PLC BASIC

04
ARCHITECTURE OF PLC
03
Why is PLC ?
02 3.1 Application 3.2 Significance

What is PLC ?

01 2.1 Definition 2.2 PLC Evolution

RECAP- LAST CLASS DISCUSSION

[Link] FUSIC, Assistant Professor- Mechatronics, Thiagarajar College of Engineering

 RECAP- LAST CLASS DISCUSSION
01
✓ Proportional Valves
✓ 4/3 Proportional DCV & regulation valve
✓ Example Problem
✓ Direct control & Indirect Control circuit
YOUR CONTENT GOES HERE
✓ Servo Valves
✓ Comparison of PV vs SV
✓ FluidSim-H Demo
 PLC
01 ✓ A Programmable Logic Controller (PLC) is a special computer device used
for automation of electro-mechanical processes in modern factory
automation.

✓ A PLC is a miniature industrial grade computer that contains hardware and

software – capable of being programmed to perform control functions

✓ Where ever there is a need to control devices, the PLC provides a flexible
way to "software" and components together.
Evolution of PLC
1. Manual Control
2. Hardwire logic (relays, contactors, timers)
3. LOGIC GATES
4. PLC
 APPLICATION
01
 APPLICATION
01
 APPLICATION
01
 01 Before the PLC-
The development of the PLC can be compared
analogously to the development of the Personal
Computer.

Machine control can be done by

using,

1. Power Relays

2. Control Relays
 Disadvantages of Relay based control systems?
03
▪ Hard wired panels / relay logic are time consuming due to
wiring and debugging related issues.
▪ Complexity
▪ Costly
▪ Hardwiring
▪ Troubleshooting problems
▪ Strict Maintenance routine
▪ Not easy to modify , etc
 Selection of PLC
03
✓ Is faster and operates in real time
✓ Withstands vibrations, temperatures, humidity, noise
✓ Has inbuilt interfacing for inputs and outputs
✓ Is flexible and adaptable (easy to program/re-program)
✓ Troubleshoot and maintain was quite easy.
✓ Consumes less space, requires less wiring.
 Why PLC ?
04
 Advantages of the PLC-
04 1. They are re-programmable
2. Complex logics can be easily represented
3. Multiple devices can be embedded in one unit
4. Can easily be scaled up or modified.
5. Smaller physical size than hard-wire solutions.
6. PLCs have integrated diagnostics and override functions.
7. Applications can be immediately documented, duplicated faster and less
expensively
8. Connection between switches/output can be modified through software easily.
9. Troubleshooting is Easier and Faster.
10. Ease of Maintenance –less downtime.
11. Easy to develop Programs by offline simulation
12. Less amount of Space Needed
 Architecture of PLC
04 A small computer with a built-in operating system which monitor inputs and
other variable values, make decisions based on a stored program, and control
outputs to automate a process or machine.

Basic parts of a PLC

1. Power Supply
2. Processor Module
✓ CPU
✓ Memory
3. Communication Interface.
4. I/O Modules
✓ Discrete/Digital Inputs
✓ Analog Inputs
5. Output Modules
 PLC SYSTEM

04
Opto-Isolator

Source: William Bolton - Programmable Logic Controllers, Sixth Edition-Newnes (2015)

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 Components of PLC

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 Power Supply Specification Power

04
A power supply is used to provide power to the PLC and any other modules.
Power supplies come in various forms:

✓ Power supply modules that fit into one of the slots in a chassis

✓ External power supplies that mount to the outside of a chassis

✓ Stand alone power supplies that connect to the PLC or I/O through a
power cable

✓ Embedded power supplies that come as part of the PLC block.

 I/O Devices of PLC
04
❖ Input Devices/Output provide inputs to the control system.

❖ In case of discrete-state process control, the I/O are two

state specifications such as:

✓ Limit switches – open or closed,

✓ Comparators – high or low,
✓ Push buttons – depressed or not depressed
✓ Lights: On / OFF,

✓ Motors : Rotating or not rotating,

✓ Solenoids : Engaged or not engaged

 Specification i/o

04 Standard discrete input modules include 24 V AC,48 VAC, 120 VAC, 220 VAC, 24 V
DC,48 V DC, 120 V DC, 220 V DC, and transistor-transistor logic (TTL) level.

Input Devices Output Devices

04
 PROCESSOR UNIT

04 • Processor unit CPU is the “brain” of the PLC that is a microprocessor for implementing the logic
and controlling the communications among the modules that convert input signals into output
action signals.

• To be more specific, it receives and casually stores input data from various of sensing devices and
user programs.

• In additional, it sends appropriate output commands to control devices. Next, CPU keeps
checking the PLC controller to avoid errors.

• When PLC is running, at first, CPU receives input conditions and data at present by scanning and
store them in I/O sector.

• Next, it would read user program step by step and execute them and then send their result in I/O
sector or data register.

• Finally, it conveys output conditions and data from I/O sector to relevant output devices by
operating cycle.

• It performs arithmetic and logic operations on input variable data and determines the proper
state of the output variables.
 Memory Unit

04 ✓ Memory: Tied to the CPU is the PLC memory, which contains the program of
logic, sequencing, and other input/output operations.
✓ The memory for a programmable logic controller is specified in the same way as
for a computer, and may range from 1k to over 48 k(bytes) of storage capacity.
✓ Memory types are ROM, RAM, EPROM
04 Communication Unit
✓ The communications interface is used to receive and transmit data
on communication networks from or to other remote PLCs.

✓ The data bus for sending data between the constituent elements

✓ The address bus to send the addresses of locations for accessing

stored data

✓ The control bus for signals relating to internal control actions

✓ The system bus is used for communications between the
input/output ports and the input/output unit.

✓ The buses are the paths used for communication within the PLC.
✓ The information is transmitted in binary form, i.e. as a group of
bits with a bit being a binary digit of 1 or 0, i.e. on/off states.

✓ The term word is used for the group of bits constituting some
information. Thus an 8-bit word might be the binary number
00100110.
 PLCs are used in all industries.
05 1. Factory Manufacturing
2. Process Plants & Systems
3. Machining
4. Packaging
5. Automated Plants
6. Process Automation (IOT) Etc.
05
 OPTO-ISOLATOR

05 • Electrical isolation from the external world is

usually by means of opto-isolators (the term
optocoupler is also often used) Figure shows the
principle of an opto-isolator.

• When a digital pulse passes through the light-

emitting diode, a pulse of infrared radiation is
produced. This pulse is detected by the
phototransistor and gives rise to a voltage in that
circuit.

• The gap between the light-emitting diode and

the phototransistor gives electrical isolation, but
the arrangement still allows for a digital pulse in
one circuit to give rise to a digital pulse in
another circuit.
 Specification of PLC

05

Source: Mitsubishi Electric Automation, Inc.

 Specification of PLC

05

Source: Mitsubishi Electric Automation, Inc.