PLC Basics

PLC TRAINING
BASIC
Title of presentation
CONCEPTS
| 2/18/2011 | Drives & Control | Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Basics Concepts of PLC
PLC & PC In Comparison

Computer
CPU/Memory
CPU/ RAM/ Hard disk
CPU/ RAM/ Flash Card
Power Supply
220V AC, 1 Ph.
220V AC / 24V DC
Key board, Mouse,

Remote station (LAN)
Push Button, Selector, Limit

Switch, PxS, Bus Interface
Inputs
Outputs
PLC
Monitor, Printer,
Projector Etc.,
Solenoids, Relays, Lamps,

Motors, HMI
Software
OS: Windows XP /
SW: MS Office
OS: Firmware / SW:

Machine Logic
Internal
Calculator etc.,
Markers, Timers,
Counters, FBs
Machine Automation Over View

Controller
Command Signals
Status Signals
Push Buttons,
Selector Switches
Limit Switch, Proximity,

Reed Switch etc.,
Inputs
Outputs
Relays, Solenoids, Power contactors
HMI
Actuators: Motors, Cylinders, Heaters, Lamps etc.,
Machine
Inputs Sample Pictures

Push Button
Selector Switch
Outputs - Switch Gear Products Over View

Power Contactor
Over Load Relay
Aux. Contactor
Relay Boards
Relays
Outputs - Actuators
Cylinders
Solenoid Coils
Servo Motor
Manifold Block
History of PLC
Before the PLC, control, sequencing, and safety

interlock logic for manufacturing automobiles was
accomplished using hundreds or thousands of
relays, cam timers, and drum sequencers and
dedicated closed-loop controllers. The process for
updating such facilities for the yearly model
change-over was very time consuming and
expensive, as electricians needed to individually
rewire each and every relay.
What is a PLC ?
The PLC is an industrial computer.

It is capable of storing instructions to implement
control functions such as sequencing, timing,
counting, arithmetic, data manipulation and
communication.
The I/O interfaces provide the connection between
the PLC and the information providers (inputs like
pushbuttons, sensors,) and the controllable
devices (outputs like valves, relays, lamps,).
10
Where is the PLC used ?
The PLC controls industrial machines and

processes. In different areas of the industry PLC are
being applied, e.g.: materials handling, packaging,
palletizing, milling, boring, grinding, filling,
sorting, weighing,...etc.
11
How does PLC work ?
In the past the movements of industrial machines

were controlled by relay circuits. These relaycontrolled systems were replaced by PLC.
The primary function of the PLC was to perform the
sequential operations that were previously
implemented with relays.
Before we can talk about the working method of an
PLC, we must understand the function of relay
circuits.
12
What is a Relay ?
A relay is an electrical switch.

It contains:
a coil
a iron core
13
a switch
and a iron bar
connected to
the switch
How does a Relay work ?
When a current goes through the coil...

I
14
a magnetic field is produced in the coil and the

iron core in the coil becomes magnetic.
I
15
The electromagnetic force pulls in the switch and...

I
16
a current can go through the switch.

I
17
How does the PLC replace Relay in an electric circuit ?
The answer to this question shall be shown with the

following example circuits, A, B, C, and D.
A).
24V
S1
technical symbol
internal
of a relay
switch
electro magn.
connection
coil
K1
L1
0V
18
The answer of this question shall be shown with a

little example circuit.
B).
Function of the electrical circuit:
24V
When the user presses button S1, the re

K1 pulls in its internal switch and the lam
L1 turns on.
S1
K1
L1
0V
19

C).
24V
24V
S1
S1
Input
Power
K1
0V
20
L1
Power
PLC
Output
L1
0V

D).
24V
24V
S1
PLC logic
S1
K1
0V
21
L1
L1
0V
What is PLC logic ?
The PLC logic is not a mechanical part of the controller

The PLC logic is a software program, which runs on the
processor in the PLC. This program has to be created w
special programming tool on a PC. After downloading t
the program into the PLC, the
24V
control automatically starts
S1
SPS logic
the program.
L1
0V
22

RELAY LOGIC
Ph.
220V AC SUPPLY
START PB
STOP PB
N
PC
TMR1
PC
TMR1
LADDER PROGRAM
I1
M1
I2
Q1
Q1
TMR1
En
23
Q1
Trig
T#5s
Time
M1
Q
How a PLC works: internal

network
Communication
module
Programming
tool
power cord
PLC
RAM
E-EPROM
CPU
Power supply
Input
modules
Output
modules
Machine
24

network
Communication
module
Programming
tool
power cord
RAM
E-EPROM
CPU
Power supply
Central
processing unit
25
PLC
Input
modules
Output
modules
Machine

network
Communication
module
Programming
tool
power cord
RAM
E-EPROM
CPU
Power supply
Working- and
program memory
26
PLC
Input
modules
Output
modules
Machine

network
Communication
module
Programming
tool
power cord
RAM
E-EPROM
CPU
Power supply
Program editor
and monitoring
27
PLC
Input
modules
Output
modules
Machine

network
Communication
module
Programming
tool
power cord
RAM
E-EPROM
CPU
Power supply
Sensor signal
input
28
PLC
Input
modules
Output
modules
Machine

network
Communication
module
Programming
tool
power cord
RAM
E-EPROM
CPU
Power supply
Actuator
command output
29
PLC
Input
modules
Output
modules
Machine

network
Communication
module
Programming
tool
power cord
RAM
E-EPROM
CPU
Power supply
Control
communication
30
PLC
Input
modules
Output
modules
Machine
How PLC works: processing cycle
Start PLC from E-EPROM

Read user program & Copy to RAM
Read input signals, store in table
processing cycle
Determine new output state of output module
31
Write output commands in table

Set output values on output module
Pick & Place Unit

Schematic:
swivel
device
pick
shuttle
cylinder
up/down
cylinder
suction
pad
place
Starting position: vac. off, slide right, up; swivel not used (front
position)
Sequence of movements:
1) slide left
5) move down
2) move down & switch on vacuum
6) switch off vacuum
3) move up
7) move up
4) slide right
32

Animation:
Sequence of movements:
slide left
move down & vacuum on
move up
slide right
move down
vacuum off
move up
33
The Drive & Control Company

34
Thank you for your Kind

Presence
Note:For any queries Pl feel free

to call.
+91 8105484950

PLC Basics

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PLC Basics

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PLC TRAINING

Basics Concepts of PLC

PLC & PC In Comparison

CPU/ RAM/ Hard disk

CPU/ RAM/ Flash Card

220V AC, 1 Ph.

Key board, Mouse,

Push Button, Selector, Limit

Solenoids, Relays, Lamps,

OS: Firmware / SW:

Basics Concepts of PLC

Machine Automation Over View

Limit Switch, Proximity,

Relays, Solenoids, Power contactors

Actuators: Motors, Cylinders, Heaters, Lamps etc.,

Basics Concepts of PLC

Inputs Sample Pictures

Basics Concepts of PLC

Outputs - Switch Gear Products Over View

Over Load Relay

Basics Concepts of PLC

Basics Concepts of PLC

Before the PLC, control, sequencing, and safety

Basics Concepts of PLC

The PLC is an industrial computer.

Basics Concepts of PLC

Where is the PLC used ?

The PLC controls industrial machines and

Basics Concepts of PLC

How does PLC work ?

In the past the movements of industrial machines

Basics Concepts of PLC

A relay is an electrical switch.

Basics Concepts of PLC

How does a Relay work ?

When a current goes through the coil...

Basics Concepts of PLC

How does a Relay work ?

a magnetic field is produced in the coil and the

Basics Concepts of PLC

How does a Relay work ?

The electromagnetic force pulls in the switch and...

Basics Concepts of PLC

How does a Relay work ?

a current can go through the switch.

Basics Concepts of PLC

How does the PLC replace Relay in an electric circuit ?

The answer to this question shall be shown with the

Basics Concepts of PLC

How does the PLC replace Relay in an electric circuit ?

The answer of this question shall be shown with a

When the user presses button S1, the re

Basics Concepts of PLC

How does the PLC replace Relay in an electric circuit ?

The answer of this question shall be shown with a

Basics Concepts of PLC

How does the PLC replace Relay in an electric circuit ?

The answer of this question shall be shown with a

Basics Concepts of PLC

What is PLC logic ?

The PLC logic is not a mechanical part of the controller

Basics Concepts of PLC

Basics Concepts of PLC

How a PLC works: internal