Programmable Automation

Table of Contents

1. OBJECTIVE........................................................................................................................................................ 2
2. INTRODUCTION.................................................................................................................................................. 2
3. HARDWARE-UL PLC-ULUI ............................................................................................................................. 3

3.1 Power supply........................................................................................................................................ 3

3.2 Processor module............................................................................................................................................. 4
3.3 Input modules....................................................... ................................................................. .................. 5
3.4 Output modules5
3.5 PID and communication modules......................................................... .5
4. PROGRAMMING AND OPERATION OF THE PLC.......................................................................................... 6
4.1 Structured Diagram Programming....................................................................................................... 6
5. FUNCTIONAL AREA OF THE NETWORK........................................................................................................................... 8

5.1 Introduction9
5.2 Classic automation panels................................................................................................................. 10
5.3 Automation panels with programmable logic controllers............................................................... 12
5.4 The stages of designing automatic control systems........................................................ ........................... 13
5.5 General aspects regarding the construction and operation of PLCof the................................................................ ....... 13
5.6 The first programmable automaton........................................................................................................................ 14
5.7 Components of programmable controllers............................................................ .15
5.8 Central processing unit– CPU16
5.9 Memory16
5.10 Programming of programmable controllers................................................................. 16
5.11 Power Supply.............................................................. ................................................................. ..... 17
5.12 Inputs of the programmable automaton.............................................................. ................................................. 17
5.13 Outputs of the programmable controller................................................................................................................ 17
5.14 Extension of the number of inputs / outputs......................................................... ................................................. 17
6. ARCHITECTURE OF PROGRAMMABLE AUTOMATA.................................................................................. 18
6.1 Generalities18
6.2 Why OMRON?............................................................................................................................................. 18
6.3 OMRON CPM1A PLC controller

6.4 Outputs of the OMRON CPM1A programmable controller......................................................... ........................... 20

6.5 Inputs of the OMRON CPM1A programmable automation controller....................................................... ........................... 21

6.6 How PLC Works-ul ?......................................................................................................................... 22

1. OBJECTIVE

The programmable logic controller (PLC) emerged as a reusable, inexpensive alternative,

flexible and secure wired relay panels. Since this beginning, in 1986, PLCs have
continuously developed and diversified. PLCmodern devices perform a lot of functions such as
logic rules, timing, counting, sequencing, PID control, and fuzzy logic. They can perform
arithmetic operations, data analysis, and can communicate with other PLCs and computers
server.
The purpose of this chapter is to introduce you to programmable logic controllers.
After completing this chapter, you will be able to achieve the following:
1. Describe the components of a PLC: power supply, processor, input module,
the output module and the programming unit.
2. Describe step by step the operation of a PLC when running a small program
sequential according to a diagram.
3. To read an input/output diagram of a PLC.
4. Read a sequential program of a diagram.
5. To use time functions in a PLC diagram.
6. Use counting functions in a PLC diagram.
7. To use sequencing functions in a PLC diagram.

2. INTRODUCTION

A PLC is a digital electronic device designed to control machines and processes.

performing operations for controlling events and time. The PLC is designed for environments
heterogeneous industrial. It can be programmed without special programming skills, and can be
maintained by factory technicians.
The automobile industry has introduced PLC to eliminate the high cost of wired panels.
inflexible, with relays. The Hydramatic Division of General Motors Corporation developed the specifications for
design for the first programmable logic controller in 1986. They requested a numeric system
reliable and flexible asre ar to survive in the industrial environment, which could be easy to program and
maintained by the factory staff and which could be reusable. Every time it was
the car model changed hundreds of wired panels with relays were thrown away.
Since this beginning in 1986, PLCs have developed much more than just as a replacement.
cheap logic panels with relays. Recent PLCs include modules that perform a multitude of functions.
of functions such as: logic, timing, counting, sequencing, PID control and
fuzzy logic. They can perform arithmetic operations, data analysis and can communicate with others
programmable controllers and server-type computers. Some advantages of PLCs include:

Flexibility.A PLC can control many different operations, andthe changes are made
at the software levelandthey are easier to implement than hardware modifications.

[Link] devices are safer and easier to maintain than

timers and mechanical relays.

Cost [Link]
advantage of PLCs comes from the ability of numerical systems to
performs multiple complex functions at a lower cost.
solve difficult problems by dividing them into a number of smaller and easier problems
resolved.

3. HARDWARE OF THE PLC

The figure presents the most important functional components that can be included in
PLC configuration-uries.
Power supply;
2. Processor module;
3. Input modules;
4. Output modules;
5. The programming unit;
6. The PID controller unit;
7. The data communications unit.

 Figure 1The components of a PLC system include a power supply, a module

3.2 The processor module

The processor module can be considered a central processing unit (or CPU). It contains
a microprocessor, or a read-only memory unit (ROM), a memory unit
with random access (RAM) and an I/O (input/output) interface (see figure ? C.18). The information
The storage in ROM is permanent. It is set once and then cannot be modified.
The information stored in RAM is temporary. It can be modified at any time and is
lost when the processor module loses power.
The operating system of the PLC (OS) is stored in ROM (OS is a program that serves
the same scope as DOS or Windows on a computer). The user program can be stored in
RAM or in one of the following non-volatile memory chips:

Programmable read-only memory (PROM). It can only be scheduled once,

then she is permanent.

Programmable memory that can be read and erased (EPROM).Can be scheduled from May
often erasing the old program with ultraviolet light.

Electrically erasable programmable memory (EEPROM).Can be programmed

several times deleting the old program with an electric signal.

Non-volatile random access memory (NVRAM). It can be programmed multiple times, but
Unlike regular RAM, the contents of NVRAM are not lost when the memory is not powered.
I am being fedă.

The data used by the PLC is stored in RAM. This data is organized into sections that
depends on the nature of the data. Each section is defined by a capital letter that is used as
part of the location address in that memory section. Memory sections include, but not
are limited to the following:
The image standsthe entrances (I).Store the state (1 or 0) of the inputs from the switches and from
ON/OFF signals from the process.

The image of the stateof the exits (O).Store the binary data (1 or 0) that will activate or deactivate.
ON/OFF devices in process.
The state of the timer(TStore the time base, the present value, the accumulated value
the status bits of the timer in the user program.
The state of the counter (C).Store the presence value, the accumulated value, and the bits of
look at the counters in the user program.
Numerical data (N).Store the data used for number conversions, etc.
Functions (F).Store the state and data used by other functions in the user's program.

The processor has two operating modes, PROGRAM and RUN. In PROGRAM mode
the processor allows the user to make changes in the program. The processor has several
status indicators that provide information to the programmer or operator. In RUN mode
the processor repeats the following cycle of four sequences under the control of the operating system:
3.3 Input Modules

There are two types of input modules, discrete and analog. Most PLC inputs
The inputs are of a discrete type, providing closed and open inputs from push-button contacts.
by pressing, from limit switches, various ON/OFF type sensors, etc. They can be used
this module is for input in both alternating current and direct current,depending onfrom the source of
power supply used on the input switch.
A typical input module has 4, 8, 16, or 32 input terminals, plus one terminal.
like a mass terminal. One terminal of the input module is connected to one side of
a contact from the process. The other part of the contact is connected to the hot terminal of the source
power supply in direct current or alternating current. The common bus terminal of the source of
the power supply is connected to the common terminal of the input module and the input module
furnishthe state of entryon the detection circuit.
The input module converts each input into a logic level voltage and isolates it.
the PLC circuit inputs. The input module converts an open contact into a voltage
from logic level 0 (0V), it converts a closed contact into a logic level 1 voltage (5V).
As the processor scans the inputs, it reads the logic levels of all the inputs and
store the logical levels in the image sectionăcontacts closed are
store as 1 logic, and open contacts as 0 [Link] image can only indicate if a
the contact is open or closed; it cannot indicate whether the entry contact is NO or NC.
Since most PLC inputs are discrete,can also be used andintrăthe analogical ones
for the control and acquisition of data. In continuous process control systems the majority of
process variables are analog and must be converted into a digital form for entry into
a digital processor. The analog input module performs this function with the help of a
analog digital converter.

3.4 Output modules

Discrete output modules provide ON/OFF signals to operate lamps, relays,

stepper motors etc. When the processor scans the section of the imageexita 1 in RAM
A logic 1 results for an ON signal at the output of the device, and a logic 0 results for an OFF signal.
OFF. To control output devices in alternating current, triacs or relays are used, and
Transistors or relays are used to control output devices in direct current.
The typical output module has 4, 8, 16, 32 output terminals, plus one common terminal and one terminal.
of mass.
Analog outputs require from 4 to 12 bits for the image [Link] memory.
A digital-to-analog converter converts the binary number stored in the output image into a
analog voltage (or current) between an output terminal and a common terminal.

3.5 PID and communication modules

PID moduleensures PID control of two process [Link] of

communicationsensures
direct communication with the operator, a programming terminal, other PLCs,
on a supervisor computer.

3.6 The programming unit

similarly a keyboard for entering instructions, addresses and data. A terminal
The CRT looks like a personal computer, but it is specially designed for programming a PLC.
CRT terminals and personal computers allow the user to write a program using a
variety of programming languages including the languageof tip diagramfuncsequential ties
(Sequential Function Chart), structured diagram language (Ladder Diagram), language of
of the type diagram with functionsblock (Function Block Diagram) and structured text language
(Structured Text).

4. PROGRAMMING AND OPERATION OF THE PLC

This section presents a simple program through a structured diagram for a PLC.
To perform a step-by-step analysis of the PLC's operation as if the respective program were running.

4.1 Programming through structured diagram

Limbajul de programare prin diagrama structurata foloseste simboluri de contact si de

coil for building diagrams that are very similar to the structured diagrams used
for the logic relay. The symbol for a normally open contact is similar to the symbol for
an electric capacitor. The symbol for a normally closed contact is the symbol for the
opened with a diagonal line through it. The symbol for an exit consists of several enclosed spaces
in parentheses. Each contact and output symbol has a number written immediately below (or
above) this one. This number identifies the location in the processor's memory (RAM) where
The image of the contact or exit is stored. Figure 2 shows a simple example of implementation.
the structured logical diagram in a programmable logic controller.
 Figure 2:Implementation of a control circuit for a pneumatic cylinder.

Figure 2a shows the schematic diagram, and figure 2b shows the structured diagram of a
circuit for controlling a pneumatic cylinder. The light switch was introduced to
illustrates a secondary control function without unnecessarily complicating the circuit. First stage
the structured diagram includes start, stop, and hold contacts in a configuration
a conventional plus a normally closed limit switch and a control relay coil. The second
The step includes a normally open relay contact and the solenoid for the pneumatic cylinder.
The third step consists of a switch and a light source.
Figure 2c shows the input, processing, and output units of a PLC used to
controls the pneumatic cylinder andlight signaling. The boxes (1,2,3 and 4) in the module of
input IM:1 contains the signal conditioning that converts the inputs into logical voltage levels.
Four lines connect the input boxes to the memory cells that hold the state inside.ăof the rilor
those little boxes. The top right cell of the memory section of the input image is connected
the
entry box 1, and it is identified as memory cell IM:1-1. Moving to the left
The memory cell IM:1-1 includes the cells IM:1-2, IM:1-3, and IM:1-4. The zero in the memory cell
IM:1-1 shows that the START switch connected to terminal 1 is open. 1 from the cells of
memories IM:1-2 and IM:1-3 show that the STOP switch and the limit switch LS1 are closed. Zero
in memory cell IM:1-4 the rate as SW1 is open. The image enterscountriesshow the contacts
connect to IM:2 if IM:3 are closed, but it cannot indicate if they are contacts (NC)
Deactivate, or contact (NO) activate.
The boxes (1, 2, 3, and 4) in the OM:1 output module contain the switching circuits that
use the logic level tensions from the image memory cellsexitto switch
the program is actually the control relay, CR1, which activates solenoid a. The first stage in
the program is equivalent to the first two steps in the structured diagram.
The structured diagram language imposes a number of restrictions on the programs, and
Restrictions vary depending on manufacturers. Typical limitations include the following:

The exit must be at the end on the right side of the step.
2. Power must flow from left to right, up or down.
3. Power must never flow from right to left.
The number of series contacts is limited to 11 (or another number set by the manufacturer).
The number of parallel contacts is limited to 7 (or another number specified by the manufacturer).
A step can have only one exit.
7. The singular exit must be at the top line on a step.

In the programming language of the structured diagram, the symbols of open contacts and
they are actually programming instructions. They tell the computer how to interpret 1
from 0 in the memory cell of image ientrancefor each contact. The normal contact symbol
open - NO(┤├inform the PLC to interpret a 1 as true (TRUE) and a 0 as
false (FALSE). If the PLC finds a path of true contacts from L1 to the output, the output is
activated (ON) and a 1 is placed in the image memory cellexitfind. If a way is found
false, the output is disabled (OFF), and a 0 is placed in the image memory cell ieşleave.
The NO contact symbol can be used with both NO physical switches and NC ones.
if the results are what we expected them to be. A NO physical switch is rated at
the true value (TRUE) if it is activated and the false value (FALSE) if it is not
A physical NC switch is rated true if it is not actuated and at
false (FALSE) if it is activated. When the STOP switch is not activated, its image is a
1, if this is evaluated as true (TRUE), which is correct. When the STOP switch is
activate, its image is a 0, and it is evaluated as false (FALSE), as it should be. This
the analysis applies to the switch LS1.
In a PLC program, the normally closed contact symbol is different, and its use can
leads to a double negative effect that can cause considerable confusion (without mentioning results
The NC contact symbol (-|/|-) informs the PLC to interpret a 1 from a cell of
entry image as false (FALSE), and a 0 as true (TRUE). If we use a physical switch
With an NC contact symbol, the NO switch is evaluated as if it were an NC switch.
If we use a physical NC switch with a NO contact symbol, the NC switch is evaluated
it's like a NO switch.

5. FUNCTION AREA OF THE ROAD

When a PLC is in the operating mode (RUN), the processor repeats the following cycle
four steps:
1. Entry scanning (Input scan).Store a new image of the entry conditions.
[Link] scanning (Scan program).Capture the new image of the exit conditions.
[Link] [Link] the new image of the exit conditions
output devices.
[Link] [Link] communications and other tasks.
The following discussion will refer to the operation of four cycles of a PLC with the configuration and
Cycle 2:START, SW1, STOP, and LS1 are all closed.

Scanning the [Link] input image: IM:1-1=1, IM:1-2=1, IM:1-3=1, IM:1-4=1.

Scanning the [Link] 1: IM:1-1=TRUE, OM:1-1=FALSE, IM:1-2=TRUE, IM:1-
3=TRUE, the path is TRUE, so 1 is stored in cell OM:1-1.
Step 2: IM:1-4=TRUE, so 1 is stored in the cell OM:1-2.
Scanning the [Link] the solenoid and the light source are turned on.

Cycle 3:START is open, SW1, STOP, and LS1 are all closed.

Scanning the [Link] input image: IM:1-1=0, IM:1-2=1, IM:1-3=1, IM:1-4=1.

Scanning the [Link] 1: IM:1-1=FALSE, OM:1-1=TRUE, IM:1-2=TRUE, IM:1-
3=TRUE, the path is TRUE, therefore 1 is stored in cell OM:1-1.
Step 2: IM:1-4=TRUE, thus 1 is stored in cell OM:1-2.
Scanning the [Link] the solenoid and the light source are turned on.

Cycle [Link] and LS1 are open, STOP and SW1 are closed.

Scanning the [Link] entry image: IM:1-1=0, IM:1-2=1, IM:1-3=0, IM:1-4=1.

Scanning the [Link] 1: IM:1-1=FALSE, OM:1-1=TRUE, IM:1-2=TRUE, IM:1-
3=FALSE, the path is FALSE, so 0 is stored in cell OM:1-1.
Step 2: IM:1-4=TRUE, so 1 is stored in cell OM:1-2.
Scanning the [Link] solenoid is closed (OFF), the light source is open (ON).

A multitude of observations are evident from the operation of a PLC. The first, the order
operations can be important because the PLC evaluates the program one step at a time
The second, there is a small delay between the action of an input device and the change
the output devices. This delay can be as large as the time of
running a cycle by the PLC.

5.1 Introduction
with the measuring instruments and sensors in the automation process, it will need to allow
it commands the entire process and what is important is to communicate the states to the operator
the process through visual and sound signals and/or through a-a communication network to a computer
local. These characteristics allow for the exploitation of automation ata high degree of flexibility, through
the easier change and monitoring of the basic parameters of the process.
Each component in the process control system plays a specific role, in accordance with
its importance. For example, without any senzor, PLC-the urine could not know the mode of variation in
time of the main parameters of the process (consider input parameters). In systems
automate, PLC-The valves are the central part of the control or automation system.

When executing the program stored in memory, PLC-it continuously monitors

the states of the system through the reception of signals from input devices (sensors). Based on logic
implemented in PLC program-it determines what action needs to be executed to c-give a
instrument. To order multiple processes simultaneously, it is possible to connect several
PLC-there to a central unit (a computer). Such a system is shown in fig.1.

5.2 Classic automation panels

automatein fact, which was concluded by their frequent replacement. The frequent replacement of
The releases also lead to the halting of production. Maintenance was costly, overburdening even the most
electrical experts in detecting and removing the fault.

Of the rIn the past, a control panel was used for managing a single process and not
it can be adapted to the requirements of the new working technologies. Ina word, the panels of
conventional automation proves to be inflexible, as the improvement of parametersteaser of
the operation of the automation system was accomplished by changing the operating topology of
of the panel and even of some component parts (which is actually costly). A typical example of a panel
The conventional automation is presented in fig.2.
In fIn the image, you will notice a fairly wide number of cables and electrical conductors, relays (of
time, intermediates...) and other elements from a-an automation panel from that period.
The automation panel in Fig. 2 is not very complex as they arethere were some panels
conventional at that time, but I believe you can imagine a much more complex one!
The most important disadvantages of conventional automation panels are:

Expensive labor for connecting the conductors;

2. Ddifficulties in changing or replacing components;
3. Ddifficulties in finding errors - requires a workforce with extensive and qualified experience;
4. AWhen a problem arises, the time for resolution cannot be determined with
accuracy, this being long in most cases.
5.3 Automation panels with programmable controllers

With the invention of the programmable automat,They have changed a lot in the design of the systems
of automated control. Several advantages have emerged. For example, in Fig. 3, a
modern automation panel with programmable logic controller (PLC).

AdvantagesThe automation panels with programmable controllers can be presented in a few

subpoints:


Compared to a classic automation panel, the required number of conductors
it is reduced by 80%;

The consumption is greatly reduced because the PLC-it consumes much less than the relays
from the conventional automation panel;

The error detection function in the programmable logic controller is very fast and very
easy to use;

The change of operating sequences within the application is different from process to
prand can be done very easily by replacing or modifying the written program in
the programmable automaton with the help of a PC (this action does not require changing
conductors or rewiring of the control panelas it was happening at
classic automation panels– it is only about the interconnection of devices
necessary for the PLC inputs and/or outputs-the)

The automation panels with PLC require some spare parts;

This is much cheaper compared to a classical automation [Link], because being
equipped with a large number of entries-outputs, a large number of peripherals can be connected
when complex functions are desired to be achieved;

Repositioning a PLC is done much faster and easier than any relay.
electromechanical or timing.

Among the disadvantages of working with programmable automata, we can mention:

1. A 'fixed' applications:some applications do not need a programmable controller due to the degree
5.4 The stages of designing automated control systems

aFirst, you will need to adopt a tool or system that you want to-you automate.
Sistemul automatizat poate să fie o maşină sau un proces mai mult sau mai puţin complex. La
the system inputs will require you to connect input devices (sensors and/or transducers)
that will need to transmit the corresponding signals to a programmable logic controller (PLC). As
response to these signals, PLC-ul sends a signal, as a result, to an external device
(also known as execution), which monitors the operation of the system or process according to the diagram.
of desired operation. This diagram may contain one or more operational cycles
of the process.

b). Secondly, it willyou must specify all input and output tools that will be
connect to the programmable controller. The input devices are various switches, sensors
of temperature, pressure and other types of transducers. Output devices canfi: bobine, valve
electromagnetic, motors, relays, light and sound instruments, etc. Following the identification
all inputs and outputs, after which they can be very easily implemented in the program
PLC-The allocation of inputs and outputs is an important step in achieving one's own-said the
of the program. To facilitate their identification, each entry and exit is given a name
in correlation with the function taken over or performed by the programmable logic controller.

c). This stage consists of developing the program that is to be implemented in memory.
programmable automaton. The simplest method consists of developing the program in the environment
ladder diagram. But to do this you will need to first choose an automatic device
programmable and an application development program that allows work in ladder diagram mode.
Usually, any manufacturer of programmable logic controllers offers its own software solution for
PLC programmingYou will not be able to use software from a manufacturer to program.
a PLC from another manufacturer. Also, the incompatibility of the interconnection solution comes into play here.
of the equipment (PC-PLC), different from manufacturer to manufacturer of programmable controllers.
After the program is completed, it is written inin PLC memory-usually. In case of
complex industrial processes, before being implemented in automation, after it is
programmed, the PLC is tested on an independent stand. On this stand, issues are detected.
any eventual errors and then eliminated. This method is primarily encountered in the case of
prototype automations.
5.5 Generalities regarding the construction and operation of PLC-uri

The industry has begun to recognize the need for improvement and increasing productivity in
the period of the 60s and 70s. Flexibility also became a major concern (the ability
to quickly change the process states and remedy the disruption has become a very requirement
important for customer satisfaction).
Try to imagine an automated production line from the '60s, '70s. This
automation contains a fairly large number of electrical cables for the control of automation
and in many cases, covers a large area. The classic automation panel contains a number
significantly bad electric relaysmagnetic that performs the work of the entire system. However, the method
The classic wiring of the panel or automation panels involves the presence of personnel
The biggest problem of this control scheme was the electromagnetic relays.
Mechanical instruments are the most prone todue to the moving components.
If a relay failed, the electrician had to check or examine the entire system.
(the entire system had to be stopped until the cause of the malfunction was identified and removed). So, another
the problem of this type of automation was the relatively long downtime of operation
the system in case of malfunction. In addition, if there was a desire to change the operating cycles of
the system (even a minor change), this was done at great costs andlarge losses
of time until the system was functional again.
It is not that hard to imagine what could happen if an engineer made a few mistakes.
minor during the implementation of the project. It is also imaginable what will happen if
eThe electrician would make mistakes in a few points of the automation system wiring. In the end, you can...
imagine a few defective components. After that, to find out if the system works, it will
we need to test its functionality. Since mistakes were initially slipped into the project, including
of execution, surely the automation system will not work. Therefore, this solution
The 'classic' execution of automated systems was very much prone to the conception of a batch.
of automation panels with many defective samples. The introduction of programmable automation has
eliminate this disadvantage from the start.

5.6 The first programmable automatic

"General Motors" was the first company to recognize the need to replace the wiring technique.
classic automation [Link] replacement of old wiring technologies of the panels
automation has increased competition among car manufacturers by raising productivity and
qualities. Not only the automotive industry benefited from the new technology. Flexibility,
cheap and easy maintenance, as well as the possibility of quickly changing production cycles of
has become a crucial necessity in the current evolution of the market economy.

The idea of the company 'General Motors' consisted of implementing wired logic in a
microcalculactor, logic that replaced the classical relay wiring technique. In most of
applications, the microcomputer is based on solutions with 8 or 16-bit microcontrollers, depending on
the complexity of the automation system. So, the computer was going to takethe place of the blocks or
automation panels with numerous relays. Any change in the operating cycles or
Production can be easily modified by changing... the program written in the programmable logic controller.
So, currently, changing the control scheme is much more convenient.

Everything was fine until the implementation of the technology, when a new problem arose and
the same as to-I ask the electricians to accept and to-and understand the functioning of the system
of automation with the new devices. Systemsthey are usually complex and require
the knowledge of certain programming techniques. It was a big question mark whether
electricians could to-and to acquire programming techniques in addition to the initial duties of
service. The Hydromatic Division of GeneralEngines recognized the necessity of implementing the new one.
technologies and thus laid the foundation for the first project with a programmable automation (there were a few more)
companies in the world that have created devices capable of controlling industrial processes, but
"Gould Modicon" developed the first device that complies withthese specifications. The key to success
the point was that learning a programming language was not necessary for programming.
Programming is done in a language similar to classic monophase schemes (ladder diagram),
with their specific characteristics. For this reason, electricians and technicians could very easily learn
programming because the logical schema drawn in the program was very similar to the schema
classic.
Initially, PLC-the s-called PC Controllers or programmable controllers. This name refers to
withoften referred to as a personal computer (PC). To eliminate this
confusion, the name 'PC' was assigned only to personal computers while the controllers
programmable s-called 'programmable logic controllers' or simply: PLC.

At the beginning PLC-the pipes were simple devices. At their entrances were connected
switches, digital sensors, etc., and at the outputs, the starting and stopping of the operation of others is controlled.
devices. When did the first PLCs appear?-these were not capable of conremove processes
more complex, such as: temperature control, position, pressure, etc. However, once
Over the years, PLC has also emerged.-paths that were able to perform these functions. In
Currently, programmable automata are capableto control very complex processes, including
position control. The method of achieving and programming them has been significantly improved. They have been
designed special modules attached to PLC-they can extend the operational range of this.
example in thisThis is the communication module, which allows the interconnection of multiple
programmable automation. Currently, it is very hard to imagine a process that is not
controlled by a programmable controller!

5.7 Components of programmable controllers

The PLC isit is currently an industrial system with a microcontroller (initially it was called a processor in
place of the microcontroller) which consists of a-the
specific hardware and software part and
adapted to function in industrial environments. The block diagram is presented in fig.4. Attention
special attention must be given to the galvanic separation of the microcontroller from the power side and
execution from the industrial environment.

The components may vary in number from one specimen to another, but the elements found in
the following are general:

1. The central unit: represents the most important part of the programmable automation and is
made up of 3 important parts: processor, memory and power supply. Through
this practically ensures the management of the entire process;

2. The programming unit: currently it is represented in many cases by a

a calculator through which programs can be written that are then loaded onto the unit
central and run. In case a unit that is easier to maneuver is desired, they are placed at
the provision of programmers (by the majority of companies) consoles (laptop-type systems) through
the environment in which programs for automata can be written;

3. Input/output modules: allow interconnection with the process by receiving or transmitting

5.8 Central processing unit– CPU

The central processing unit (CPU) is the brain of the programmable logic controller. The CPU isin a way
usually a microcontroller. In the past, these microcontrollers were 8-bit, such as 8051, and
Currently, there are 16-bit or 32-bit microcontrollers. In branded programmable controllers,
such as Siemens, Hitachi, and Fujitsu, you will find differentmicrocontroller ipur produced by
different companies, such as Motorola. The communication module is attached to one of the ports
of the microcontroller. Programmable controllers have different routines for memory checking, this
for safety reasons. Generally speaking, the general processing unit performs
a whole series of routines for checking the technical status of the PLC-of. For signaling
different errors or operating states of the PLC-uen are equipped with optical indicators (diodes
luminescent or LEDs.

5.9 Memory

System memory - currently of FLASH type -is used by the programmable machine for
the storage of the program used for automation control. Before being written into memory, the program
it needs to be compiled, with the help ofanother program with which the logic of automation was written in
leader diagram. Reprogramming or rewriting memory is usually done with the help of
of a serial cable.

The used memory is divided into different blocks with different functions. Certain parts of the memory
they are used to record the states of the ports (input or output). Each state of memory
it is stored through-a bit: 1 or 0. Each input or output corresponds to a bit in memory.
Other parts of the memory store the variables used by the program. For example,
the other advantages it brings, allows for monitoring the automation process from
distance, including checking the PLC status-of.

Almost every program for car programmingProgrammable controllers include various options
useful as: switching from ON to OFF for inputs and outputs, real-time program simulation
These options are necessary for determining errors or functioning
defects of the program. PThe programmer can add comments, names of inputs and outputs,
very useful in maintaining the system. For example, adding comments helps electricians
and technicians to understand much better the control scheme outlined in the programming environment.e
ladder diagram. These comments are very helpful for the maintenance and troubleshooting of automation.

5.11 Power supply

The power supply serves to provide electrical energy to the programmable controller.
Most PLCs-wires work with tensionsof 24Vdc or 230Vac. Some automats
programmable is powered through-a separate module. PLC-urinals with power supply
the large programmable automatons are separate. To determine the electric power of the source
to feed we will need to know consumptionul PLC-determined largely by
the power requirements of the outputs. The power supply must meet certain requirements for
electromagnetic compatibility, for example: to be immune to electromagnetic disturbances,
corrosive mediafound predominantly in the industrial environment.

5.12The inputs of the programmable logic controller

The intelligence of an automation system largely depends on the capability of the machine.
programmable to read the signal coming from various sensors and input devices. Keys,
kepad-switches with and without self-holding are some of the elements that made
the connection between man and machine. On the other hand, to check the parts that are in motion,
to check the pressure or fluid level, you will need transducers that
it transmits a unified signal at their output (0...5V or 4...20mA), recognized by the automation
programmable. There are different methods to obtain a sensor. For example, you could use a
optocoupler or a transformer.

5.13Outputs of the programmable automaton

An automation system is incomplete if no device is connected to its outputs.

The most common devices are: motors, coils, relays, indicators, signaling sounds.
Greetings. To start a motor or power a relay, PLC.-it transmits "1" logically at the output
afferent - depending on the characteristics of the program. In this case, we say that the output of the automaton
The programmable one is digital. However, the outputs can also be analog. An analog output is used
to generate an analog signal (e.g., a motor works at a certain speed that
corresponds to a certain tension).

5.14Extension of the number of entries / exits

6. ARCHITECTURE OF PROGRAMMABLE CONTROLLERS

6.1 Generalities

I remind you that this article addresses the overall construction and operation of PLC.-uri. In
at this point, due to the multitude of programmable automation devices available on the market, it is impossible to
we describe the architecture of each PLC in detail. There is no space forThis is not the purpose of this article.
plus, the block schema is approximately the same, each PLC manufacturing company-making uri
variations alongside this. Therefore, in this section of the article, I will take as a reference
only one model of PLC. The other types of PLCs, sold by other companies, are
more or less identical to this, the principle of operation remains the same.

6.2 Why OMRON?

Why not? It's a large company that produces at a high standard of quality, machines.
programmable, like other renowned companies in the field, such as Siemens, Mitsubishi or
Hitachi. Today we can say with certainty that the programmable logic controllers produced by these
companies are excellent devices for achieving high-precision automation and
quality. However, for a specific application, we must adopt and know the characteristics
of the PLC.

The programmable controller is adopted only after it-a outlined the schema of c-give "classic" and it
know exactly the number of inputs/outputs and sensors or transducers needed. In order to
create some examples that are much easier to understand and apply in practice, I chose, for description,
the programmable controller produced by OMRON company, micro class CPM1A. The adjective 'micro'
it signifies the existence of a minimum number of options attached to the programmable machine. But even
the model we will discuss in the following is sufficient for
the understanding of the operation and practical implementation of programmable logic controllers.

6.3 OMRON CPM1A PLC controller

Each PLC is essentially a microcontroller [Link] central processing unit of
the programmable controller is based on a microcontroller, or more recently, on a PC processor
from an older generation - which has various peripherals connected: digital input/output or relays like
in our case. Anyway, this is not an ordinary microcontroller system. A whole team
worked on improving the microcontroller and developing the program used for
his programming. Initially sused programarea in assembler, which is also used in
present in microcontroller programming. Companies producing PLCs-I had to
develop this programming mode to be much easier to understand for electricians and technicians,
and of course, fordeepens in as short a time as possible. Thus, it-programming was born
"in ladder" that we will discuss in point 6 of this article.
An overview image with the OMRON CPM1A PLC can be seen in figure 5. On the panel from
there are 4 LED indicators and the RS232 connector for the PC interface-street. Other than
these, the input and output terminals can also be seen. With the help of these terminals (with
you can connect PLC-to the automation scheme. From the terminals L1 and L2
power PLC-or, in this case, with 230VAC. Programmable logic controllers usually operate at
24Vdc, so for their control through sensors we will need access to the ground.
DC power sources that internally power them. In this regard, any PLC must
equipped with a table or GND access terminal. In our case, this terminal is labeled
"COM". The PLC microcontroller-is powered through-an internal reference voltage or
5V DC voltage regulator. The outputs of the programmable automaton are at 2.4Vdc, from where it is
we can easily guess what we can use these outputs for (for example: for controlling some relays
intermediaries located between the PLC and the execution part of the process). PLC- OMRON also includes
two holes for securing it in the car panelcan be highlighted or mounted, much more
easy, on an industrial rack or the well-known omega rail.

The presented programmable controller is only 8 cm tall and is vertically divided into two parts: a
part with a 230/24Vdc converter and another with CPU- the memory, betweendigital circuits and output relays
relevant. If you remove the plastic part from the left side, you will discover
the RS232 connector, that is, the serial interface with the PC-This interface is used for
programming of the programmable controller cuathe computer's help. When you install PLC-the no
6.4 ExitOMRON CPM1A programmable controller specifications

Except for the output transistor in NPN or PNP configuration, the programmable controller can
there are relays at the outputs. By having relays at the outputs of the programmable automation, connections can be made
Much easier external devices. The CPM1A model contains exactly these relays at the output.
CPM1A has a total of 4 relays whose contacts are found at the output terminals of
programmable controller. In reality, the internal diagram of a PLC output-the owl looks like in figure 6.

Once the optocoupler is activated by the transition of the microcontroller output to logic zero, the coil
the relay is powered and contacts A and B close. In our case, contacts A and B can
close or interrupt an external circuit. So the state of these contacts is determined by
the state of the microcontroller output ports. Figure 7 illustrates the case where the port
the output corresponds to a certain sequence of binary digits, noted as IR010. As was also the case and
the individual programming of microcontrollers and in the case of PLC-we will have to set the state
output ports at the beginning of the program writing. Using ladder programming of the PLC-of
we can veryit is easy to define the input and output states. If you do not define the output state, it can
It happens that when you activate the programmable machine, it starts off,
example, a motor, when in fact it should have waited to receive a command on an input like
to do this.
6.5 Inputs of the OMRON CPM1A programmable controller

Various sensors, keys, switches, and other similar elements can be connected to the PLC inputs.-
To be able to connect the mentioned sensors to the PLC inputs.-we will have to use a
power supply that activates the input circuits. It is necessary to do this.
because the input ports of the microcontroller that equips the PLC-they are galvanically isolated,
with the help of some optocouplers, by hairproper tea from c-give the programmable automaton. How
to activate an optocoupler we need an external voltage source, for
the proper functioning of the input sensors, we will need to intersperse these sensors along the route
feed to enteroptocouplers. The simplest method is to use the source of
24Vdc voltage of the PLCSuch a method is shown in figure 9.
If a sensor has a higher current, then another external source can be used for
its feeding or in other words, an adaptation will need to be made.

6.6 How PLC Works-ul ?

Executing the program:Here PLC-he runs the program, instruction by instruction.
Knowing the state of the inputs obtained from the previous step, the program will execute the steps
necessary. The reaction of executing a step can be observed by activating an output, which can be
memorized and used in the next step.
Check and correct the status of the outputs: In the final step, PLC-he checks the status of the outputs and
correct, if applicable, these errors using- program logic.
7. LADDER DIAGRAM

Over time, ever since the emergence of PLC-of, s-they presented several solutions for
programming of programmable automata -the most popular solution being programming in "ladder"
"diagram". Accordingly, at present, the majority of programmable controllers are programmed in
"ladder diagram" (relay scheme), which is nothing other than the drawing of a scheme.e
classic relay control but with a unique symbolism. This mode of programming was much
easier to understand for both electricians and technicians, because the symbols of the devices and
their contacts were very similar to those in classic automation schemes.

The ladder diagram consists of-a vertical line, which you can find on the left side of the program,
and one or more horizontal lines, on which, for example, the input contacts are arranged,
output and certain logical programming elements (fig. 11). The line on the left is called 'bus
bar" and the horizontal line is the instruction line. The elements are arranged on the instruction line.
logic of the program (normally closed contacts, normally open contacts, logic gates, contactors, etc.).
Combining several coneslogical elements in line, it is possible to determine which instruction
it will be executed and finally which output element it can command.
Most instructions can be carried out with the help of a single operand while others can be executed with multiple ones.
[Link] operand can be a binary digit from a-a certain location in memory or a
number. In a previous example, I presented operand 0 from memory location IR000. In
Fig. 12 shows an example of a program in ladder diagram where the relay IR010.00 is
activated when the microcontroller input is in '00'. The condition can be active (ON) or inactive
(OFF). The condition can practically simulate a switch. When the switch is closed, the relay is
acted and vice versa. If we use a switch without self-holding, when we press the first
oară comutatorul, releul va fi acţionat, iar când vom apasa a doua oară comutatorul, releul va
return to the initial position.

This is just a simple example. An alarm system can be very well implemented in-
a dwelling. For example, the condition can be represented by the doors at the entrance to the house. You can
consider these doors as switches connected to the PLC inputs- If the alarm is
the army and a door is opened unauthorized, the corresponding switch conditions the related entry
a PLC-turn on the "ON" and the corresponding output will attain that state. A circuit can thus be activated.
alarm sound.

7.1 A practical example with the OMRON CPM1A PLC

In the example below, a simple program is outlined. The example consists ofa device of
input (switch) and one output (light bulb). The input 000.00 represents the execution condition of
instructions 010.00. If we cancel the entry or in other words 'turn off the switch', the output
the switch will change and turn on the bulb. For the proper functioning of the program, it will
we need to close the corresponding instruction through a-another program line 'END'.
8. BIBLIOGRAPHY

 [1] - Nelson, V.P., Nagle, [Link] Logic Circuit Analysis and DesignPrentice Hall,
NJ, 1995.
 [2] - Petruzella, [Link] Logic Controllers, Second ed., McGraw Hill, New
York, 1996.
 [3] -Mange, [Link] Systems. An Introduction to Firmware Theory,
Chapman & Hall, London, 1992.

[4] -Moses, [Link] Automation. Design. Applications,Ed. MatrixRom, Bucharest,
2004.
 [5]Hugh JackAutomating Manufacturing Systems with PLCs, (Version 5.0, May 4,
2007)