Programmable Logic Controller
Programmable Logic Controller
www.iji-cs.org
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D. Ahuja1, N. Chaudhary1 Department of Electrical and Electronics Engineering, YMCA University of Science and Technology, Faridabad, 121006, India
(Abstract)A PLC (Programmable Logic Controllers) is a digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions such as logic sequencing, timing, counting, and arithmetic to control, through digital or analog input/output modules, various types of machines or processes. It is an easily understood programming language .It can hold data for a long time i.e. for a indefinite time but requires excessive work in connecting wires. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result. Keywords: PLC, Central Processing Unit, NEMA, Sinking, Sources
1.1 History
PLC development began in 1968 in response to a request from an US car manufacturer and were first installed in the industry in 1969.These could be used in the 70 s to send and receive varying voltages and entered in the analog world along with communications abilities. In 80s there was an attempt to standardize communications with manufacturing automation protocol (MAP), reduction in the size of the PL and making them software programmable through symbolic programming on personal computers instead of dedicated programming terminals or handheld programmers. In the 90s there was a gradual reduction in the introduction of new protocols and the modernization of the physical layers of some of the more popular protocols that survived the 1980s [2].The latest standard IEC 1131-3 has tried to merge PLC programming languages under one international standard. We now have PLCs that are programmable in function block diagrams, instruction lists, C and structured text all at the same time.
2. PLC Hardware
2.1 Hardware Components of a PLC System
PLC has following hardware components: (i) Central Processing Unit (CPU) CPU makes a great number of check-ups of the PLC controller itself so as eventual errors would be discovered early.
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Microprocessor based CPU may allow arithmetic operations, logic operators, block memory moves, computer interface, local area network, functions, etc. (ii)System Buses The internal paths along which the digital signals flow within the PLC are called buses.The system has four buses: The CPU uses the (a)data bus for sending data between the different elements, (b) address bus to send the addresses of locations for accessing stored data,(c) control bus for signals relating to internal control actions and (d) system bus for communications between the I/O ports and the I/O unit. (iii)Memory System (ROM) is the component to give permanent storage for the operating system and the fixed data used by the CPU.RAM is for data where information is stored on the status of input and output devices and the values of timers and counters and other internal devices. EPROM is for ROMs that can be programmed and then the program is made permanent. (iv) I/O Sections It includes inputs monitor field devices, such as switches and sensors and outputs control with other devices, such as motors, pumps, solenoid valves, and lights. (v)Power Supply Most PLC controllers work either at 24 VDC or 220 VAC. Some PLC controllers have electrical supply as a separate module, while small and medium series already contain the supply module. (vi) Programming Device The programming device is used to enter the required program into the memory of the processor.The program is developed in the programming device and then transferred to the memory unit of the PLC.
Fig.1 S7-300
can count up, down or both up and down. Since they are simulated they are limited in their counting speed. Some manufacturers use hardware based highspeed counters . (iv)Timers Timers also do not physically exist. These are of many varieties and increments.The most common type is an on-delay type.Others include off-delay and both retentive and nonretentive types. Increments vary from 1ms through 1s. (v) Output Relays 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. (vi) Data Storage Typically there are registers assigned to simply store data .temporarily for math or data manipulation.They can be used to store data when power is removed from the PLC.
4. PLC Programming
4.1 Programming Languages
Programming languages include loading of a program into PLC systems in machine code and a sequence of binary code numbers to represent the program instructions. A computer program called an assembler can be used to translate the mnemonics into machine code. High level Languages used are C, BASIC, etc.
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Statement list is a programming language using mnemonic abbreviations of Boolean Logic operations. Boolean operations work on combination of variables that are true or false. 6.1 Statement List Operations These are following (i)Load (LD) instruction. (ii)And (A) instruction. (iii)Or (O) instruction. (iv)Output (=) instruction.
Most PLCs contain some software checking program through the installed program and provides a list on a screen or as printout with any errors detected.
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9. PLC Applications
Following is the information on drawing numbers for automatic gates using PLC (Fig.4): 1. Area Sensor (If there are objects, the sensor output OFF) 2. Area Sensor (If there are objects, the sensor output OFF) 3. Area Sensor (If there are objects, the sensor output OFF) 4. Area Sensor (If there are objects, the sensor output OFF) 5. Electric Motor and Gearbox 6. Limit Switch for Open gate condition 7. Limit Switch for Closed gate conditions 8. Gate
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(9) Limit Switch for Position 1 (10) Limit Switch for Position B (11) Limit Switch for Door Open (12) Limit Switch for Door Close (13) Safety Sensor
Information on Drawing Numbers for Elevator PLC Program (Fig.6) (1) Push Button Switch (Push Button Switch with Light) In Floor B Outside. (2) Light Push Button Switch (Push Button Switch with Light) In Floor B Outside. (3) Push Button Switch (Push Button Switch with Light) In Floor 1 Outside. (4) Light Push Button Switch (Push Button Switch with Light) In Floor 1 Outside. (5) Push Button Switch (Push Button Switch with Light) In B Inside. (6) Light Push Button Switch (Push Button Switch with Light) In B Inside. (7) Push Button Switch (Push Button Switch with Light) In 1 Inside. (8) Light Push Button Switch (Push Button Switch with Light) In 1 Inside.
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ning to overlap in responsibilities, and many vendors sell RTUs with PLC-like features and vice versa. The industry has standardized on the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs, although nearly all vendors also offer proprietary alternatives and associated development environments [5]. In recent years "Safety" PLCs have started to become popular, either as standalone models (Pilz PNOZ Multi, Sick etc.) or as functionality and safety-rated hardware added to existing controller architectures (Allen Bradley Guardlogix, Siemens Fseries etc.). These differ from conventional PLC types as being suitable for use in safety-critical applications for which PLCs have traditionally been supplemented with hard-wired safety relays. For example, a Safety PLC might be used to control access to a robot cell with trapped-key access, or perhaps to manage the shutdown response to an emergency stop on a conveyor production line. Such PLCs typically have a restricted regular instruction set augmented with safety-specific instructions designed to interface with emergency stops, light screens and so forth. The flexibility that such systems offer has resulted in rapid growth of demand for these controllers [6].
[1] .W. Bolton, Programmable Logic Controllers, Fifth Edition, Newnes, 2009 ISBN 978-1-85617-751-1, Chapter 1. [2]...Gregory K. McMillan, Douglas M. Considine (ed), Process/Industrial Instruments and Controls Handbook Fifth Edition, McGraw-Hill, 1999 ISBN 0-07-012582-1 Section 3 Controllers. [3] .M. A. Laughton, D. J. Warne (ed), Electrical Engineer's Reference book, 16th edition,Newnes, 2003 Chapter 16 Programmable Controller. [4] "The father of invention: Dick Morley looks back on the 40th anniversary of the PLC". Manufacturing Automation. 12 September 2008.,http://www.automationmag.com/programablecontrol/features/the-father-of-invention-dick-morley-looks-backon-the-40th-anniversary-of-the-plc.html. [5] W. Bolton, Programmable Logic Controllers, Fifth Edition, Newnes, 2009 ISBN 978-1-85617-751-1, Chapter 1. [6] Daniel Kandray, Programmable Automation Technologies, Industrial Press, 2010 ISBN 978-0-8311-3346-7, Chapter 8 Introduction to Programmable Logic Controller.s
13. Conclusion
PLC is an easily understood programming language .It can hold data for a long time i.e. for a indefinite time but requires excessive work in connecting wires. The functionality of the PLC has evolved over the years to include sequential relay control, motion control, process control, distributed control systems and networking. The data handling, storage, processing power and communication capabilities of some modern PLCs are approximately equivalent to desktop computers. PLC-like programming combined with remote I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in certain applications. Regarding the practicality of these desktop computer based logic controllers, it is important to note that they have not been generally accepted in heavy industry because the desktop computers run on less stable operating systems than do PLCs, and because the desktop computer hardware is typically not designed to the same levels of tolerance to temperature, humidity, vibration, and longevity as the processors used in PLCs. In addition to the hardware limitations of desktop based logic, operating systems such as Windows do not lend themselves to deterministic logic execution, with the result that the logic may not always respond to changes in logic state or input status with the extreme consistency in timing as is expected from PLCs. Still, such desktop logic applications find use in less critical situations, such as laboratory automation and use in small facilities where the application is less demanding and critical, because they are generally much less expensive than PLCs.
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