PLC
What is PLC?
A programmable logic controller (PLC) is an industrial grade computer that is
capable of being programmed to perform control functions.
The History of PLC ?
The concept of the Programmable Logic Controller (PLC) emerged in the late
1968s as a solution to replace traditional relay-based control systems.
PLC Hardware Components
Processor Memory
The central processing unit Stores the PLC's control
(CPU) of a PLC, responsible for program, user data, and system
executing the control program .settings
.and managing I/O operations
Power Supply Input/Output (I/O) Modules
Provides the necessary Interface the PLC with sensors,
electrical power to operate the actuators, and other devices,
.PLC and its peripherals enabling communication and
.control
PLC Hardware Components
How Does a PLC Work?
starts cycling and monitoring time.
The CPU starts read data from input
module and checks.
user program working.
Write data into output module.
Other tasks.
PLC Forms
compact plc modular plc
MAJOR PLC MANUFACTURING
Siemens
Rockwell Automation
Mitsubishi Electric
Omron
Panasonic
Difference between PLC and Classic Control
Architecture and Design
Programming and Modification
Response Time and Reliability
Cost and Implementation
Programming Languages
The 5 most popular Types of PLC Programming Languages are:
1. Ladder Diagram (LD)
2. Function Block Diagram (FBD)
3. Structured Text (ST)
4. Instruction List (IL)
5. Sequential Function Charts (SFC)
In this Presentation we will focus on ladder Digram
LADDER DIAGRAM
Most Popular PLC Language
Online Debugging & Editing
Easy to Read & Comment
Limited Instructions:
i.e. Motion Control
LADDER DIAGRAM
Consider circuit for switching on/off electric motor
We con redraw circuit by ladder diagram as shown
Power supply always shown as two vertical lines (rails)
Rest of circuit shown as horizontal lines
Horizontal rungs show the control portion of circuit
LADDER DIAGRAM Example
When button 1 pressed, the motor starts
When push button 1 released, holding contacts maintain
power to the motor
To stop the motor, push button 2 is pressed
Thus, we have motor starts by pressing button 1 and stopped by pressing button 2
Scanning the ladder program
Basic Symbols of Ladder Diagram
Normally Open (NO) Contact:
NO Contact is closed when assigned bit value in memory is 1
Normally Closed (NC) Contact:
NC contact is open when assigned bit value is memory is 0
Output Coil:
Output coil writes value for output bit in PLC memory based on
power-flow status
Example
When switch is closed (there is input), output of motor is a activated
Output of motor only activated as long as switch is closed (no input)
Logic Functions
And logic:
Logic Functions
And logic:
Application: machine tool only operate when safety guard in position AND
power switched on
Logic Functions
OR logic:
Logic Functions
OR logic:
Application: conveyor belt for packaging reject bottles if either weight is not
not acceptable OR no cap on bottle.
Logic Functions
NOT logic:
Logic Functions
NOT logic:
Application: light comes on when it becomes dark (when on light input to
light sensor, there is an output).
Logic Functions
Exclusive Or (XOR):
Logic Functions
XOR logic
Latching
In many situations, it is necessary to hold output energized even when input
deactivated.
Example: Motor continue running after pressing push-button switch
until stop push-button switch is pressed.
When input A close, output energized.
When output energized, another contacts associated with output close.
Even if the input A open, circuit maintain output energized.
The only way to release output is by operating normally closed contact B.
Multiple Output
With ladder diagrams, more than one output can be connected to a contact
Example: Ladder rung with two output
Example: Ladder rung with two inputs
and two outputs.
Multiple Output
Example: Sequenced Outputs
Program Examples
Example 1: Signal lamp required to be switched on if pump is running and pressure is satisfactory, or if
lamp test switch is closed.
Function block diagram
Ladder diagram
Program Examples
Example 2: Valve is operated to lift load when pump is running and either lift switch or switch indicating
that load has not already been is operated
Function block diagram
Ladder diagram
Location of Emergency Stop Switches
If failure of PLC occurs, output must be “Fail-safe” state so that no harm occur
If emergency stop located in input of PLC, may not work if PLC malfunction
Locating emergency stop in output of PLC ensure safe operation
Timers
Liquid flow Switches
Piston Pressure Switches
Diaphragm Pressure Switches
Limit Switches
Limit switches
• Are used to detect when an
object is present or absent
from a particular location
• They can activated by the
motion of a machine or by
the presence or absence of
a particular object.
Control of hydraulic cylinder using
PLC & Limit switch
Control of hydraulic cylinder using
PLC & Limit switch
Control of hydraulic cylinder using
PLC & Limit switch