Looking for usage ideas for PLCs and other industrial control bits

[Boilermakr]

I have a few older PLCs from a prototype project that never went anywhere. Most are small brick PLCs with 8 discrete inputs and 6 relay outputs that can be expanded to up 56 I/O in the same ratio; or 24 discrete I/O, 4 analog inputs, and 2 analog outputs. I have one "rack & module" style PLC similar to an A-B SLC5/04 as well. I don't remember how many I/O is can have, but it has 7 or 8 slots.

Along with the PLCs I have two operator interface panels, photoelectric, inductive, and capacitive sensors. indicator lights, pushbuttons, terminal blocks, etc.

I never sold the equipment and I've been sitting on it for a while (8 years) but it all still works since I have the old program still in the PLCs. The original plan for the equipment was to automate a greenhouse for commercial hydroponics and the customer's capital fell through. My yard has too much shade for a greenhouse, so now I need new ideas.

I believe there are 3 or 4 small PLCs, plus the large one. So, start posting ideas!


Edit - I don't have a mill yet, but I'm considering the IH mill or a Tormach. One idea I've thought of is an automatic tool changer, but I'm not how easy it would be to integrate into either mill with the Mach3 sw.

[trubleshtr]

PLC is good for any auxillary machine controls. grippers,pumps,coolant,clamping,hydraulic/pneumatic stuff. tool changer
house projects..furnace/AC, home security, lights control.
anything with a actuator and sensors when you really think of it.
let us know what you build.

[Al_The_Man]

Edit - I don't have a mill yet, but I'm considering the IH mill or a Tormach. One idea I've thought of is an automatic tool changer, but I'm not how easy it would be to integrate into either mill with the Mach3 sw.

The way it is done with most CNC/PLC systems wether the PLC is Internal or external, is that a bit is set on the CNC side when a T code is issued, this bit is input to the PLC, together with a coded value for the tool, the PLC then goes about the process of changing the tool, however you have programmed it.
When the tool change has completed, the PLC issues a finished signal to the CNC side and the part program will continue, up to that point it has hung up, waiting for the PLC to finish.
Al.

[Boilermakr]

I already have the home automation covered and a security system is a little more specialized than what these PLCs can handle...

I do like the idea of using it in combo with pneumatics, but I'd need to upgrade my filters on my air compressor. The lubricant eats up MAC valves. Hmmm... pneumatic gripper and clamping. Maybe a small automated Annodizing line out in the garage? LOL!

[kaye7877]

I've been selling everything on ebay and getting a decent price for the stuff. Then I try to find exactly what I want.

[Boilermakr]

I've been selling everything on ebay and getting a decent price for the stuff. Then I try to find exactly what I want.

I've thought about that, but I've got all the software to program these PLCs. The hanrdware is usually pretty cheap, it's the software that kills you. Hmmm, kind of like CNC. Plus, I just hate selling stuff on eBay, I don't mind buying from good sellers, but hate dealing with all the BS and I've had three of my four attempts fall through due to deadbeat bidders.

I know I'll use them, I just want to see what cool ideas the members here can come up with that haven't crossed my mind. I'm thinking about using one for a vacuum-bagging controller and another for a small curing oven controller with two temp controllers.

I almost used one with a pair of through-beam photoelectrics and a stacklight with horn to make a parking assistant for my wife, but decided to just hang a tennis ball from the ceiling.