INTRODUCTION

A Programmable Logic Controller (PLC) or Programmable Controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, control of amusement rides, or control of lighting fixtures.

A formal definition Of a PLC comes from the National Electrical Manufacturers Association (NEMA): A digitally operating electronic system, designed for use in an industrial environment, which uses a programmable memory for the internal storage of user-oriented instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic, to control, through digital or analogue inputs and outputs, various types of machines or processes. Both the PC and its associated peripherals are designed so that they can be easily integrated into an industrial control system and easily used in all their intended functions."

PLCs are used in many different industries and machines such as packaging and semiconductor machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory. A PLC is an example of a real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.

Brief History of PLC :In 1960s and 1970s, electromachanical relays, timer, counters and sequencers were the standard. Many Control Panels Contained Hundreds of these electromachanical devices and in some cases, a mile or more of wire. The primary negative aspect of mechanical control was that reliability was low, in contrast to maintenance costs associated with keeping these panels operating, which were extremely high. The auto industry complained that the real cost of purchase and replace a single relay could run as high as $50. A second major factor was time, expense, and labor required when a change in control needs dictated a control panel modification. In fact, during the model year changeovers, the auto industry discarded entire control panels and replaced them with new ones as the quickest and cheapest solution.

The programmable controller is a solid state electronic device designed in the early 1970s to replace electromechanical relays, mechanical timers, counters, and sequencers. The Hydromatic division of General Motors was the first to see the need for a device that would become what we know as the programmable logic controller. High speed manufacturing, as in the auto industry, required reliable control devices that was smaller, consumed less power featured fast switching, and were quickly and easily changeable. These devices must also be able to withstand the harsh industrial environment. Keep in mind that the first PLCs were little more than relay replacers.

Area of Application of a PLC :Every system or machine has a controller. Depending on the type of technology used, controllers can be divided into pneumatic, hydraulic, electrical and electronic controllers. Frequently, a combination of different technologies is used. Furthermore, differentiation is made between hard-wired programmable (e.g. wiring of electro-mechanical or electronic components) and programmable logic controllers. The first is used primarily in cases, where any reprogramming by the user is out of the question and the job size warrants the development of a special controller. Typical applications for such controllers can be found in automatic washing machines, video cameras, and cars.

Fig (A): Example of a PLC application However, if the job size does not warrant the development of a special controller or if the user is to have the facility of making simple or independent program changes, or of setting timers and counters, then the use of a universal controller, where the program is written to an electronic memory, it is the preferred option. The PLC represents such a universal controller. It can be used for different applications and, via the program installed in its memory, provides the user with a simple means of changing, extending and optimizing control processes.

How works PLC :The original task of a PLC involved the interconnection of input signals according to a specified program and, if "true", to switch the corresponding output. Boolean algebra forms the mathematical basis for this operation, which recognizes precisely two defined statuses of one variable: "0" and "1" (see also chapter 3). Accordingly, an output can only assume these two statuses. For instance, a connected motor could therefore be either switched on or off, i.e. controlled. This function has coined the name PLC: Programmable logic controller, i.e. the input/output behavior is similar to that of an electromagnetic relay or pneumatic switching valve controller; the program is stored in an electronic memory. In our Project, we are going to work with Controlling of a stepper motor, so that it is required pulses to rotate a motor. And pulse is given to PLC by using Parallel Port. However, the tasks of a PLC have rapidly multiplied: Timer and counter functions, memory setting and resetting, mathematical computing operations all represent functions, which can be executed by practically any of todays PLCs.