Training on
PLC
Module 3: PLC Intermediate
Programming
Presented By
Belay E. (MSc. in
Mechatronics)
Biruk S. (MSc. in
Contents
2
Intermediate PLC programming
Advanced Programming Languages
Advanced Instructions
Data Structures
Advanced Industrial Control
Case Study-Soap Factory
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Intermediate PLC
3
programming
Intermediate PLC programming is the
level that bridges the gap between basic
automation tasks and complex, fully
integrated industrial systems.
While basic programming focuses on
simple on/off logic, timers, and counters,
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intermediate programming
introduces complex data handling,
advanced control techniques, and
system integration.
It's about moving from controlling a
single, simple machine to developing
logic for a larger, more dynamic
process that requires data
management, communication with
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other devices, and more sophisticated
Advanced Programming
5
Languages
Function Block Diagram (FBD):
A graphical language excellent for
processes with
continuous signals and data flows, like PID
loops.
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Advanced Programming
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Languages
Structured Text
(ST):
A high-level, text-
based
language (similar to
Pascal or C) used for
complex math,
looping,
and handling large
amounts of data.
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Advanced Programming
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Languages
Sequential Function Chart (SFC):
A graphical method for programming machines or Processes that
operate in a step by-step, sequential manner.
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Advanced Instructions
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Data Handling:
Using MOVE
instructions to transfer
values, COP (Copy File)
instructions to move
blocks of data, and
masking to isolate
specific bits.
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Advanced Instructions
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Math Operations:
Implementing
formulas using
addition (ADD),
subtraction (SUB),
multiplication
(MUL), and
division (DIV).
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Advanced Instructions
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Comparison:
Using instructions like EQU (Equal), GRT
(Greater Than), and LIM (Limit) to make
decisions based on analog values or set
points.
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Advanced Instructions
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Data Structures:
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Data Structures
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Arrays:
Organizing data (like
recipes, fault codes, or
sensor readings) into lists.
Indirect Addressing:
A powerful technique where
you use the value of one
memory address to point to
another. This is key for
handling arrays, recipes,
and tracking parts through a
system
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ADVANCED INDUSTRIAL CONTROL
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Case Study-Soap Factory
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Raw Material Handling &
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Mixing
PLCs manage the precise measurement
and mixing of raw materials (oils, lye,
fragrances, colors, and other additives).
This often involves a weighing system
with feedback loops (like fuzzy control
for fine adjustments) to ensure the
correct chemical ratios for consistent
quality.
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Saponification & Processing
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Temperature, pressure, and reaction
times in the saponification reactors are
monitored and controlled by the PLC to
ensure the process completes correctly.
In liquid soap production, the PLC
controls the blending, dispersing,
heating, and cooling functions.
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Finishing
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PLCs synchronize processes in the
finishing line, such as grinding soap
noodles into thin sheets, vacuum
plodding (extruding into bars), and
stamping the soap into final shapes.
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Cutting & Packaging
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Automated cutting and stamping
machines are controlled by PLCs to
ensure exact synchronization and
precision, often using vision systems to
check and reject defective products.
PLCs manage the speed and timing
intervals for precise labelling and
packaging.
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Quality Control &
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Monitoring
Through a Human-Machine Interface
(HMI) or SCADA (Supervisory Control and
Data Acquisition) system, operators can
monitor real-time production data, set
parameters, and diagnose faults.
The PLC collects and handles this data,
allowing for consistent quality control
and data logging
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THANK YOU!
Q&A
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