms, CNC machines, and servo motor control, where precise
positioning and speed adjustments are needed. Since IL executes commands quickly and
efficiently, it ensures smooth motion sequences without unnecessary delays. IL also allows
real-time feedback processing, enabling PLC-controlled motion adjustments based on sensor
inputs.
4. Safety and Emergency Systems
Many industrial safety mechanisms rely on IL programming for fault detection and emergency
stop functions. IL can monitor temperature, pressure, or machine overloads and trigger
immediate shutdowns to prevent damage or accidents. It is commonly used in manufacturing
plants, power stations, and automated warehouses to enforce safety protocols.
5. Data Handling and Communication
IL enables PLCs to store, retrieve, and process data from sensors, human-machine interfaces
(HMIs), and networked devices. It allows efficient data comparison, mathematical calculations,
and memory management, making it useful in industrial monitoring systems. Many SCADA
(Supervisory Control and Data Acquisition) systems use IL for real-time data logging and
control.

C. Use of IL in Siemens, Allen-Bradley, and Mitsubishi PLCs

Different PLC brands implement IL in unique ways, depending on their software environment,
instruction set, and hardware architecture. Although IL follows a standardized structure, its
usage varies across Siemens, Allen-Bradley, and Mitsubishi PLCs, which are among the most
widely used in the industry.

1. Siemens S7 PLCs (TIA Portal Software)

Siemens PLCs support IL programming through TIA Portal, a software environment used for
industrial automation and motion control. Siemens IL is designed to work alongside Ladder
Logic (LAD) and Function Block Diagram (FBD), allowing engineers to switch between
programming styles as needed.
In Siemens PLCs, IL is often used for bitwise operations and logical decision-making in
assembly lines, automotive manufacturing, and automated sorting systems. It is also commonly
used for timer and counter-based process control in chemical plants and food processing
industries. IL is particularly useful for memory-efficient logic execution, which is why it is still
used in many high-performance automation tasks. However, Siemens has gradually shifted
towards Structured Text (ST) and graphical programming methods, reducing IL’s role in
modern PLCs.

2. Allen-Bradley (Rockwell Automation) PLCs (RSLogix 5000/Studio 5000)

Allen-Bradley PLCs, manufactured by Rockwell Automation, support IL programming within
RSLogix 5000 and Studio 5000 software. While Ladder Logic (LAD) remains the most common
programming method for Allen-Bradley PLCs, IL is still used in applications requiring compact
and efficient control logic.
Common uses of IL in Allen-Bradley PLCs include event-driven programming, where actions
depend on real-time sensor feedback and machine conditions. It is also used for mathematical
calculations and process optimization, especially in manufacturing plants and material handling
systems. IL remains useful for direct control of industrial actuators and motors, reducing
execution time compared to Ladder Logic. Rockwell Automation has gradually replaced IL with
more user-friendly programming languages, but IL remains a viable option for engineers who
require low-level hardware control and efficient instruction execution.

3. Mitsubishi Electric PLCs (GX Works2/GX Works3 Software)

Mitsubishi Electric PLCs use IL programming within GX Works2 and GX Works3 software,
which are widely used in factory automation and motion control. Mitsubishi’s IL implementation
is optimized for compact logic execution, making it ideal for embedded PLCs, high-speed
machinery, and conveyor belt automation.
IL is commonly used in Mitsubishi PLCs for positioning and motion control in servo-driven
automation systems and robotics. It is also widely applied in time-sensitive operations, where
fast execution of logical conditions is required. Mitsubishi’s IL is still actively used, especially in
regions where compact industrial automation systems are dominant. However, like Siemens
and Allen-Bradley, Mitsubishi is also shifting towards more graphical programming approaches
to improve accessibility and reduce programming complexity.
D. Conclusion
Instruction List (IL) is a low-level PLC programming language that enables efficient, structured,
and precise automation control. It is used in logic control, motion sequencing, process
automation, safety enforcement, and data handling, making it essential for high-speed and
memory-sensitive applications.
Across different PLC brands, Siemens, Allen-Bradley, and Mitsubishi implement IL in ways that
suit their respective software environments and industry applications. Siemens focuses on
industrial automation and process control, Allen-Bradley integrates IL into event-driven
manufacturing, and Mitsubishi uses IL for compact motion control and high-speed automation.
Despite the gradual shift to graphical programming methods, IL remains a valuable tool for
engineers who need direct, efficient, and real-time control over industrial machines and
processes. Understanding IL across different PLC platforms is crucial for optimizing automation
efficiency, improving system reliability, and ensuring smooth industrial operations.
 Introduction to the IC 555 Timer in Industrial Automation

The IC 555 timer is a widely used integrated circuit designed for generating accurate time
delays, oscillations, and pulse signals. In industrial automation, especially in pneumatic and
hydraulic systems, it is essential for controlling actuator timing, regulating process
sequences, and automating mechanical operations.
The IC 555 operates by charging and discharging a capacitor through a resistor network,
creating precise electrical pulses that can be used to control machines. It has three primary
modes of operation:
1. Monostable Mode – Produces a single pulse for a fixed duration when triggered.
2. Astable Mode – Continuously generates a square wave output at regular intervals.
3. Bistable Mode – Functions as a flip-flop, staying ON or OFF until manually reset.
These functions make the IC 555 a simple yet powerful component in industrial automation,
replacing more complex electronic controllers for timing-based mechanical operations.

Use of IC 555 in Pneumatic and Hydraulic Automation

Pneumatic and hydraulic systems play a crucial role in manufacturing, processing, and
material handling industries. These systems rely on air pressure or fluid power to drive
actuators, presses, valves, and lifting mechanisms. The IC 555 is used in these systems to
precisely control timing, sequence mechanical actions, and enhance automation
efficiency.
Based on your notes and research, the IC 555 is integrated into both semi-automated and
fully automated systems to regulate pneumatic and hydraulic operations.

1. Use of IC 555 in Pneumatic Actuators

Pneumatic actuators operate using compressed air to produce motion. However, many
operations require precise timing to ensure smooth movement. The IC 555 timer is used in:
• Time-delayed activation: Ensuring that a pneumatic actuator does not engage immediately
when a signal is received but instead waits for a set time.
• Pulse-based operation: Controlling the rate at which air valves open and close in packaging
machines, conveyor systems, and robotic arms.
• Sequence control: Ensuring that actuators in an assembly process operate in a specific timed
order for precision.
For example, in a pneumatic clamping system, the IC 555 ensures that the clamp engages
for a specific time before releasing, preventing damage to delicate components.

2. Hydraulic Press and Valve Control

Hydraulic systems use fluid pressure to drive heavy-duty industrial machinery, such as
presses, injection molding machines, and forging systems. The IC 555 is commonly used
in:
• Controlling the press duration: In hydraulic presses, a monostable IC 555 circuit ensures
that the pressing force is applied for a fixed time, preventing defects.
• Regulating hydraulic valve timing: The IC 555 helps sequence valve operation, allowing
precise control of hydraulic flow in automated metal stamping, bending, and forming
machines.
• Safety locking mechanisms: Prevents premature engagement of hydraulic actuators by
introducing a delayed response, ensuring operators have sufficient time to clear work areas.
For example, in automotive part manufacturing, hydraulic presses require controlled
engagement and release cycles, which the IC 555 manages for consistency and
repeatability.

3. Pneumatic Conveyor and Air Jet Systems

In industries like food processing, pharmaceuticals, and bulk material handling, pneumatic
systems use compressed air to move objects. The IC 555 is applied in:
• Pulse control for air jets: Used in sorting systems to deliver precise bursts of air, directing
items along the correct path.
• Start-stop control in pneumatic conveyors: Ensures that materials move at timed
intervals, preventing clogging or excessive speed.
• Cycle timing in automated dispensers: Controls filling and packaging machines, ensuring
accurate dosing of products.
For instance, in grain sorting machines, IC 555-controlled air jets remove defective grains
by activating solenoid valves in millisecond pulses.

4. Timed Lubrication and Maintenance Alerts in Hydraulic Systems

Hydraulic machines require regular lubrication to prevent overheating and wear. The IC 555,
in astable mode, is used for:
• Triggering lubrication pumps at fixed intervals, ensuring oil is applied evenly.
• Setting maintenance reminders by activating an indicator light or alarm after a certain
operating time.
This is crucial in CNC machines, robotic arms, and industrial presses, where automated
lubrication increases efficiency and reduces downtime.

Use of IC 555 in Semi-Automated vs. Fully Automated Systems

The IC 555 is used in both semi-automated and fully automated systems, with different roles
in each.

1. Semi-Automated Systems

These systems require human intervention to start or control the process, but rely on the IC
555 for timed sequences. Examples include:
• Operator-triggered hydraulic presses: The press remains engaged for a fixed time before
automatically releasing.
• Manual assembly stations with pneumatic actuators: The IC 555 ensures that clamps or
pistons engage and release after a delay, reducing human error.
• Safety interlocks: The IC 555 introduces a mandatory wait period before machines can be
restarted, preventing accidental activation.
These applications improve operator efficiency and safety in workshops, assembly lines,
and fabrication units.
 2. Fully Automated Systems

In fully automated systems, the IC 555 timer operates independently, triggering mechanical
processes without human input. Examples include:
• Continuous air-jet sorting in food processing: The IC 555 generates high-speed pulses to
remove defective items.
• Hydraulic press cycle automation: The IC 555 ensures precise timing of press force,
release, and reloading cycles.
• Automated lubrication and maintenance systems: The IC 555 regulates oil pumps in robotic
systems, reducing downtime.
These applications enhance productivity, precision, and energy efficiency in mass
production, robotic assembly, and automated packaging lines.

Conclusion

The IC 555 timer is an essential component in pneumatic and hydraulic automation,

providing timed control, precision, and synchronization for actuators, valves, and presses.
In semi-automated systems, it assists operators by ensuring consistent mechanical
response, while in fully automated systems, it enables continuous, high-speed operation
without manual intervention.
By integrating the IC 555 into hydraulic presses, pneumatic conveyors, air jet sorters, and
lubrication systems, production engineers improve machine efficiency, reliability, and
safety, making it a vital part of modern industrial automation.
 a) As Production /Plant Engineer discuss some 5 situations where dedicated Electric motors
are needed in industries (in each case specify if some dedicated control methods are
needed to achieve their tasks e.g robotics, process control etc…)

Electric motors are fundamental to production engineering industries, driving

automation, material handling, and precision manufacturing. They convert electrical energy
into mechanical motion, making them essential in CNC machining, robotics, conveyor
systems, hydraulic pumps, and HVAC systems. Each industrial application requires a
specific motor type and control method to ensure efficiency, precision, and reliability.
This section examines five key industrial applications of dedicated electric motors,
explaining where they are used and how they are controlled to optimize production
processes.

1. Electric Motors in CNC Machines and Precision Machining

Industry: Manufacturing, Aerospace, Automotive, Tooling
CNC machines rely on servo motors and stepper motors to achieve precise cutting,
drilling, and shaping of materials. These motors provide high accuracy and repeatability,
which are essential for mass production and complex geometries.
Control Methods Used:
• Pulse Width Modulation (PWM) ensures precise speed control of the motor's spindle and
cutting tools.
• Closed-loop feedback with encoders detects motor position and adjusts movement for
micron-level precision.
• Programmable Logic Controllers (PLCs) coordinate motor motion with tool changes,
workpiece positioning, and automated cycles.
Without dedicated electric motors, CNC machines would lack automation and precision,
impacting product quality and efficiency in industries such as automotive part
manufacturing and aerospace engineering.

2. Electric Motors in Robotics and Automated Assembly Lines

Industry: Electronics, Automotive, Pharmaceuticals, Packaging

Industrial robots rely on servo motors and brushless DC motors to perform repetitive,
high-speed tasks such as welding, assembling, and material handling. These motors
provide fast response times, smooth motion, and high torque control.
Control Methods Used:
• PID (Proportional-Integral-Derivative) controllers adjust motor speed and torque for precise
robotic arm movement.
• Machine Vision Systems guide motors for accurate placement, improving quality control.
• Real-Time Motion Controllers synchronize robotic movements with conveyor belts and
assembly processes.
Electric motors in robotic automation increase production speed, reduce human labor,
and ensure consistency, making them essential in mass production industries.

3. Electric Motors in Conveyor Belt and Material Handling Systems

 Industry: Warehousing, Food Processing, Logistics, Mining
Conveyor belts and automated material handling systems depend on three-phase
induction motors and gear motors to move raw materials, components, and products
efficiently. These motors ensure continuous, smooth material transport in high-speed
production environments.
Control Methods Used:
• Variable Frequency Drives (VFDs) regulate motor speed dynamically, optimizing power
consumption based on load requirements.
• Programmable Logic Controllers (PLCs) synchronize conveyors with robotic arms, sensors,
and automated storage systems.
• Load Sensors and Proximity Switches adjust belt speed based on real-time weight
measurements and object positioning.
In industries like warehousing and food processing, electric motors help automate
material movement, reducing manual labor and increasing workflow efficiency.

4. Electric Motors in Hydraulic and Pneumatic Pump Systems

Industry: Heavy Machinery, Construction, Oil & Gas, Injection Molding

Hydraulic and pneumatic systems depend on electric motors to drive pumps that
generate fluid pressure. These systems power hydraulic presses, injection molding
machines, and lifting equipment, where high torque and controlled pressure
regulation are critical.
Control Methods Used:
• Soft Starters gradually increase voltage to avoid sudden power surges in hydraulic pumps,
extending motor lifespan.
• Pressure Sensors and Speed Controllers adjust motor speed based on real-time system
demand, improving efficiency.
• Closed-Loop Control Systems maintain stable hydraulic pressure by dynamically adjusting
motor operation.
Industries such as automotive manufacturing and metal forging rely on motor-driven
hydraulic systems for precision forming, stamping, and material processing.

5. Electric Motors in Industrial HVAC and Cooling Systems

Industry: Factories, Data Centers, Power Plants, Chemical Processing

Industrial Heating, Ventilation, and Air Conditioning (HVAC) systems use induction
motors and variable-speed motors to regulate airflow, cooling, and exhaust in large
production facilities. These motors maintain safe operating temperatures for machinery
and workers.
Control Methods Used:
• Variable Frequency Drives (VFDs) adjust motor speed based on real-time cooling demand,
reducing energy waste.
• Thermostatic Sensors trigger motors when temperature thresholds are exceeded, ensuring
optimal climate conditions.
• Building Management Systems (BMS) monitor and optimize HVAC motor operation to
enhance overall energy efficiency.
 Electric motors in HVAC systems prevent machine overheating, improve worker safety,
and reduce operational costs in industries like chemical processing and electronics
manufacturing.

b) As a Production/Plant Engineer, your boss asks you to purchase an electric motor capable
to carry the load of 500kg at a height of 200m in 4minutes what motor power capacity in
kW will you purchase?

As a Production/Plant Engineer, I need to determine the appropriate electric motor

power capacity to lift a 500 kg load to a height of 200 meters in 4 minutes while
considering efficiency losses.

Step 1: Calculate the Work Done

Work done to lift a load against gravity:
W=mgh
where:
m=500 kg (load mass)
g=9.81 m/s² (acceleration due to gravity)
h=200 m (lifting height)
W=500×9.81×200=981000 J

Step 2: Calculate the Required Power

Power is the rate of work done over time:
𝑤
𝑃=
𝑡
where t= 4 min = 240 s
981000
𝑃= = 4087.5𝑤 = 4.09𝑘𝑤
240
Step 3: Adjust for Motor Efficiency
Motors are not 100% efficient; assuming 85% efficiency (= 0.85):

𝑷
𝑷𝒂𝒄𝒕𝒖𝒂𝒍 =
𝜼
𝟒. 𝟎𝟗
𝑷𝒂𝒄𝒕𝒖𝒂𝒍 = = 𝟒. 𝟖𝟏 𝑲𝑾
𝟎. 𝟖𝟓

Final Motor Selection

Since motors come in standard power ratings, the closest available motor size is 5 kW.
This ensures reliable operation without overloading.