Ia Theory

PLC Working Principle with Industrial
Applications
Programmable Logic Controller

Programmable Logic Controller (PLC) is a special computer
device used in industrial control systems. Due to its robust
construction, exceptional functional features like sequential
control, counters and timers, ease of programming, reliable
controlling capabilities and ease of hardware usage – this
PLC is used as more than a special-purpose digital
computer in industries as well as in other control-system
areas. Most of the industries abbreviate these devices as
“PC” but it is also used for personal computers; due to this,
many manufacturers named these devices as PLCs.
The programmable logic controller is used not only for
industrial purpose but also in civil applications such as
washing machine, elevators working and traffic signals
control. Different types of PLCs from a vast number of
manufacturers are available in today’s market. Therefore, in
the following paragraphs, let us study about programmable
logic controller’s basics, principles and applications.
Principle of Programmable Logic Controller:
Programmable Logic Controllers are used for continuously
monitoring the input values from sensors and produces the
outputs for the operation of actuators based on the program.
Every PLC system comprises these three modules:
 CPU module
 Power supply module
 One or more I/O module
PLC Architecture
CPU Module:
A CPU module consists of central processor and its
memory. The processor is responsible for performing all the
necessary computations and processing of data by
accepting the inputs and producing the appropriate outputs.
Power Supply Module:
This module supplies the required power to the whole
system by converting the available AC power to DC power
required for the CPU and I/O modules. The 5V DC output
drives the computer circuitry.
I/O Modules:
The input and out modules of the programmable logic
controller are used to connect the sensors and actuators to
the system to sense the various parameters such as
temperature, pressure and flow, etc. These I/O modules are
of two types: digital or analog.
Communication Interface Modules:
These are intelligent I/O modules which transfers the
information between a CPU and communication network.
These communication modules are used for communicating
with other PLC’s and computers, which are placed at
remote place or far-off locate.
The program in the CPU of programmable logic controller
consists of operating system and user programs. The
purpose of the operating system with CPU is to deal with the
tasks and operations of the PLC such as starting and
stopping operations, storage area and communication
management, etc. A user program is used by the user for
finishing and controlling the tasks in automation.
The Principle of operation of the PLC can be understood
with the cyclic scanning also called as scan cycle, which is
given in the below figure.
PLC Scan Cycle
A typical PLC scans cycle includes of the following
steps:
 The operating system starts cycling and monitoring of
time.
 The CPU starts reading the data from the input module
and checks the status of all the inputs.
 The CPU starts executing the user or application
program written in relay-ladder logic or any other PLC-
programming language.
 Next, the CPU performs all the internal diagnosis and
communication tasks.
 According to the program results, it writes the data into
the output module so that all outputs are updated.
 This process continues as long as the PLC is in run
mode.
To get an idea about the PLC operation,consider the simple
mixer process control as shown in the figure below.
Simple Mixer Process Control

In the above figure, the set up has a mixer motor to
stir liquid automatically in the container whenever the
temperature and pressure reaches the preset values. In
addition, a separate manual push button station is used for
the operation of the motor.The process is monitored with a
pressure-sensor switch and temperature-sensor
switch. These switches close their respective contacts when
conditions reach their preset values.
The input field devices like pressure switch, temperature
switch and manual push buttons are hardwired to an
appropriate input module, and the output device like motor-
starter coil is hardwired to an appropriate output module of
the PLC. Based on the program done in the PLC, the
system continuously scans all the input preset values and
correspondingly updates the outputs, i.e., when both the
pressure and temperature switches get energized or the
push button gets energized, the PLC automatically
energizes the motor-starter coil so that a stirring action
takes place.
Applications of Programmable Logic Controller (PLC)
The PLC can be used in industrial departments of all the

developed countries in industries like chemical industry,
automobile industry, steel industry and electricity industry.
Based on the development of all these technologies,
functionality and application, the scope of the PLC increases
dramatically.
1. Application of PLC in Glass Industry
From the year 1980 the Programmable-logic controllers are

in use in the glass industry, and they are assembled bit by
bit. PLCs are used mainly in every procedure and workshop
for controlling the material ratio, processing of flat glasses,
etc.
With the development of PLC and increasing demand in the
real world, the control mode of the programmable-logic
controller with an intelligent device is applied in the glass
industry. In making of a float glass, PLC itself cannot finish
some controlling tasks because of the complexity of the
control system and processing of huge data. For the
production of glass, we make use of bus technology to
construct the control mode of a PLC with a distributed-
control system. This control system deals with analog
controlling and data recording; the PLC is also used for
digital quality control and position control.
This type of control mode is a big advantage for PLC and
DCS for improving reliability and flexibility of the control
system.
2. Applications of PLC in Cement Industry
Along with the best-quality raw materials, the accurate data

regarding process variables, especially during mixing
processes within the kiln, ensures that the output provided
should be of the best possible quality. Nowadays a DCS
with bus technology is used in the production and
management industry. By using this existing DCS control
system, the PLC is in user mode of SCADA. This mode
comprises PLC and configuration software. This SCADA
mode comprises the PLC and host computer. The host
computer consists of slave and master station. The PLC is
used for controlling the ball milling, shaft kiln and Kiln of
coal.
To know more about these programmable-logic controllers’
function, you can go through the following project, which is
given as a practical example used mostly for industrial
automation.
Thus, this article has covered the principle of operation of
programmable logic devices or controller and its
applications in various industries like glass industry, steel
industry and cement industry. For any help regarding this
topic, please contact us by commenting in the comment
section given below.

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PLC Working Principle with Industrial

Programmable Logic Controller

Simple Mixer Process Control

The PLC can be used in industrial departments of all the

From the year 1980 the Programmable-logic controllers are

Along with the best-quality raw materials, the accurate data

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