PLC

TOPICS TO BE COVERED
• Programmable Logic Controllers
• Relay Device components
• Programmable controller architecture
• programming a programmable controller
• Tools for PLC logic design.
 PLC DEFINITION
• A programmable Logic Controller (PLC) is a
specialized computer used for the control and
operation of manufacturing process and
machinery.
• It uses a programmable memory to store
instructions and execute functions including
on/off control, timing, counting, sequencing,
arithmetic, and data handling.
• The PLC is a microcontroller based device
with input/output circuitry that monitors the
status of field connected sensor (inputs) and
controls the attached (output) actuators (motor
–starters , Solenoids , Speed drives, Valves
etc.) according to a user created logic program
stored in the memory.
• PLCs are armoured for severe condition (dust ,
moisture, heat, cold, etc.) and have the facility
for extensive input/output (I/O) arrangements.
These connect the PLC to sensors and
actuators.
• PLCs read limit switches, analogue process
variables (such as temperature and pressure),
and the positions of complex positioning
systems.
• PLCs operate electric motors, pneumatic or
hydraulic cylinders, magnetic relays or
solenoids, or analog outputs.
• The input/output arrangements may be built
into a simple PLC, or the PLC may have
external I/O modules attached to a computer
network that plugs into the PLC.
RELAY DEVICE COMPONENTS
• Switches
• Relays
• Counters
• Timers
 Switches

• Switch is a device that opens or close circuit.

 Non-locking Locking

SPDT Normally Open Normally Closed

DPST

P1

P2
Multiple Throw Multiple Pole

Break-before-make Make-before-break
 TERMS
Throw - number of states
Pole - number of connecting moving parts (number of individual circuits).

SPDT

DPST
 TYPES OF SWITCHES
1. Basic switch, operated by a mechanical level,
2. Push-button switch,
3. Slide switch,
5. Limit switch,
6. Proximity switch, and
7. Photoelectric switch.
 Relays
• The relay is an electromechanical switch used as a
protecting device and also as a controlling device
for various circuits, equipments, and electrical
networks in a power system.
• The electromechanical relay can be defined as an
electrically operated switch that completes or
interrupts a circuit by physical movement of
electrical contacts into contact with each other.
 Counters
• Counters are used to detect pieces numbers
and events. Controllers frequently need to
operate with counters in practice.
• For example: a counter in circuit is required if
exactly 20 identical components are to be
conveyed to a converyor belt via a sorting
device.
 Timers

• Many control tasks require the programming

of time.
• For example, cylinder 2 is to extend, if the
cylinder 1 is retracted- but only after a delay
of few seconds.
PLC Architecture
There are six basic components in a PLC
system:
1. Power Supply module
2. Input module
3. Central processing unit
4. Output modules
5. Software
6. Memory
 CPU
• It stores the control program and data in its
memory.
• Reads the status of connected input devices.
Executes the control program.
• Commands connected outputs to change state
based on program execution
• For example: Turn a light on, start a fan, adjust
a speed, or temperature and Comes in various
physical forms.
Functions of CPU are :
1. It receives input from various sensing devices
and switches
2. It executes the user program
3. It makes various decisions to control the
operation of the equipment or process
4. It can perform various arithmetic and data
manipulation functions
5. It delivers corresponding output signals to
various load control devices such as relay coils and
solenoids
 Input module
• They Physically connect to field devices. Input
modules convert electrical signals coming in from
input field devices such as pushbuttons, to
electrical signals that the PLC can understand.
• Input devices include push buttons, sensors,
potentiometers, pressure switches.
• The function of the input module is to covert high
voltages from input devices to low level logic
voltages that the CPU uses internally for
processing.
 Output modules
• Output modules take information coming from the
PLC and convert it to electrical signals the output
field devices can understand, such as a motor
starter, or a hydraulic solenoid valve.
• Output module amplifies the low–level logic
signals generated by the CPU and pass these
modified signals to the final control elements to
operate the output devices.
 Power Supply module
• Power Supply. A power supply is needed to
provide power to the PLC and any other
modules.
• Usually input output modules require 24V DC
and processor require 5V DC.
• Usually power supply is integral part of PLC.
• Power supply units convert 120/230 V AC line
voltage to standard supply of 24 VDC or 5V
DC using standard rectifier circuits
 Software
• PLC consists of two parts: Operating systems and user
program.
• The PLC operating system provides effective support
ranging from the creation of project structure to the
creation of user programs.
• The OS system is accessed through a graphical user
interface window ( also known as Main window). The
main window contains all the functions needed to set
up a project , configure the hardware , write and test
programs.
• User program can be written in any standard PLC
programming language like ladder diagram or
statement list.
 Memory
• Memory: The type of RAM (Random Access
Memory) normally used is CMOS
(Complementary Metal Oxide Semiconductor)
to store the program.
 ADVANTAGES
Cost of PLC automation is less.
PLC can be commissioned and installed easily.
Programming of PLC is quite simple.
They can be programmed and reprogrammed to
accommodate frequent changes in program.
They can be used in harsh environment where
humidity and temperature are high.
Their working is not effected by vibration and
shock.
 APPLICATIONS
• Control system of industrial robots.
• Control system of material handling equipment
like cranes, elevators.
• Control system of machine tools.
• Control system of automated assembly equipment.
 PLC PROGRAMMING
• There are various approaches for entering the
program into PLC they are :
1. Ladder diagram
2. Low level based on Boolean expressions
3. Functional blocks
4. High level language
 LADDER DIAGRAM
• Most of the programming methods used today for
PLC are based on the ladder logic diagram.
• The ladder diagram consists of two vertical lines
representing the power rails.
• Circuits are connected as horizontal lines, i.e., the
rungs of the ladder, between these two verticals.
• The left side line represent line with a positive
voltage and right side represent a line with zero
voltage.
• Between these two sides are the horizontal rungs
for the assumed power flow.
• Starting with the input, we have the normally open
symbol II for the input contacts.
• There are no other input devices and the line
terminates with the output, denoted by the symbol
( ).
• When the switch is closed, i.e., there is an input,
the output of the motor is activated.
• Only while there is an input to the contacts is there
an output. If there had been a normally closed
switch I / I with the output , then there would have
been an output until that switch was opened.
• Only while there is no input to the contacts is
there an output
• There are five program elements/operations
commonly used in PLC ladder diagram they
are
1. PLC Bit logic operations
2. Timer Operations
3. Counter operations
4. Comparison operations
5. Arithmetic operations.
Logic Functions
 AND GATE
• Example 1 : Double acting cylinder is used to
perform machinng operation. Pneumatic cylinder
is advanced by pressing two push buttons
simultaneously. If any one of the push button is
released, cylinder comes back to start position.
Draw ladder diagram to implement this task.
Tools for plc logic design