Mechatronics and

automation
ET ZC323/24
BITS Pilani Lecture
Pilani Campus
Recap
• Logic gates
• Apply
• Absence of memory – will not remember
anything – present state input will be
processed as o/p
• PLC – memory – store program + i/p = o/p
• i/p and o/p comp.
• PLC components

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Representation of PLC circuit

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Representation of PLC circuit

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Use of Relay Controllers and Ladder Diagram

Use of momentary push-button switches

and a relay to implement a latch
Mechatronics & Automation ET ZC323 BITS Pilani
Use of Relay Controllers and Ladder
Diagram

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 Relay Sequencers
 Before the PLC, control, sequencing, and safety interlock logic for manufacturing
automobiles was mainly composed of relays, cam timers and dedicated closed-loop
controllers.

 One way to provide a discrete state controller is to use physical relays to put
together a circuit that satisfies the requirements of the ladder diagram.

 When a program has been wired into the relays that make up the relay logic panel, it
has been programmed to meet the ladder diagram.

 If the event sequence is to be changed, it is necessary to rewire all or part of the

panel. It may even be necessary to add more relays to the system, or to use more
relays than the previous program.

Mechatronics & Automation ET ZC323 BITS Pilani

Latching circuits

When the input A contacts close, there is an

output.

However, when there is an output,

another set of contacts associated with the
output closes.

These contacts form an OR logic gate system

with the input contacts. Thus, even if the
input A opens, the circuit will still maintain the
output energised.

The only way to release the output is by

operating the normally closed contact B.

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Multiple contacts from one coil 10

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Elements of Ladder Diagram

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Ladder Diagram: AND Logic

A.B

The lamp energizes only if contact A and contact B are

simultaneously actuated.
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Ladder Diagram: OR Logic

The lamp energizes if either of contact A or contact B are actuated.

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Ladder Diagram: NOT Logic

The lamp energizes if the contact is not actuated, and de-energizes

when the contact is actuated.
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Logics in Ladder diagram form

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Ladder Logic Diagrams for AND Gate

Mechatronics & Automation ET ZC323 BITS Pilani

Internal Relays
The term internal, auxiliary relay or marker is used for what can be
considered as internal relay in PLC.

It behaves like relays with their associated contacts, but in reality are not
actual relays but simulation by the software of the PLC.

• Internal can be very useful aids in the implementation of switching

sequences.

• They are often used when there are programs with multiple input
conditions.

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Latching circuit Application

There are often situations where it is necessary to

hold an output energised, even when the input
ceases.

A simple example of such a situation is a motor

which is started by pressing a push button switch.

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Popular Ladder Logic software

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Programmable logic controller

Internal
Relays

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Programmable logic controller

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 • In a certain bank, each of
the three bank officers has
a unique key to the vault.
The bank rules require
that 2 of the 3 officers be
present when the vault is
opened. Develop a PLC
ladder program that will
unlatch the door and turn
ON a light when 2 of the
3 keys are inserted.
A,B,C as officers
A & B OR
A&C OR
B&C must be present
Mechatronics & Automation ET ZC323 BITS Pilani
 • A small house has 3
windows and 2 doors.
Each window and door
has a switch attached such
that the contacts close
when a door or window
opens. Develop a PLC
ladder that will turn ON a
light if one or more
windows are open, or if
both doors are open.
A,B,C as windows
D, E doors

A or B or C
D and E
Mechatronics & Automation ET ZC323 BITS Pilani
 PLC Timer Function

Component on assy line

conveyor
Stop for operation to take place
LS After 65 sec the conveyor should start
Motor
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PLC Timer Function
• The Programmed timer function plays an important role in PLC applications to
provide for needed delays in some manufacturing sequence and to specify the
period of time that some operation is to last.

• While activated by a true path, the timer begins to accumulate time in form of
“ticks”.

• Each “tick” is worth a certain amount of time.

• The timer is preloaded with a certain number of these ticks.

• When the accumulated time ticks equals the preload value, the timer itself
becomes TRUE.

• The timer only counts while it has a TRUE input. If the input becomes FALSE
and then TRUE again, the timer will reset to ZERO and start to count again.

Stop for operation to take place

After 65 sec the conveyor should start
65 sec Mechatronics & Automation ET ZC323 BITS Pilani
PLC Timer Function

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PLC Timer Function sequencing

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PLC Timer Function

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TIMERS

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PLC Counter Function

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 PLC Counter Function
• A counter is a programmed function that counts (increments) every
time the input changes from FALSE to TRUE.
• If in one scan, the input is False, and in the next scan, the input is
True, the counter increments. No further counts will occur until the
input goes False again and then True.
• The counter has an address and a preset number of counts. When
the preset number of counts have been accumulated, the counter
becomes TRUE and can activate some other part of the ladder
program.

Mechatronics & Automation ET ZC323 BITS Pilani

PLC Counter Function

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Mechatronics & Automation ET ZC323 BITS Pilani
 Design and write ladder logic for a
simple traffic light controller for
following
sequence of operation as below,
Step 1 : Turn Green on for 10 seconds
Step 2 : Turn Yellow 1 on for 5
seconds.
Step 3 : Red 2 on for 40 seconds.
Step 4 : Sequence repeats thereafter.

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N.O / N.C

A1 – Normally Open or closed?

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Ladder Diagram

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Ladder Diagram

part
fixture
Machine base
Door open sensor

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Ladder Diagram

Load

Pump Valve

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Ladder Diagram

Pressure
sensor

Pump AND OR Test

switch

Turbine
Test circuits, where you would like to check operation of meter or
system before commissioning encoder

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Ladder Diagram

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Data Comparison

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Arithmetic Operations

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Sequencing of cylinders (A+ B+ A- B-)

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Sequencing of cylinders (A+ B+ B- A-)

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Repetition of Output coils

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Reverse Power flow

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Shift registers

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Shift registers

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 Shift registers – Ice cream cone Machine
We have 4 steps.
1) First we verify the cone is not broken. Next http://home.isr.uc.pt/~lino/AIR/Arquivo/PLC_T
we put ice cream inside the cone.(turn on utor/shift.htm
output 500)
2) Next we add peanuts.(turn on output 501)

3) And finally we add sprinkles.(turn on

output 502)

4) If the cone is broken we obviously don't

want to add ice cream and the other items

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 Shift registers – Ice cream cone Machine
We have 4 steps.
1) First we verify the cone is not broken. Next http://home.isr.uc.pt/~lino/AIR/Arquivo/PLC_T
we put ice cream inside the cone.(turn on utor/shift.htm
output 500)
2) Next we add peanuts.(turn on output 501)

3) And finally we add sprinkles.(turn on

output 502)

4) If the cone is broken we obviously don't

want to add ice cream and the other items

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Master Control

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Jump Instruction

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Jump Instruction

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Jump control Relays

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Function Boxes

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Code conversions

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Analog – Digital converter

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Proportional controller

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 Proportional controller
Rung 0 reads the ADC and stores the
temperature value in data register DR1.

Rung 1, the data register DR2 is used to store the set point
temperature. Rung 2 uses the subtract function
to subtract the values held in data registers DR1 and DR2
and store the result in data register DR3, i.e. this data
register holds the error value.

Rung 3 multiply function is used, in this case to multiply the

value in data register DR3 by the proportional gain of 4.

Rung 4 uses an internal relay which can

be programmed to switch off DR3 if it takes a negative
value.

Rung 5 the data register DR3 is reset to zero when the

input is switched off.
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Assignment problem A- A+ B- B+

Input 3 - a+
Input 2 – a-

Input 5 – b+
Input 4 – b-

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PLC Processor Scan

Home Work!

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 Types of PLCs
• Single Box Type: The single box type (or, as sometimes termed, brick) is
commonly used for small programmable controllers and is supplied as an
integral compact package complete with power supply, processor, memory,
and input/output units. Typically such a PLC might have 6, 8, 12 or 24 inputs
and 4, 8 or 16 outputs and a memory which can store some 300 to 1000
instructions.

• Modular: The modular or the Rack type consists of separate modules for
power supply, processor, input module, output module, memory.

Mechatronics & Automation ET ZC323 BITS Pilani

Types of PLCs

Brick Type PLC

Rack Type PLC

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