Basic Conceptual

1 Day Seminar

PLC Technology
in
Industrial Automation
 Basic Conceptual

PLC (Programmable Logic Control)

 Software ‘Programming’ of Application Logics …
consisting of Sequencing / Timings /
Countings / Value Processing etc.

 In a Standard Electronic Hardware, desired ‘Application

Program’ is downloaded, and the unit starts working
accordingly.
 Basic Conceptual

Machine

Inputs
Outputs

Power Circuit
PLC Outputs

Contains M/c Hardware for ‘Power Electricals’

Function Control (Running of Motors / Valves /
Actuators etc. on Machine)
 Basic Conceptual

Inputs Outputs
Section Section
PLC H/W at Macro Level
CPU with
Program Memory

Input Section … Receives information about various ‘Status Signals’ from

Machine
CPU/Program Memory … Contains Application Program as written by User. It sees
the status of Inputs & generates outputs.
Output Section … The Output Signals as generated by CPU are physically
conveyed Outside.
 Basic Conceptual
INPUT SCAN

PLC Internal Memory

Status Data Addr 1
Input Section Addr 2
from M/c (H/W)
.
.

CPU
Memory Area
for Input
Image
Addr. n

During the Input Scan Cycle, the Machine Status Data as available
at ‘Input Section’ is written into respective (individual) Memory
Location in the PLC Internal Memory.
 Basic Conceptual
LOGIC SCAN

Application – Program Memory PLC Internal Memory

Rung 1 Addr 1
Rung 2 During Logic Scan Addr 2
Cycle, the PLC CPU . Memory Area
.
“executes the program for Flags
rung by rung by (Internal
reading the Instruction Relays)
and the Data, & result Addr. n
is stored in Flags or
Output Memory Area.
Memory Area
for Outputs

X1 X2 Y1
Eg:
 Basic Conceptual
OUTPUT SCAN

PLC Internal Memory

Output Section
(H/W)
Output
CPU Memory
Image

During Output Scan, the content of the Output Memory are sent to
respective Output (H/W) in the Output Section
 Basic Conceptual
SCAN CYCLE

Input Scan

I/P Logic O/P I/P Logic O/P I/P Logic O/P

Logic Scan

Time

Output Scan Scan Cycle is a Non-Stop Time Cycle containing

Input Scan Logic Scan Output Scan
 Basic Conceptual
SCAN CYCLE
The individual functions in the Input Scan / Logic Scan /
Output Scan are as explained earlier.

The Outputs are ‘Latched’ in the Hardware Section, so that

till the Status is changed from CPU side, the Status (ON or
OFF) does not change on its own, in the Hardware Section.

As long as PLC is in healthy condition, the Scan Cycle keeps

on running without any break.
 Basic Conceptual
The “Timings” of Scan Cycle …

The Timing of Scan Cycle is Quite Fast.

The Input Scan Cycle / Output Scan Cycle Timings …

Typical about 0.5 milli seconds

Logic Scan Cycle Timing …

Depends on Length of Program, &
Type of Instructions used.
Typical Timing : 5 milli seconds
 Basic Conceptual

APPLICATION PROGRAM / MEMORY

 The ‘Application Program’ is a software program developed by

the User in some Specific ‘Format’ as given by PLC Mfr.

 The Memory is a Hardware Piece. It is embedded on the CPU

Board itself, and also can be an external Hardware like Memory
Cassette. The Application Program is developed by PLC User on
PC and then downloaded into this Memory.
 Basic Conceptual
SCRATCH PAD MEMORY
The PLC CPU has 2 types of Memories, for Application Purpose.

1) Application Program Memory

Written (Prepared) by PLC User .. M/C Builder

2) Scratch Pad Memory

Temporary Data Storage Memory area. The “Contents” of this
are not written by PLC User. While executing the Application
Program, PLC comes out with Multiple Flags / Values which get
dynamically changed. These are temporary Data Storage
Registers.
 Basic Conceptual
Bit / Byte / Word …
Single Bit

Contents of this Memory Location … 1 or 0

(High / Low or ON / OFF)

Byte : Set of 8 Bits

MSB LSB

WORD : Set of 16 Bits

 Basic Conceptual
Binary Numbering System

The entire working of any Digital Device (like PLC) works on Bits
(ON / OFF), so when it comes to Value Processing, the ‘Numbers’
(normally used in Decimal System) are converted and used in
Binary Numbering System, which is combination of Zeroes &
Ones.

The Base of Binary System is “2” (unlike 10 in Decimal System)

1 1 0 1 Decimal Number 13 is Binary 1101

8 + 4 + 0 + 1 = 13
 Basic Conceptual
SOFTWARE INSTRUCTIONS SET
Instructions are either 1 Bit Type or Multiple Bit (WORD or
Byte) Type;

 1 Bit Instructions for Logic Functions / Results

(Zero or One as Result)

 WORD Instructions can have large variety of Functionality

Logics / Timers / Counters / Data Comparison /
Data Transfer / Arithmetic / Special Functions
like PID, Trigonometry etc.
 Basic Conceptual
EXAMPLE OF SINGLE BIT INSTRUCTIONS

Software Instructions … The function / Logic Opn. to be done on the Data.

Eg:
X1 X2 Y2
Rung consisting of
1 Bit Instructions

X1 / X2 … Field Inputs
Y2 … Output

If, X1 is ON & X2 is OFF, then Y2 is ON.

X1 AND X2 … AND is a Boolean Instruction.
Result STORE at Y2 … STORE is a Boolean Instruction.
 Basic Conceptual

Some Examples of Single BIT Instructions ….

AND / OR / STORE
NAND / NOR / SET / RESET / COMPLEMENT … etc.
 Basic Conceptual
WORD Instruction
Instruction which is used with WORD as operand is called
WORD Instruction.
Eg: Compare 2 Words for Equal Value …

If Values (Contents) of Words W1 &

X1 Y1 W2 are same, then result 1 gets
Compare stored at Y1.
W1 Otherwise Zero gets stored at Y1.
W2
X1 .. Pre-condition for execution of
compare Instruction.
 Basic Conceptual

Some Examples of WORD Instructions

Logical … AND / OR / COMPARE etc.

Data Transfer … MOVE / INDEX / FIFO etc.
Timer / Counters
Arithmetic … Add / Sub / Multiply / Divide / Square Root
Trigonometric … Sine / Tan etc.
Statistical … Min. / Max. / Avg. etc.