Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

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In automation equipment, multi-station rotary table mechanisms are a classic design for improving production efficiency. Today, we will delve into a real project case—the 6-station rotary table automatic drilling and tapping machine—analyzing how to use the Xinjie PLC as the core controller to complete the full set of solutions from electrical circuit design, PLC logic programming to human-machine interface design.

1. Project Requirements and Function Analysis

First, we clarify the core requirements of the system:

  • Device Function: A 6-station rotary table, with station 1 as the loading/unloading station, station 2 as the drilling station, station 3 as the tapping station, and the remaining stations being idle or reserved. The rotary table is driven by a stepper motor for indexing. When the workpiece reaches the corresponding station, it is positioned by a lifting cylinder, followed by drilling or tapping actions.

  • Control Core: Xinjie PLC (this system uses XD5-32T-E).

  • Input Signals (X Points): A total of 13 digital inputs, including various sensors and buttons.

  • Output Signals (Y Points): A total of 9 digital outputs, controlling solenoids, motors, and buzzers.

I/O Point Allocation Table (Planning)

Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

2. Circuit Diagram Design

The circuit design is the cornerstone of the system’s stable operation, mainly including the main circuit and control circuit.

1. Main Circuit Design

Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

2. Control Circuit Design (PLC Wiring)

Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

3. PLC Program Design (Xinjie PLC Programming)

The program adopts a structured design, mainly including overall control, alarm buzzer, alarm reset, lifting rotary table control, drilling station and alarm, tapping station and alarm, and production statistics.

1. Program Structure Framework

  • Overall Control: Start, stop, reset, and cycle control; when the start button is pressed, the system enters automatic operation mode.

    Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

  • Alarm Buzzer: Activate the buzzer for alarms.

    Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

  • Alarm Reset: Reset the alarm state.

    Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

  • Lifting Rotary Table Control:

  • Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

    • Lower the lifting cylinder (Y4=OFF) to the bottom (X2=ON).

    • Start the stepper motor (drive Y0 with pulses via the DRVI instruction).

    • After the rotary table reaches position, stop the pulses.

  • Drilling Station and Alarm:

    Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

  • Tapping Station and Alarm:

    Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

  • Production Statistics:

    Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

Key Programming Techniques:

  • Interlocking: The forward and reverse rotation of the tapping motor (Y7 and Y10) must include hardware interlocking (relay interlocking) and software interlocking.

  • State Holding: Use auxiliary relays (M points) to mark the status of each station (e.g., “Processing Complete”).

  • Alarm Handling: When the stepper driver alarms (X1 is activated) or the emergency stop is pressed, immediately stop all outputs and trigger the buzzer (Y7).

4. HMI Program Design

1. Main Monitoring Screen:

Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

2. Manual Operation Screen:

Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

3. Parameter Setting Screen:

Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

4. Alarm History Screen:

Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

5. IO Monitoring Screen:

Practical Case: Xinjie PLC Controls a 6-Station Rotary Table Automatic Drilling and Tapping System (Source Code Attached at the End)

5. Conclusion

Through this case, we systematically completed the electrical control system design for the 6-station rotary table drilling and tapping machine.Xinjie PLC with its stable performance and rich instruction set perfectly implements complex sequential control logic. A clear circuit diagram serves as a reliable guide for hardware connections, while a structured PLC program ensures efficient and safe operation of the equipment, and a user-friendly HMI interface greatly enhances the usability and maintainability of the equipment.

This design approach has high versatility and can be slightly modified for application in other multi-station rotary table devices, such as inspection, assembly, and dispensing, making it a valuable practical reference for automation engineers.

I have shared the “Xinjie PLC 6-Station Rotary Table Drilling and Tapping System” with you via Quark Cloud Disk. Click the link or copy the entire content to open the “Quark APP” to access it.

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Link: https://pan.quark.cn/s/28be0a41dbba

Warm Reminder:

  • In actual projects, please be sure to adjust the instructions and addresses according to the specific manual of the selected PLC model (such as Xinjie XD3, XD5).

  • Before wiring and debugging, please ensure power is off for safety.

I hope this case analysis can be helpful to you! Feel free to discuss in the comments section.

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