DESIGN AND IMPLEMENTATION OF A PLC-BASED CONTROL SYSTEM FOR A FLEXIBLE MANUFACTURING CELL.
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| Title: | DESIGN AND IMPLEMENTATION OF A PLC-BASED CONTROL SYSTEM FOR A FLEXIBLE MANUFACTURING CELL. |
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| Authors: | Dragu, George1, Bucur, Gabriela1 gbucur@upg-ploiesti.ro, Popescu, Cristina1, Gocan, Benjamin Emil1 |
| Source: | Romanian Journal of Petroleum & Gas Technology. 2026, Vol. 7 Issue 1, p89-112. 24p. |
| Subject Terms: | *Programmable controllers, *Manufacturing cells, *Industrial robots, *Numerical control of machine tools, *Synchronization, *Finite state machines |
| Abstract: | In the context of the accelerated development of industrial automation and the increasing requirements for flexibility and efficiency of production processes, flexible manufacturing systems represent a modern solution for integrating machine tools, transport systems, and assembly equipment, supporting digital twin and real-time monitoring approaches [29-30]. This paper presents the design and implementation of a control system based on a programmable logic controller (PLC) for a flexible manufacturing cell comprising two CNC machines and a subsystem dedicated to the assembly of finished products. In the first part of the paper, the general structure of the system is presented, identifying and describing the component subsystems: the raw material transport subsystem, the parts reception, processing and evacuation subsystem, the semi-finished product transport subsystem and the assembly subsystem. For each of these, the functional role, the hardware elements used and the interactions between the subsystems are analysed. The manufacturing process is detailed in stages, from sorting and feeding CNC machines to assembling and counting finished products. A central aspect of the work is the modelling of the system's operating logic in the form of a finite automaton, by defining the inputs, outputs and states corresponding to each subsystem. State transition graphs are presented and how they ensure process synchronization, deadlock prevention and safe operation of the manufacturing cell. The simulation of the system's operation was performed using the Factory I/O software, through the Control I/O driver, which allows the development of control logic using functional blocks specific to real PLCs. The simulation allowed testing the system's behaviour in various operating scenarios and validating the proposed solution, without the risks associated with physical implementation. The results obtained confirm the correct and stable operation of the designed control system, highlighting the advantages of using industrial simulation in the design and training process. The presented solution can constitute a basis for further extensions, such as the integration of advanced control strategies, monitoring systems or manufacturing process optimization functions. [ABSTRACT FROM AUTHOR] |
| Database: | Energy & Power Source |
| Abstract: | In the context of the accelerated development of industrial automation and the increasing requirements for flexibility and efficiency of production processes, flexible manufacturing systems represent a modern solution for integrating machine tools, transport systems, and assembly equipment, supporting digital twin and real-time monitoring approaches [29-30]. This paper presents the design and implementation of a control system based on a programmable logic controller (PLC) for a flexible manufacturing cell comprising two CNC machines and a subsystem dedicated to the assembly of finished products. In the first part of the paper, the general structure of the system is presented, identifying and describing the component subsystems: the raw material transport subsystem, the parts reception, processing and evacuation subsystem, the semi-finished product transport subsystem and the assembly subsystem. For each of these, the functional role, the hardware elements used and the interactions between the subsystems are analysed. The manufacturing process is detailed in stages, from sorting and feeding CNC machines to assembling and counting finished products. A central aspect of the work is the modelling of the system's operating logic in the form of a finite automaton, by defining the inputs, outputs and states corresponding to each subsystem. State transition graphs are presented and how they ensure process synchronization, deadlock prevention and safe operation of the manufacturing cell. The simulation of the system's operation was performed using the Factory I/O software, through the Control I/O driver, which allows the development of control logic using functional blocks specific to real PLCs. The simulation allowed testing the system's behaviour in various operating scenarios and validating the proposed solution, without the risks associated with physical implementation. The results obtained confirm the correct and stable operation of the designed control system, highlighting the advantages of using industrial simulation in the design and training process. The presented solution can constitute a basis for further extensions, such as the integration of advanced control strategies, monitoring systems or manufacturing process optimization functions. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 27345319 |
| DOI: | 10.51865/JPGT.2026.01.07 |
