ELECTRIC DRIVE

AND PLC I

Benjamin Addo-Mensah
Definition
Programmable Logic Controller (PLC) is a digital industrial
computer control system designed for multiple inputs and outputs
arrangements. A PLC has extended temperature measurement
ranges, electrical noise immunity and it is resistant to vibration.
Basically the PLC is robust and rugged for the industrial settings.
History
The PLC was invented as a response to the challenges within the
automotive industry. The control, sequencing , and safety
interlock logic for manufacturing automobiles was accomplished
using electromechanical relays, timer and dedicated closed-loop
controllers until the PLC was evented as a response to the cost and
time consuming process of updating the facilities for yearly model
change-over. Basically, the relay system required a rewiring by
skilled electricians. The relays are relegated to high current or
voltage switching systems.

Figure 1. Show a relay panel.

This panel is from the 60s. Imagine a yearly rewiring or routine
fault finding.
Figure 2. Show a sample picture of a PLC, the Siemens S7-200

Automation
Automation Engineering is aimed basically at having systems to
work on their own with as little human interventions as possible.
This implies that, the automated system has to be smart.
SMART
Smart is an acronym for Self-Monitoring Analysis and Response
technology.
For a system to be smart, it needs to be able to be aware of its
environment (Inputs), analyze what it gathers from its
environment (Process) and then respond to the analyzed data
(Output).
The smartness of a systems is its ability to monitor its
environment and then react to what it gathers from this
environment.
So a PLC can be said to be an industrial computer system that
continuously monitors the state of input devices and makes
decisions based upon a custom program to control the state of
output devices.
Major Components of a PLC
 Power Supply: This provides the voltage needed to run the
primary PLC components

 I/O Modules: They provide signal conversion and isolation

between the internal logic level signals inside the PLC and
the high level field signal.

 Processor: Receives input signals and then provides output

response based on a set of instruction code.

 Programmer: this is used to enter the program which

determines the sequence of operation and control of output
device or process equipment.

Block diagram of the PLC

Operation Sequence
The PLC runs the following as a routine sequence at start:
 Self-test: this involves the testing of the PLCs own
hardware and software for faults
 Input scan: if the PLC finds no problems, it copies all the
inputs and their values into memory.
 Logic scan: Using the inputs, the logic program is solved
once and then updates the outputs.
 Output scan: While the logic is being solved, the output
values are updated only in memory after the program scan,
the outputs are updated using temporary values in memory

PLC Advantages
 Flexibility
 In the past, each electronically controlled production
machine required its own controller but now it is
possible to use just one model of a PLC to run any one
of the 15 machines.
 Each of the 15 machines under PLC control would have
its own distinct program (or a portion of one running
program).

 Implementing Changes and Correcting

Errors

 With a wired relay-type panel, any program alterations

require time for rewiring of panels and devices.
  When a PLC program circuit or sequence design change
is made, the PLC program can be changed from a
keyboard sequence in a matter of minutes.
 No rewiring is required for a PLC-controlled system.
 Also, if a programming error has to be corrected in a
PLC control ladder diagram, a change can be typed in
quickly.

• Large Quantities of Contacts

 The PLC has a large number of contacts for each coil

available in its programming. Suppose that a panel-wired
relay have all contacts in use, when a design change is
required needing more contacts, time would have to be
taken to procure and install a new relay or relay contact
block but using a PLC only three more contacts would be
typed in. Contacts are now a “software” component.

• Lower Cost

 It is possible to condense more functions into smaller and

less expensive packages. It is possible to purchase a PLC
with numerous relays, timers, and counters, a sequencer,
and other functions for a few hundred dollars.

• Pilot Running

 A PLC programmed circuit can be evaluated in the

laboratory. The program can be typed in, tested,
observed, and modified if needed, saving valuable
factory time.
• Visual Observation

 A PLC circuit's operation can be seen during

operation directly on a CRT screen. The operation or
mis-operation of a circuit can be observed as it
happens.
 Logic paths light up on the screen as they are
energized so troubleshooting can be done more
quickly during visual observation.

• Reliability and Maintainability

 In general, solid-state devices are more reliable, than

mechanical systems or relays and timers.
Consequently, the control system maintenance costs
are low and downtime is minimal.

• Documentation

 An immediate printout of the true PLC circuit is

available in minutes, if required.
 The PLC prints out the actual circuit in operation at a
given moment so there is no need to look for the
blueprint of the circuit in remote files.
 Often, the file prints for relay panels are not properly
kept up to date. A PLC printout is the circuit at the
present time; no wire tracing is needed for
verification.
PLC Disadvantage
• Fixed Program Applications

 Some applications are single-function applications. It

does not pay to use a PLC that includes multiple
programming capabilities if they are not needed.
Their operational sequence is seldom or never
changed, so the reprogramming available with the
PLC would not be necessary.
• Fail-Safe Operation

 In relay systems, the stop button electrically disconnects

the circuit; if the power fails, the system stops. This, of
course, can be programmed into the PLC; however, in
some PLC programs, you may have to apply an input
voltage to cause a device to stop. These systems may not
be fail-safe.

 Lack of Openness
 PLC devices are proprietary hence part or whole
software of one manufacturer cannot be used in
combination with parts of another manufacturer