PROGRAMMABLE

LOGIC
CONTROLLERS
DHARUN
715523105014
BE EEE (2ND YEAR)
 Agenda
• Review brief history of PLCs and
manufacturing control systems
• Introduce the concepts of discrete control of
manufacturing
 Types of control
• Temporal -- control based in time
• State -- control based in state level
• Hybrid – both temporal and state
 Objectives
• To define the basic components of a PLC
• To apply PLC based control to a
manufacturing system
• To be identify instrumentation required to
implement a PLC control system
• To program a PLC
• To implement a PLC control program and
hardware
 PURPOSE OF Programmable
Logic Controllers (PLCs)
• Initially designed to replace relay logic
boards
– Sequence device actuation
– Coordinate activities
• Accepts input from a series of switches
• Sends output to devices or relays
 FUNCTIONS OF
CONTROLLERS
• 1) on-off control,
• 2) sequential control,
• 3) feedback control, and
• 4) motion control.
 CONTROL
DEVICES
1) mechanical control - cam, governor, etc.,
2) pneumatic control - compressed air,
valves, etc.
3) electromechanical control - switches,
relays, a timer, counters, etc,
4) electronics control - similar to
electromechanical control, except uses
electronic switches.
5) computer control.
 PLC
Input
CPU Input
Module
Flag
System
Output
Output Module
User Ladder
Diagram

Working
memory
registers
 PLC
Configuration
 What devices does a PLC interact
with?
• INPUT RELAYS-(contacts)These are connected to the outside world. They
physically exist and receive signals from switches, sensors, etc. Typically they
are not relays but rather they are transistors.
• INTERNAL UTILITY RELAYS-(contacts) These do not receive signals from
the outside world nor do they physically exist. They are simulated relays and
are what enables a PLC to eliminate external relays. There are also some
special relays that are dedicated to performing only one task. Some are always
on while some are always off. Some are on only once during power-on and are
typically used for initializing data that was stored.
• COUNTERS-These again do not physically exist. They are simulated counters
and they can be programmed to count pulses. Typically these counters can
count up, down or both up and down. Since they are simulated they are limited
in their counting speed. Some manufacturers also include high-speed counters
that are hardware based. We can think of these as physically existing. Most
times these counters can count up, down or up and down.
 What devices does a PLC interact
with?
Continued
• TIMERS-These also do not physically exist. They come in many
varieties and increments. The most common type is an on-delay type.
Others include off-delay and both retentive and non-retentive types.
Increments vary from 1ms through 1s.
• OUTPUT RELAYS-(coils)These are connected to the outside world.
They physically exist and send on/off signals to solenoids, lights, etc.
They can be transistors, relays, or triacs depending upon the model
chosen.
• DATA STORAGE-Typically there are registers assigned to simply
store data. They are usually used as temporary storage for math or data
manipulation. They can also typically be used to store data when
power is removed from the PLC. Upon power-up they will still have
the same contents as before power was removed. Very convenient and
necessary!!
 SWITCHE
S
Non-locking Locking

Normally Open Normally Closed

SPDT
P1
DPST
P2
Multiple Throw Multiple Pole

Break-before-make Make-before-break
 TERM
Throw - number of states S
Pole - number of connecting moving parts (number of individual circuits).

SPDT
A serial switch box (A-B box) has
two 25 pin serial ports to switch from.

A B

Output
DPST Input

Knob
How is this switch classified?
 TYPES OF
SWITCHES
1. Basic switch, operated by a mechanical level,
2. Push-button switch,
3. Slide switch,
4. Thumbwheel switch,
5. Limit switch,
6. Proximity switch, and
7. Photoelectric switch.

RATING: voltage, current

 RELAY
A switch whose operation is activated by an electromagnet is called a "relay"
S
contact

coil

input

Relay coil Output contact

 COUNTE
R
Digital counters output in the form of a relay contact when a
preassigned count value is reached.
input
Register 5

Accumulator
reset

contact

output

Input

Reset

Output

Count 0 12 3 4 5 0 1
 TIME
A timer consists of an internal clock, a count value register, and
Ror some timing purpose.
an accumulator. It is used for

Clock

Accumulator
reset

Register

Clock
contact
Contact
Reset
output

Output

Count 0 1 2 3 4 5

Time 5 seconds.
 AN EXAMPLE OF RELAY
seconds after a part touches a limitLOGIC
For process control, it is desired to have the process start (by turning on a motor) five
switch. The process is terminated automatically
when the finished part touches a second limit switch. An emergency switch will stop
the process any time when it is pushed.
L1
LS1 PB1 LS2 R1

R1

TIMER R2
R1 PB1
LS1 LS2

PR=5

TIMER

5
Motor
R2

R1
 PLC
Programmable ARCHITECTURE
controllers replace most of the relay panel wiring
by software programming.

PC
Program
Loader
Switches

Printer
I/O
Processor
Modules Machines
Cassette
Loader
Power
EPROM Memory Supply
Loader

Peripherals External Devices

A typical PLC
 PLC
1. Processor Microprocessor based, may allow arithmetic
COMPONENTS
operations, logic operators, block memory moves,
computer interface, local area network, functions, etc.

2. Memory Measured in words.

ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electronically Erasable Programmable
ROM),
EPROM (Erasable Programmable Read Only Memory),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.
 PLC
3. I/O Modular plug-in periphery
COMPONENTS
AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g.., high speed timers,
Stepping motor controllers, etc. PID, Motion
4. Power supply AC power
5. Peripheral Hand held programmer (loader),
CRT programmer,
Operator console,
Printer,
Simulator,
EPROM loader,
Cassette loader,
Graphics processor, and
Network communication interface. MAP, LAN
 LADDER
A ladder diagram (also called contact symbology) is a means of
DIAGRAM
graphically representing the logic required in a relay logic
system.

Rail
start emergency stop
PB1 PB2
R1

Rung R1

R1

A
Ladder Representation
 PLC WIRING
DIAGRAM
Input PLC Output

01 01 02 20 11 A
12
02
20
03
20 11

External
switches

Stored program
 SCA
A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to
N
the bottom. Usually, all the outputs are updated based on the status of the internal
registers. Then the input states are checked and the corresponding input registers are
updated. Only after the I/Os have been resolved, is the program then executed. This
process is run in a endless cycle. The time it takes to finish one cycle is called the
scan time.
Output
Input
begin

Idle

Scan cycle

Resolve
logic