Name of Activity (Week 1: Introduction to PLCs and Automation)
I. EXPECTED COMPETENCIES…………………………………
At the end of this activity, the student should be able to learn and understand the concept of
Programmable Logic Control and its role in the automation industry
II. THEORIES / PRINCIPLES…………………………………
What Is a Programmable Logic Controller?
A programmable logic controller (PLC) is a digital computer used for automation of
electromechanical processes, such as control of machinery on factory assembly lines,
amusement rides, or lighting fixtures. PLCs are used in many industries and machines. Unlike
general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact. Programs to control machine operation are typically stored in battery-
backed or nonvolatile memory. A PLC is an example of a real time system since output
results must be produced in response to input conditions within a bounded time, otherwise
unintended operation will result.
NEMA defines a PROGRAMMABLE LOGIC CONTROLLER as:
“A digitally operating electronic apparatus which uses a programmable memory for the
internal storage of instructions by implementing specific functions such as logic sequencing,
timing, counting, and arithmetic to control, through digital or analog input/output modules,
various types of machines or processes”.
Traditional PLC Applications
In automated system, PLC controller is usually the central part of a process control
system.
To run more complex processes, it is possible to connect more PLC controllers to a
central computer.
Major Types of Industrial Control Systems
Industrial control system or ICS comprise of different types of control systems that are
currently in operation in various industries. These control systems include PLC, SCADA and
DCS and various others:
PLC
They are based on the Boolean logic operations whereas some models use timers and some
have continuous control. These devices are computer based and are used to control various
process and equipment within a facility. PLCs control the components in the DCS and SCADA
systems but they are primary components in smaller control configurations.
DCS
Distributed Control Systems consists of decentralized elements and all the processes are
controlled by these elements. Human interaction is minimized so the labor costs and injuries
can be reduced.
Embedded Control
In this control system, small components are attached to the industrial computer system
with the help of a network and control is exercised.
SCADA
Supervisory Control and Data Acquisition refers to a centralized system and this system is
composed of various subsystems like Remote Telemetry Units, Human Machine Interface,
Programmable Logic Controller or PLC and Communications.
Advantages of PLCs
There are six major advantages of using PLCs over relay systems as follows:
1. Flexibility - One single PLC can easily run many machines. Ease of troubleshooting
- Back before PLCs, wired relay-type panels required time for rewiring of panels
and devices. With PLC control any change in circuit design or sequence is as simple
as retyping the logic. Correcting errors in PLC is both fast and cost effective.
2. Space efficiency - Fewer components are required in a PLC system than in a
conventional hardware system. The PLC performs the functions of timers,
counters, sequencers, and control relays, so these hardware devices are not
required. The only field devices that are required are those that directly interface
with the system such as switches and motor starters.
3. Low cost - Prices of PLCs vary from few hundreds to few thousands. This is minimal
compared to the prices of the contact, coils, and timers that companies pay to
match the same things. Using PLCs also saves on installation cost and shipping.
4. Testing -A PLC program can be tested, evaluated, and validated in a lab prior to
implementation in the field.
5. Visual operation - When running a PLC program a visual operation displays on a
screen or module mounted status lamps assist in making troubleshooting a circuit
quick, easy, and relatively simple.
PLC and Computer
• A PLC and a computer both are electronic processor unit. The architecture of a PLC’s CPU
is basically same as that of a general purpose computer; however, some important
characteristics set them apart.
• Unlike computer, PLCs are specifically designed to survive the harsh conditions of the
industrial environment. A well-designed PLC can be placed in an area with substantial
amounts of electrical noise, electromagnetic interference, mechanical vibration, and
noncondensing humidity.
• Distinction of PLCs is that their hardware and software are designed for easy use by plant
electricians and technicians. The hardware interfaces for connecting field devices are
actually part of the PLC itself and are easily connected.
• The modular and self-diagnosing interface circuits are able to pin point malfunctions and
moreover, are easily removed and replaced.
• Software programming uses conventional relay ladder symbols, or other easily learned
languages, which are familiar to plant personnel.
• A computer can execute a complex programming task and also multitasking. An
standard PLC is designed to executes a single program in an orderly fashion. As PLCs
are rapidly changing, modern PLCs have multitasking capabilities.
III. TOOLS, EQUIPMENT & MATERIALS…………………….
Research materials, pen, paper
IV. TASKS (STEPS) & KEY POINTS…………………….…….
V. TEST REVIEW EXERCISES…………………….…….…….…….
VI. PRODUCTIVITY TEST SHEET/RUBRICS…………………….
On a clean white paper write down an industrial processing system that
utilizes PLC. Explain each process briefly.