Programmable Logic
Controller (PLC)
CONTENTS
• AUTOMATION
• TYPES OF AUTOMATION
• INDUSTRIAL AUTOMATION
• DEVELOPMENT OF CONTROL SYSTEM
• WHAT IS PLC
• WHY PLC?
• COMPONENTS OF PLC
• PLC OPERATION
• PLC PROGRAMMING
• APPLICATIONS
• ADVANTAGES AND DISADVANTAGES
• CONCLUSION
AUTOMATIO
N
Automation is basically the delegation of human
control functions to technical equipment aimed
towards achieving:
Higher productivity.
Superior quality of end product.
Efficient usage of energy and raw materials.
Improved safety in working conditions etc.
TYPES OF AUTOMATION
Building automation
Example: lifts, smoke detectors
Office automation
Example: printers, cctv cameras
Scientific automation
Example: rocket launching
Light automation
Example: street solar lightening
Industrial automation
Example: automated bottle filling stations , steel factories etc
INDUSTRIAL AUTOMATION
The use of Computerized or robotic devices to
complete manufacturing tasks.
FIELD
PLANT INSTRUMENT
CONTROL SYSTEM
HARDWARE SOFTWARE
CONTROL CONTROL
DEVELOPMENT OF CONTROL SYSTEM
Manual control
Pneumatic control
Hard wired logic control
Electronics control
PLC control.
PLC(PROGRAMMABLE LOGIC CONTROLLER)
Programmable Logic Controller (PLC)is an industrial
computer that monitors inputs, makes decisions based on its
program and controls outputs to automate a process or machine.
(Introduced in 1960s)
The automation of many different processes, such as controlling
machines or factory assembly lines, is done through the use of small
computers called a programmable logic controllers (PLCs).
WHY PLC?
To reduce human efforts .
To get maximum efficiency from machine and control them
with human logic .
To reduce complex circuitry of entire system .
To eliminate the high costs associated with inflexible, relay-
controlled systems.
UNDERSTANDING OF PLC (Example )
Machine can be controlled by PLC without human efforts
MAJOR COMPONENTS OF A PLC
POWER
SUPPL
Y
I M O M
N O U O
P D T D
U U PROCESSOR P U
T U L
From T E To
SENSORS L OUTPUT
Pushbuttons, Solenoids,
contacts, E
contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE
COMPONENTS (INPUT /OUTPUT)
1. INPUT MODULES accepts and converts signals from sensors into a
logic signal
Ex. : Switches, Pushbuttons.
2.OUTPUT MODULES that convert control instructions a signal that can
be used by actuators.
Ex. : lamps, alarm.
INPUT OUTPUT
PUSH BUTTONS PLC
COMPONENTS (CPU
,MEMORY)
3. CENTRAL PROCESSING UNIT(CPU)
It is the brain of PLC and governs the activities of the entire PLC
systems
The CPU consists of following blocks :
Arithmetic Logic Unit (ALU),
Internal memory of CPU
Internal timers ,counters and Flags . PROCESSOR
The various operations performed are :
Scanning I/O bus traffic control,
Program execution,
Peripheral and External device
communication,
Data handling and self diagnostics.
4. MEMORY is the component that stores information, programs and data in
a PLC.
Types of memories used in PLCs are read only memory (ROM) and
random access memory (RAM).
COMPONENTS (POWER SUPPLY, PROGRAMMING DEVICE)
5. POWER SUPPLY
Provides the voltage needed to run the primary PLC
components. POWER
SUPPL
Y
6. PROGRAMMING DEVICE
The programming terminal is used for programming
the PLC and monitoring/sequencing PLCs PROGRAMMING
operation. DEVICE
PLC OPERATION
CHECK INPUT STATUS
First the PLC takes a look at each
I/O to determine if it is on or off.
EXECUTE PROGRAM
Next the PLC executes the program
one instruction at a time.
UPDATE OUTPUT STATUS
Finally the PLC updates the status of
the outputs .It updates the outputs
based on which inputs were on during
the first step.
ADVANTAGES
Replacing Human Operators
Dangerous Environments
Beyond Human Capabilities
Fast
Easily programmed and have an easily understood
programming language.
Improves Productivity
Improves Quality
DISADVANTAGES
PLC Devices Are Proprietary
Initial Costs Are High
There's Too Much Work Required In
Connecting Wires
Unemployment Rate Increases
• Forms of PLC – single box, modular / rack type
• Input addresses – X401, Y302 …
• Input output processing –
continuous updating and
mass input / output copying
PLC / LADDER PROGRAMMING
Ladder logic is a programming language used to develop software for
PLC used in industrial control applications.
RUNGES
RAIL RAIL
PLC / LADDER PROGRAMMING - Symbols
ELEMENTS OF LADDER LOGIC
NORMALLY OPEN NORMALLY CLOSED
(CONTACT) (CONTACT)
COILS
LADDER LOGIC EXAMPLE
OR OPERATION
C
A
In the above diagram, it can be seen that either
input A or B is be true (1), or both are true, then the
output C is true (1).
LADDER LOGIC - EXAMPLE
- output from the PLC is to energize a solenoid when
a normally open start switch connected to the input is
activated by being closed
LADDER LOGIC - EXAMPLE
- an on/off temperature control in which the input goes
from low to high when the temperature sensor
(thermistor) reaches the set temperature; the output is
then to go from on to off
LADDER LOGIC – Logic fuctions
AND
OR
NOR
NAND
LADDER LOGIC - EXAMPLE
- output to the solenoid controlling the valve that will
open a shop door when the shopkeeper has closed a
switch to open the shop and a customer approaches
the door and is detected by a sensor which then gives
a high signal
Latching
- hold a coil / device energised, even when the input
which energised it ceases
- to stop we momentarily open the stop switch and this
unlatches the start switch. But, if the stop switch
cannot be operated then we cannot stop the system,
hence unsafe
Internal Relays
• Internal Relay, auxiliary relay or marker
• behave like relays with their associated contacts,
but in reality are not actual relays but simulations by
the software of the PLC
• very useful aids in the implementation of switching
sequences
Internal Relays
An output controlled by
starting of multiple outputs
two input arrangements
Internal Relays – safe latch resetting
Timers
• timers behave like relays with coils which when
energised result in the closure or opening of
contacts after some preset time
Timers
Timers for sequencing Cascading of timers – to
give larger delay times
Timers
Delay-off timer
On/off cyclic timer
Counters
Counters - Example
• direct 6 items along one
path for packaging in a
box, and then 12 items
along another path for
packaging in another
box
Other functionalities
• Shift registers
• Master and jump controls
• Data handling – movement, comparison, arithmetic
operations
• Code conversions
• Analogue input / output
Examples
Draw the ladder rungs to represent:
(a) two switches are normally open and both have to
be closed for a motor to operate;
(b) either of two, normally open, switches have to be
closed for a coil to be energised and operate an
actuator;
(c) a motor is switched on by pressing a spring-return
push-button start switch, and the motor remains on
until another spring-return push-button stop switch is
pressed.
Examples
Devise a circuit that can be used to start a motor and
then after a delay of 100 s start a pump. When the
motor is switched off there should be a delay of 10 s
before the pump is switched off.
Examples
Devise a circuit that could be used with a domestic
washing machine to switch on a pump to pump water
for 100 s into the machine, then switch off and switch
on a heater for 50 s to heat the water. The heater is
then switched off and another pump is to empty the
water from the machine for 100 s.
AREAS OF APPLICATION
Manufacturing / Machining
Food / Beverage
Textile Industry
Travel Industry
Aerospace
Printing Industry
CONCLUSION
The PLC have in recent years experienced an
unprecedented growth as universal element in industrial
automation .
It can be effectively used in applications ranging from
simple control like replacing a small number of relays to
complex automation problems.
Today the PLCs are used for control & automation job in a
single machine & it increases up to full automation of
manufacturing / testing process in a factory.
