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Lec#02 Intro To Programmable Logic Controller

The document discusses programmable logic controllers (PLCs), including their history, components, advantages over traditional hardwired systems, and applications. PLCs were developed in the late 1960s to replace relay-based control systems and are now widely used in manufacturing and other industries.

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mido AA
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51 views12 pages

Lec#02 Intro To Programmable Logic Controller

The document discusses programmable logic controllers (PLCs), including their history, components, advantages over traditional hardwired systems, and applications. PLCs were developed in the late 1960s to replace relay-based control systems and are now widely used in manufacturing and other industries.

Uploaded by

mido AA
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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M1452 Control Applications

Introduction to Programmable Controller


Lec.#02
Omar Salim; Ph.D.
Benha Faculty of Engineering
Benha University

April 2024

M 1452 Control Applications (3-2-1)


 Basic components of process control loops (Sensors and actuators).
 Control modes (Discrete, proportional, integral and derivative control)
 Design of process control system and controller hardware (hydraulic, pneumatic,
electric/electronic controller)
 Tuning of PID controllers, Optimal control system
 Digital control system, Sampled Data Systems and the z-Transform
 Pulse Transfer Function, Mapping the s-Plane into the z-Plane
 Digital system stability, Digital Controller Design
 Programmable logic controllers with applications
 Microcontroller (layout, assembly programming)
 Embedded system design
 Case studies.
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Today’s Outline
 Relay
 Introduction to Programmable Controllers
 Historical overview

What is a Control System?


 In general, a Control System is a collection of electronic devices and
equipments which are in place to ensure the stability, accuracy and
smooth transition of a process.

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Relay

What is PLC?
A programmable controller, formally called the programmable
logic controller (PLC) can be defined as a solid-state device
member of the computer family.
It is capable of storing instruction to implement control
functions such as sequencing, timing, counting, arithmetic, data
manipulation and communication to control industrial
machines and processes.

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Prior to PLCs
 Contactors and relays hard-wired together
 Circuit first had to be designed and drawn up
 Components were specified and installed
 Electrician would then wire it all together

With PLC
 PLC can perform the same task as hard-wired devices
 Connections between field devices & relay contacts take place in
PLC
 Installation is less extensive, Also more complex function.

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Advantages of PLCs
 Faster and less costly duplication of application
 Easier and faster system changes
 Integrated diagnostic and override functions
 Centrally available diagnostic
 Immediate documentation
 Smaller size

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How PLC works

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PLC “Programmable Logic Controller


 Origin
 Developed to replace relays in the late 1960s
 Costs dropped and became popular by 1980s
 Now used in many industrial designs

 The Hydramatic Division of the General Motors Corporation


specified the design criteria for the first programmable controller in
1968

 Their primary goal: To eliminate the high costs associated with


inflexible, relay-controlled systems.
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Historical Background
 The controller had to be designed in modular form, so that sub-
assemblies could be removed easily for replacement or repair.

 The control system needed the capability to pass data collection


to a central system.

 The system had to be reusable.

 The method used to program the controller had to be simple, so


that it could be easily understood by plant personnel.

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Programmable Controller Development


1968 Programmable concept developed
1969 HW CPU controller, with logic instructions, 1KB & 128 IO pts
1974 Use multi-processors within a PLC - timers & counters;
arithmetic operations; 12K of memory and 1024 IO pts
1976 Remote input/output systems introduced
1977 Microprocessors - based PLC introduced
1980 Intelligent I/O modules developed Enhanced communications
facilities, SW features (e.g. documentation) Use of PC as programming aids.
1983 Low - cost small PLC’s introduced
1985&on Networking of all levels of PLC, computer and machine using
SCADA software.
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Programmable Logic Controllers
( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic apparatus which uses


a programming memory for the internal storage of
instructions for implementing specific functions such
as logic, sequencing, timing, counting and arithmetic
to control through digital or analog modules, various
types of machines or process.

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Leading Brands Of PLC


AMERICAN 1. Allen Bradley
2. Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cuttler Hammer
EUROPEAN 1. Siemens
2. Klockner & Moeller
3. Telemechanique

JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi 16

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Areas of Application
Manufacturing / Machining
Food / Beverage
Metals
Power
Mining
Petrochemical / Chemical

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Advantages of PLCs
• Less wiring.
• Wiring between devices and relay contacts are done
in the PLC program.
• Easier and faster to make changes.
• Trouble shooting aids make programming easier and
reduce downtime.
• Reliable components make these likely to operate
for years before failure.
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PLC VS PAC Differences
PLC Definitions
 PLC: A Programmable Logic Controller (PLC) is a single
microprocessor based device used to automate equipment
operation in process and manufacturing machinery,
infrastructure and transportation control. Designed to replace
relays and timers, it uses electrician and maintenance friendly
ladder logic to program sequence of events and reaction via
real-world input and output devices.
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PLC VS PAC Differences


PAC Definitions
 PAC: A Programmable Automation Controller (PAC) is a 2 or more
processor based device like a personal computer (PC) is and is basically
a PC merged with a PLC using multitasking capabilities to automate
control of one or more pieces of equipment. The term PAC was first
defined by ARC Advisory Group in 2001. Although the PAC includes
PLC capabilities, its hardware architecture and software are designed to
be more user friendly to the IT/Computer Programmer. Differences
include multitasking; multiple processor modules per rack, multiple
programming languages like structured text, distributed control system
(DCS), Tag based addressing, motion control, standard PC networking
like Ethernet, to name a few. 20

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PLC / PAC difference from a training perspective...
 Many maintenance, engineering and even some college instructors
refer to a PAC as a PLC. Some correctly argue that it doesn’t matter
which terminology you use, as long as the device you are referring to,
meets your automation control needs. But when referring to training
for a PAC, it is critical to distinguish between a PAC and a PLC.

 https://www.youtube.com/watch?v=amTY765AVOM

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PLC Size
SMALL: Covers units with limited # of IO’s & memory up to 2 KB.
- these PLC’s are capable of providing simple to advance levels of
machine controls.
MEDIUM: have up to 2048 IO’s & memory up to 32 KB.
LARGE: the most sophisticated units of the PLC family. They’ve up to
128K IO’s and memory up to 32 MB.
- can control individual production processes/entire plant.

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