PLC in Industrial Process

Control
Lecture by:
Ojaswi Bahadur Lakhey

Content by:
Dr. Diwakar Bista , Aayush Bista and Ojaswi Bahadur Lakhey
1
Discrete State Process control
(Sequential control)
• Discrete-State Process Control or On/Off Control
• Execution of predefined sequence of operations in a specific order,
often based on events or conditions rather than continuous feedback
• Has to follow a predefined sequence by turning On or turning Off the
actuators.
• Solved by Boolean logic [Combinational Boolean Logic + Sequential
Boolean Logic].
Relay Logic
• Conventional method of implementing Sequential Control
• Use of array of relays and switches
• Special kind of relays/switches
• timer relay (for delays)
• Limit switches
• Level switch (to detect level)
• thermal switch (to detect temperature)

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Relays/Switches

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 Relay Logic: OR
• Using two switches, a logical “OR” operation can be
constructed. An example is given below:
• Switch 1 “OR” Switch 2 = Coil

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 Relay Logic: OR
• Switch 1 off “OR” Switch 2 off = Coil off

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 Relay Logic: OR
• Switch 1 on “OR” Switch 2 on = Coil on

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PLC: Programmable Logic Controller
• PLC is a digital computer designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical
noise, and resistance to vibration and impact.
• PLC is an example of real-time system.

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What sets apart a PLC from a conventional
computer?

• Their vast I/O (input/output) configurations, features such as heat,

dust, and cold protection. Lastly, their low cost compared to a
microcontroller system. This is what sets them apart from
conventional computer systems.

Slide 9
What advanced features does a PLC have?

• Internet of Things (IoT) and Industry 4.0 programmable controllers

are required to send data via Web browser, connect to databases via
SQL, and even send data to the cloud

Slide 10
 PLC System
• Software solution to Relay Logic
Programmer/
Monitor

CPU
Microprocessor
Input Memory Output
Module Module

Power
Supply

Rack and Chasis

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PLC System
PLC System / Architecture
• CPU: Central Processing Unit, generally consists of
• Microprocessor: mathematical and logical operation
• Memory: stores data and program.
basic PLC programming → ROM
user program and data in → EEPROM
• Power Supply: DC supply to CPU and modules
• Programmer/Monitor: device to program and monitor PLC.
PC also used.
• I/O Modules: Interface with process to be controlled. E.g. Digital I/O, Analog
I/O, Encoder interface, PWM output etc.
• Special Modules: for special purpose. E.g. PID controller module, Interrupt
handling module
• Racks and Chassis: to enclose CPU and different modules. The CPU and modules
are attached by a bus system within the racks.
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Architecture of PLC
• CPU: Executes control program, handles logic, memory includes
program and data memory.
• I/O Modules: Interface between field devices and CPU
(digital/analog).
• Power Supply: Converts AC to regulated DC power for PLC
components.
• Communication Modules: Provide protocol interfaces (Modbus,
Ethernet/IP, Profibus, etc.).
PLC Input and Output Devices
• Input Devices: Push buttons, limit switches, proximity sensors,
photoelectric sensors, temperature/pressure transmitters, encoders.
• Output Devices: Contactors, relays, solenoid valves, motor drives,
alarms, indicator lamps.
Basic electrical design of a PLC panel (Wiring
diagrams)

Slide 16
Basic Program Instruction Methods
• A program is a connected series of instructions written in a language
that the PLC can understand.
• There are three forms of program format; instruction, ladder and
SFC/STL.
• Not all programming tools can work in all programming forms
Process Scan of PLC
OUTPUT SCAN
INPUT SCAN

PROGRAM SCAN

INPUT INPUT USER OUTPUT OUTPUT

TERMI- STATUS PROGRAM STATUS TERMI-
NALS TABLE TABLE NALS

INPUT PROGRAM SCAN OUTPUT

SCAN SCAN

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Basic Conne4ction Structure
 Need of PLC in Industrial Automation
• Replaces traditional relay-based control panels
• offers compactness, reliability, and easy logic modifications.
• Designed for harsh industrial environments
• vibration, temperature, humidity, electrical noise.
• Flexibility: Change control logic by re-programming (no rewiring).
• Scalability: Expand I/O modules as plant grows.
• High-Speed Operation: Fast response time for critical applications.
• Diagnostics and Troubleshooting Tools: Built-in LEDs, error codes, status
flags.
• Networking Capability: Integrate with SCADA, HMI for data exchange and
centralized control.
• Safety and Reliability: Continuous operation with minimal down-time; vital for
24 × 7 industries.
Application of PLC

MANUFACTURING AUTOMOBILE MONITORING MACHINE

PRODUCTION AUTOMATION TOOLS

STEEL INDUSTRY ROBOTIC AUTOMATION FOOD PROCESSING

SYSTEM INDUSTRY

Slide 21
Types of PLC Models
Based on Size (Memory/I/O Capacity):
• Nano PLC
• <15 I/O points
• Small machines, home automation, packing units
• Micro PLC
• 15–128 I/O
• Stand-alone machines, elevators, HVAC
• Medium PLC
• 128–1024 I/O
• Plant sections, distributed systems
• Large PLC
• 1024 I/O, modular
• Entire plant automation, heavy process industries
Types of PLC Models
Based on Construction:
• Compact PLC:
• All components (CPU, I/O, power supply) in one enclosure
• Low cost, minimal expansion – used in small applications
• Modular PLC:
• Separate individual modules fitted into a rack or chassis
• High expansion capability – suitable for complex/large automation
Types of PLC Models
Based on I/O System:
• Discrete PLCs – Handle only digital ON/OFF signals
• Analog PLCs – Process continuous signals (temperature, pressure,
flow)
 Relay Logic
• Example 1: On/Off push button of a motor

Motor OFF

Relay OFF

Stop pressed Start pressed

Motor ON

Relay ON

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Relay Logic
• Example 1: On/Off push button of a motor
Relay Contact a1
+VCC (Normally Open)

Start Push Button Relay Contact a2

(Normally Open) (Normally Open)

Stop Push Button

(Normally Closed)
Motor
M
Relay Coil M
A

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Sequential Logic
• RS Flip Flop

S R Yn Yn+1 Yn\SR 00 01 11 10
0 0 0 0 0 0 0 X 1
0 0 1 1 1 1 0 X 1
0 1 0 0
0 1 1 0
1 0 0 1
1 0 1 1
1 1 0 X
1 1 1 X Yn +1 = R ( S + Yn )

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Sequential Logic
• RS Flip Flop
State Diagram

S R Yn Yn+1 Reset
0 0 0 0 Y=0
0 0 1 1
0 1 0 0 S = 0; R=1 S = 1; R = 0
0 1 1 0
1 0 0 1 Set
1 0 1 1
Y=1
1 1 0 X
1 1 1 X

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