CHAPTER ONE

INTRODUCTION

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 CHAPTER ONE
INTRODUCTION

1.1 Introduction To PLC

The emergence and application of microprocessors and specific new tools such
as programmable logic controllers (PLCs), supervisory control and data acquisition
(SCADA), and distributed control systems (DCS) have increased productivity,
accuracy, and efficiency. These systems have reduced human intervention and
increased flexibility in process control [1].

The current project report briefly discusses current automation systems and
previous technologies to identify and explore the capabilities of programmable
logic controllers for any process. In order to overcome the difficulties of classical
logic controller circuits, which were implemented by relay circuits. Relay logic and
contact logic (RLC) were used in the old days which involved human intervention
and errors [1]. A Programmable Logic Controller (PLC) is the central control unit
in an industry or process. Efficient process operation and safety considerations if
appropriately programmed can meet the desired objectives. The word automation
clearly refers to running or repeating a process in an efficient manner by
integrating mechanisms and control sequences in the correct order multiple times
with acceptable deviations in the process output [1].

Industrial automation began long before programmable logic controllers. In the

early to mid-twentieth century, automation was typically done using complex
electromechanical relay circuits. However, the amount of relays, wiring, and space
required to create even simple automation was a problem. Thousands of relays

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could be needed to automate a simple factory process. It was extremely difficult to
get any improvement if something in the logic circuit needed to be changed. In
1968, the first PLC appeared, replacing complex relay circuits in industrial plants.
The PLC is designed to be easily programmed by plant engineers and technicians
who are already familiar with relay logic and control diagrams. From the
beginning, PLCs were programmable using ladder logic, which was designed to
mimic control circuit diagrams. Ladder diagrams look like control circuits where
power flows from left to right through closed contacts to energize a relay coil [2].

1.2 PLC Architecture

A PLC is composed of a few basic parts. They might look slightly different
from various manufacturers, but the purpose and scope of each component are the
same. These include a power supply, a central processing unit (CPU), input/output
modules, and a rack that the input/output (I/O) modules are placed into [3].

1.2.1 Processor: CPU & Memory:

Similar to a personal computer, the CPU is the brain of the PLC. They contain
microprocessors that monitor the PLC program, store memory, and transfer data
using I/O modules. They replace traditional timers, relays, and counters [4].

1.2.2 Input/output units:

Input/output modules provide the physical interface between the PLC processor
and real-world field devices. Inputs can be switches or sensor data; The outputs can
be controlled instructions for motors, pumps, valves, etc. There are different types
of modules to control different types of sensors and actuators but they all share
common features: removable terminal blocks, isolation, and diagnostic indicators.

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These features enable the PLC to be effective in internal maintenance, protection,
and troubleshooting tasks [4].

1.2.3 Power Supply:

The power supply unit converts the main AC voltage to a low DC voltage
suitable for delicate processors and internal circuits in the I/O interface modules
[4].

1.2.4 Communication interface:

The communications interface is used to receive and transmit data on

communications networks from or to other remote PLCs. This includes data
communication protocols, human-machine interfaces (HMI) and hard-wired
control panels, operator mimic screens, and so on [4].

1.2.5 Programming devices:

The programming device is a computer installed with programming software,

which enables you to enter and download desired programs into the PLC
processor’s memory, or to edit existing programs. These can be a PC, a laptop, or

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even an inexpensive compact hand-held computer for easy troubleshooting
equipment [4].

1.3 PLC Applications

Process Control: Monitor and control machines and industrial processes.

Monitoring and Analysis: Collecting and analyzing data to improve performance.
Automation: Turning machines and equipment on and off based on inputs and
programming.

1.4 Features of PLC VS the classic control

The difference between PLC (Programmable Logic Controller) and Classic

Control (Traditional Control) is a big topic and is supposed to include multiple
aspects of technical and functional aspects [5].

Here is a detailed explanation of the most prominent differences between the two
types:

1.4.1 Basic definition:

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 Programmable Logic Controller is a programmed computing device that aims to
control industrial processes or automated systems using dedicated programs. It is
characterized by flexibility and the ability to process events in real-time [5].

Classic Control (Traditional Control): Refers to control systems that rely on

traditional electronic or electrical devices such as relay control, timers, and
contactors to implement operations or control machines [5].

1.4.2 Flexibility and modification:

Programmable Logic Controller can be easily programmed to change functions

or control processors based on the needs of the system. Changing functions does
not require hardware modification, just rewriting or modifying the program.
Classic Control relies on mechanical and electrical connections. Changing
functions requires modifying the devices themselves (sequences, wires, settings)
[5].

1.4.3 Structure and Components:

Programmable Logic Controller Consists of input units (Inputs) and output units
(Outputs) such as sensors and motors. Includes the central processing unit (CPU)
that processes data and executes commands. It can be integrated with sensors,
electrical devices, and other networks.

Classic Control depends on components such as relays, switches, timers, and

sensors directly. Relies on traditional electrical circuits to execute commands [5].

1.4.4 Programming:

Programmable Logic Controller is programmed using specialized languages

such as Ladder Logic, Structured Text, or Functional Block Diagrams.
Programming is flexible and can be easily modified. Classic Control does not

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require programming in the traditional sense. It relies on connecting wires and
components to each other. Modification requires changing the connections or
components manually [5].

1.4.5 Process Control:

Programmable Logic Controller has the ability to control complex and multiple
processes such as simultaneous production processes, and control equipment via
network protocols such as Modbus, and Ethernet/IP. It can handle and analyze data
from multiple sensors simultaneously.

Classic Control is suitable for simple processes or those that do not require
interaction with complex systems. It cannot handle large amounts of data in real-
time or handle advanced processes [5].

1.4.6 Diagnosis and Maintenance:

Programmable Logic Controller can diagnose faults via graphical interfaces,

and faults can be easily identified by the messages or codes displayed by the
device. Classic Control Fault diagnosis requires examining traditional hardware
components such as relays and wires. Maintenance sometimes requires manual
intervention to replace damaged components [5].

1.4.7 Reliability and Safety:

Programmable Logic Controller is usually more reliable because it is designed

to operate in harsh industrial environments and supports safety features such as
redundancy and fault control.

Classic Control heavily relies on mechanical components, making it less

flexible in dealing with faults failures in mechanical components can lead to the
complete system shutdown [5].

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 1.5 Advantages of a PLC System

Programmable Logic Controller are capable of performing many more complex

applications than hard-wired control systems. PLC systems and electronic
communication lines replace much of the interconnecting wires required by hard-
wired control systems [5].

Here are some more advantages of PLC systems compared to hard-wired systems:
 They’re smaller
 It’s easier and faster to make changes to them
 They have integrated diagnostics and override functions
 Their diagnostics are centrally available
 Their applications can be immediately documented
 Their applications can be duplicated faster and less expensively [5]

1.6 The key differences between the Siemens S7-200 and S7-1200
PLCs

1.6.1 Architecture:

S7-200: This series employs a modular design and is more suited for smaller and
less complex applications.

S7-1200: This series has a more advanced architecture, allowing for greater
flexibility and scalability with a higher performance level suitable for mid-sized
applications [5].

1.6.2 Performance:

S7-200: Generally has lower processing power and speed compared to the S7-
1200.

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 S7-1200: Offers faster processing speed and better multitasking capabilities [5].

1.6.3 Programming Environment:

S7-200: Uses the Step 7 Micro/WIN software, which is simpler but less powerful.

S7-1200: Utilizes the TIA Portal (Totally Integrated Automation Portal), which
integrates multiple automation aspects and provides a richer programming
environment [5].

1.6.4 I/O and Expansion:

S7-200: Has limited I/O options and expansion capabilities.

S7-1200: Provides extensive I/O options and modules, allowing for significant
expandability.

1.6.5 Networking and Connectivity:

S7-200: Limited networking capabilities, primarily using proprietary Siemens

protocols.

S7-1200: Enhanced networking options, including Profinet, Ethernet, and other

standard protocols, allowing easier integration into modern automation systems
[5].

1.6.6 Safety and Security:

S7-200: Basic security and safety features.

S7-1200: Advanced security and safety measures, including user management and
software password protection [6].

1.7 Advanced features of PLC s7 1200 project user device

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 1.7.1 Enhanced integrated functions such as web server capabilities, data
logging, and advanced control functions, enabling more sophisticated applications
[6].

1.7.2 Provides a variety of programming languages, including ladder logic,

structured text, function block diagram, and Structured Control Language (SCL),
allowing for greater programming flexibility [6].

1.7.3 Provides much larger memory resources, allowing larger programs and
more data processing.[6]

1.7.4 More suitable for a wide range of applications, including complex

operations, intensive data processing, and integration within industry settings [6].

1.7.5 Can support HMI (Human Machine Interface) integration, allowing easy
interaction with the control system [6].

1.8Summary

Automation and control engineers design this high-level view of the PLC. These
engineers understand control systems, control algorithms, and configuration. They
model the process and determine the size and scale of the system needed. From
there, the PLC and all of its components are purchased. This could be a single rack
with eight I/O cards, or twenty racks all communicating over an industrial network
with thousands of I/O points - all of the control being done by a single CPU.

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References
1. F. M. A. Fernández, M. W. Gutiérrez and S. J. A. López, "Neural control
design implemented in a PLC for a laboratory plant," 2013 II International
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2. V. Khrulkov, S. Vasilchenko and S. Cherny, "Method of Implementing a
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10.1109/FarEastCon50210.2020.9271539.
3. F. Rossi, J. P. Sembiring, A. Jayadi, N. U. Putri and P. Nugroho,
"Implementation of Fuzzy Logic in PLC for Three- Story Elevator Control
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4. Burhanuddin Ahmad , Prawito Prajitno, " Design of neural network and
PLC-based water flow controller," Journal of Physics: Conference Series,
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Measurement and Metrology 14th November 2019, Padang, Indonesia.

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5. Programmable Logic Controllers: Principles and Applications Author: John
W. Webb and Ronald A. Reese Publication Date: Sixth Edition, 2011
6. Programmable Logic Controllers: An Introduction Author: Frank D.
Petruzella Publication Date: Fourth Edition, 2010 Publisher: McGraw-Hill
Education

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