( 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.
12 Introduction What is a PLC (Programmable Logic Controller) ? A Programmable Logic Controller, or PLC, is more or less a small computer with a built-in operating system (OS). This OS is highly specialized to handle incoming events in real time, i.e. at the time of their occurrence.
The PLC has input lines where sensors are connected to notify upon events (e.g. temperature above/below a certain level, liquid level reached, etc.), and output lines to signal any reaction to the incoming events (e.g. start an engine, open/close a valve, etc.).
The system is user programmable. It uses a language called "Relay Ladder" or RLL (Relay Ladder Logic). The name of this language implies that the control logic of the earlier days, which was built from relays, is being simulated.
There are some other languages also used are:
1. Sequential Function chart 2. Functional block diagram 3. structured Text 4. Instruction List Major Components of a Common PLC
POWER SUPPLY
I M O M N O U O P D T D U U PROCESSOR P U T L U L From E T E To SENSORS OUTPUT Pushbuttons, contactors, contacts, alarms limit switches, etc. etc. PROGRAMMING DEVICE
22 Major Components of a Common PLC
POWER SUPPLY
Provides the voltage needed to run the primary PLC components
I/O MODULES Provides signal conversion and isolation between the internal logic- level signals inside the PLC and the field’s high level signal.
23 Major Components of a Common PLC
PROCESSOR Provides intelligence to command and govern the activities of the entire PLC systems.
PROGRAMMING DEVICE used to enter the desired program that will determine the sequence of operation and control of process equipment or driven machine.
24 Scan Cycle While the PLC is running, the scanning process includes the following four phases, which are repeated continuously as individual cycles of operation: PHASE 1 Read Inputs Scan PHASE 2 Program Execution PHASE 3 Diagnostics/ Comm PHASE 4 Output Scan
25 Scan Cycle PHASE 1 – Input Status scan A PLC scan cycle begins with the CPU reading the status of its inputs.
PHASE 2– Logic Solve/Program Execution
The application program is executed using the status of the inputs
PHASE 3– Logic Solve/Program Execution
Once the program is executed, the CPU performs diagnostics and
communication tasks PHASE 4 - Output Status Scan •An output status scan is then performed, whereby the stored output values are sent to actuators and other field output devices. The cycle ends by updating the outputs. 26 What are the Types of PLC
Comparison between fixed & modular PLC
Fixed PLC Modular PLC
All parts are built into one self All parts can be purchased separately contained unit. i.e. piece by piece. Size is small Size is large Have less memory have far more memory and has the capability to store a higher volume of information. Limited number of inputs & outputs Base allows numerous I/P & O/P modules Not suited for future expansion Future upgrade, expansion possible Inexpensive Expensive PLCs execute a single program in PCs, by design, are meant to handle sequential order. The have better simultaneous tasks. They have difficulty ability to handle events in real time. handling real time events. By design PLCs are friendlier to Operating systems like Windows are technicians since they are in ladder common. Connecting I/O to the PC is logic and have easy connections. not always as easy. How to select a PLC ? PLC Companies, Size and Applications: Based on the following points:
Type of inputs and outputs.
Number of inputs and outputs.
Type of PLC unit (compact or modular).
Manufacturing Company and unit price.
Communication.
Type of its power supply (AC o DC)
Processing speed.
Memory. 30 PROGRAMMING Inputs
Normally Open Normally Closed
(NO) (NC)
• Power flows through these contacts when they are closed.
• The normally open (NO) is true when the input or output status bit controlling the contact is 1. • The normally closed (NC) is true when the input or output status bit controlling the contact is 0.
31 PROGRAMMING
Coils
Coils represent relays that are energized when power flows to them. When a coil is energized it causes a corresponding output to turn on by changing the state of the status bit controlling the output to 1. That same output status bit maybe used to control normally open or normally closed contact anywhere in the program.
32 PROGRAMMING
Boxes
Boxes represent various instructions or functions that are
Executed when power flows to the box. Some of these Functions are timers, counters and math operations.
33 PROGRAMMING LOGIC GATE
AND OPERATION
A B C
Each rung or network on a ladder program represents
a logic operation. In the rung above, both inputs A and B must be true (1) in order for the output C to be true (1).
34 PROGRAMMING LOGIC GATE
OR OPERATION
A C input
In the rung above, it can be seen that either input A or B is be true (1), or both are true, then the output C is true (1).
35 PROGRAMMING LOGIC GATE NOT OPERATION
A C input
In the rung above, it can be seen that if input A is be true (1), then the output C is true (0) or when A is (0), output C is 1.
36 Examples of Input Signals
1. Mechanical switches
• A mechanical switch generates an on/off signal or signals as a result of some
mechanical input causing the switch to open or close.
• The term limit switch is used to detect the presence or passage of a moving part. Examples of Input Signals
2.Proximity switches Proximity switches are use to detect the presence of an object without making contact with it. There are a number of forms of such switches, some being only suitable for metallic objects. a. Inductive proximity switch Consists of a coil wound round a ferrous metallic core. When one end of this core is placed near to a ferrous metal object, there is effectively a change in inductance. Inductance change can be measured by resonant circuit and can be made to activate a switching circuit. b. Reed switch Consists of 2 overlapping, but not touching strips of a springy ferromagnetic material sealed in glass or plastic casing. When the magnet is brought close to the switch , the strips become magnetized and are attracted to each other, causing the contacts to close. Examples of Input Signals
3.Photoelectric sensors
Photoelectric switch devices can either operate as transmissive types where the object being detected breaks a beam of light, usually infrared and stops it from reaching the detector or reflective types where the object being detected reflects a beam of light onto the detector. Examples of Input Signals
4.Encoders Device that is used to provide a digital output as a result of angular or linear displacement. Figure below shows the basic form of an incremental encoder. A beam of light passes through the slots in a disc and is detected by a light sensor. When the disc is rotated the beam is alternately transmitted and stopped thereby producing a pulsed output. The number of pulses is proportional to the angle through which the disc has rotated.
Types of encoders 1. Linear encoder 2. Optical encoder 3. Incremental encoder 4. Absolute encoder Examples of Output Signals
1.Solenoid Valves - logical outputs that can switch a hydraulic or pneumatic
flow. 2.Lights - logical outputs that can often be powered directly from PLC output boards. 3.Motor Starters - motors often draw a large amount of current when started, so they require motor starters, which are basically large relays. 4.Servo Motors - a continuous output from the PLC can command a variable speed or position.
