programmable logic controller (PLC) The Unitary PLC is typically the smallest and least expensive.

It would be used in a small machine or fixed application such as overhead door controls or a stand-alone parts inspection system. They are not expandable so the application is limited to on-board I/O. There are, however, some very powerful units available with built in GSM, color screens, and web servers. Most have 1 or 2 analog I/O channels as well as a high speed input and pulse train output for simple motion control. The Modular PLCs start with a processor with a few or no on-board I/O. They typically mount to a DIN rail and sometimes require a separate power supply. Additional I/O as well as specialty modules also snap onto the DIN rail and plug into the processor or adjacent module. Modular PLCs are used in applications where a higher I/O count is needed or when using specialty modules such as quadrature encoders, thermocouple inputs, etc. They are also useful in small applications that have options or upgrades available to the end user. Systems can be expanded (within certain limits) without adding additional rack space. Rack style PLCs are usually more expensive, expandable, and powerful than unitary or modular PLCs. The rack provides a power and communication backplane that greatly increases the communication rate between the processor and the modules as well as allowing some specialty modules to communicate with each other without the processor. In some brands, multiple processors can be in the same rack and share the inputs. Racks also allow for redundant processors for critical systems such as waste water pumps or fire control systems. The types of modules available for rack systems are far more extensive than modular systems. The number of available I/O points is also much higher in the rack systems. Around 1000 for some modular PLCs versus over 100,000 for the same brand of rack system. Ladder Logic Most basic PLC programming processes rely on ladder logic, which aims to replace relay logic systems. This type of programming consists of a software that programs the direction of circuit diagrams of relay-based logic hardware. It is used to reduce the workload of technicians, as the appropriate commands are sent to the hardware machinery for them to operate via two vertical rails and a series of horizontal rungs coiled around them. Traditional Programming Another type of PLC programming is traditional programming. In this approach, computers used in PLC machinery apply computer language protocols such as BASIC and C in order to provide commands and signals to the components of the assembly-line machinery. This method has grown popular during the 1980s and 1990s, and is still common today. State Logic One highly advanced type of PLC programming is state logic. It is a high-performance programming language that works on state transition diagrams, in which the order of activities can be changed and altered according to priority. State logic programming is usually found in computer software and hardware systems, as the said technique accommodates both finite state performance and event activity. What are different comonents in PLC? Answer: 1. Input Interface 2. Memory Section 3. Central Processing Unit (CPU) 4. Programmable Language 5. Programming tool 6. An output Interface Advantages of PLCs than Hard wired Relay? Answer: PLCs are highly reliable, easily programmable, Small and Inexpensive, PLCs can be designed with the communication capabilities so they can converse with the local or remote computer, They can sustain in robust environment less maintenance. What is the programmable language used in PLC? Answer: The general language program consists of Ladder Diagrams. Relay logic control scheme is represented in Ladder diagrams. Alternative languages uses Boolean representation of these control schemes as base of the computer representation.

What does Central Processing Unit (CPU) of PLC consists? Answer: CPU is the brain of the system and consists of Microprocessor: To carryout arithematic and logical operations Memory: The area in the CPU in which the information is stored and reterived Power Supply: The electrical supply that converts the ac voltage to various DC operating voltages. What is SCAN in PLC ? Answer: The sequential operation of the controller that goes through the ladder diagram from top to bottom of the ladder. In this process it updates all the outputs corresponding to the inputs. SCAN takes place from left to right of each rung. Usually SCAN time is in milliseconds and it is a continuous process. Why SCAN time of DCS is more than PLC? or Why does PLC have scan time less than DCS. If so,then why do we use DCS instead of PLC? My Interview Answer: Scan time of DCS(distributed control system ) is more than the scan time of PLC when the I/O's are digital.Whereas the scan time of DCS is less than the scan time of PLC when the I/O's are analog.Hence DCS is better when analog signals are considered whereas PLC is better when digital signals are considered.However DCS do handle both analog and digital signals. It can also have more no. of I/O's compared to PLC.About 1 lakh I/Os are available in DCS. Hence we use DCS. SCADA (supervisory control and data acquisition) generally refers to industrial control systems (ICS): computer systems that monitor and control industrial, infrastructure, or facility-based processes vendors such as Allen Bradley, Schneider, Siemens, GE and Honeywell.