PLC ASSIGNMENT-1

• A programmable logic controller (PLC) is a special form of microprocessor-

based controller that uses programmable memory to store instructions and to
implement functions such as logic, sequencing, timing, counting, and arithmetic
in order to control machines and processes. The term logic is used because
programming is primarily concerned with implementing logic and switching
operations.
• PLC or programmable logic controller is also called the “Workhorse of
the Industrial Automation”, is an industrial computer that is specially
designed to control the specific process or sometimes the entire
production line.

ADVANTAGES:
• Advantages of PLCs
• Reliability
o Description: Designed to operate in harsh industrial environments.
o Benefit: Less likely to fail compared to other control systems1.
• Flexibility
o Description: Easily reprogrammable to perform new tasks.
o Benefit: Adaptable to changing conditions and requirements1.
• Ease of Use
o Description: Programmed using specialized, user-friendly languages.
o Benefit: Simplifies programming and troubleshooting1.
• Cost-Effectiveness
o Description: Generally, more affordable than other control systems.
o Benefit: Lower installation, maintenance, and repair costs1.
• Safety
o Description: Can include safety features to protect workers and
equipment.
o Benefit: Enhances operational safety by shutting down processes under
unsafe conditions1.
• Small Size
o Description: Compact components.
o Benefit: Saves space in electrical panels2.
• Faster Response Times
o Description: Quick processing of information.
o Benefit: Essential for systems where speed is critical.
 • Simulation Capability
o Description: Ability to simulate programs before implementation.
o Benefit: Identifies errors before going live, saving time and resources2.
• Fault Diagnosis
o Description: Easy fault finding by connecting to the PLC.
o Benefit: Simplifies troubleshooting and maintenance2.

• Disadvantages of PLCs

• Limited Processing Power

o Description: Not as powerful as some other systems like DCS.
o Drawback: May struggle with complex tasks or large data volumes 1.
• Limited Expandability
o Description: Designed for specific tasks and processes.
o Drawback: May not be easily expanded or modified1.
• Dependence on Programming
o Description: Performance relies on correctly written programs.
o Drawback: Errors in programming can lead to malfunction.
• Cross-Manufacturer Incompatibility
o Description: Different brands may not be compatible with each other.
o Drawback: Limits flexibility in choosing components3.
• Automatic Start-Ups
o Description: May automatically restart after power restoration.
o Drawback: Can be a safety concern if not properly managed3.

PLC VS COMPUTER:

PLCs are similar to computers, but whereas computers are optimized for calculation
and display tasks, PLCs are optimized for control tasks and the industrial environment.
Thus PLCs:

• Are rugged and designed to withstand vibrations, temperature, humidity, and

noise
• Have interfacing for inputs and outputs already inside the controller
• Are easily programmed and have an easily understood programming language
that is primarily concerned with logic and switching operations

The first PLC was developed in 1969. PLCs are now widely used and extend from small,
self-contained units for use with perhaps 20 digital inputs/outputs to modular systems
that can be used for large numbers of inputs/outputs, handle digital or analog
inputs/outputs, and carry out proportional-integral-derivative control modes.

PLC System:
There are two common types of mechanical design for PLC systems a single box and
the modular/rack types.

❖ The single-box type (or, as it's sometimes called, a 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 that can store some 300 to 1000 instructions.

Systems with larger numbers of inputs and Outputs are likely to be modular and
designer to fit in racks.

❖ The MODULAR TYPE consists of separate modules for power supply. processor,
and the like, which are often mounted on rails within a metal cabinet. Easy to
expand by adding more I/O or memory modules.
❖ RACK type:
❑ Components: Functional units packaged in individual modules.
❑ Mounting: Modules plugged into sockets in a base rack.
❑ Customization: User decides the mix of modules for specific purposes.
❑ Expansion: Easy to expand I/O connections and memory by adding modules.
❑ Backplane: Copper conductors in the backplane provide power and data
interfaces.
 Connection: Modules engage with connectors in the backplane when
slid into the rack.
 Type Description Applications
Fixed/Integrated PLC Integrated units with fixed Small-scale automation
I/O points. tasks, simple control
systems.
Modular PLC Expandable units with Medium to large-scale
customizable I/O automation tasks,
modules. complex control systems.
Rack-Mounted PLC Large systems with Industrial plants, large
centralized manufacturing facilities.
communication modules.
Compact PLC Small, integrated units Simple automation tasks,
with limited I/O. space-constrained
environments.
Micro PLC Very small units with Basic automation tasks,
fewer I/O points. educational purposes.
Pico/Nano PLC Extremely small units Simple control tasks,
with minimal I/O points. hobby projects.
Safety PLC Designed for fail-safe Safety-critical systems in
operation in critical automotive, aerospace,
applications. and industrial sectors.
Soft PLC PLC functionality Flexible and cost-
implemented in software effective solutions for
running on a general- various automation tasks.
purpose computer.
Distributed PLC Networked PLCs with Large-scale systems
distributed I/O and requiring decentralized
control. control3.

PLC PROGRAMMING LANGUAGES:

Five languages are defined:

1. Ladder Diagram (LAD),

2. Sequential Function Charts (SFC),
3. Function Block Diagram (FBD),
4. Structured Text (ST),
5. Instruction List (IL).
1. Ladder diagram (LAD): Consider it like an electrical relay logic diagram. If you have
knowledge about electrical circuits then it is quite simple.

Almost at every case, especially for simple control systems and logic.

Pros - Simple and comprehensible. - Very effective especially for diagnosis.

Cons

- Complicated algorithms and, data management, is not their best exaction area.

2. Sequential function charts (SFC): A block-based representation style that depicts

the order of actions in a process.

: Suitable for batch processing as there has to be an order in the operations.

Pros

- The process flow is well illustrated.

- Sequences can easily be altered and organized.

Cos

- Heavily detailed processes may be awkward.

3. Function block diagram (FBD): As with numerous diagrams, functions are depicted
in the blocks and also connections among them. Same as with electronic circuit
diagrams.

Where it’s used: Best on sophisticated control system and data algorithm processing.

Pros

- Code that is modulated and can be reused.

- Suitable for systems that are logically interrelated as well as control applications.

Cons

- If poorly documented can be a challenge during diagnosis and correction.

PLC brands list by country-wise

You can find the country-wise PLC brands list in the below-mentioned table.

Country Leading Automation Brands

Japan Omron Industrial Automation

Yaskawa Electric Corporation

Mitsubishi Electric

Fuji Electric

Yokogawa Electric

Toshiba

Panasonic

Keyence

Emerson Electric
United States
Rockwell Automation

Siemens
Germany Bosch
Phoenix Contact

Switzerland ABB

France Schneider Electric

 Delta Electronics
Taiwan
Fatek

Israel Unitronics

Wecon Technology
China
Kinco

RS Enterprises
India
General Industrial Controls (GIC)

Communication Cables Used in PLCs

❖ Ethernet Cables
o Description: Used for high-speed data transfer and network connectivity.
o Applications: Connecting PLCs to networks, HMIs, and other devices.
o Brands: Belden, Panduit, Siemens.
❖ RS-232 Cables (R-Recommended S- Standard )
o Description: Serial communication cable for point-to-point connections.
o Applications: Connecting PLCs to sensors, actuators, and programming
devices.
o Brands: Tripp Lite, StarTech, Black Box.
❖ RS-485 Cables
o Description: Serial communication cable for longer distances and
multiple devices.
o Applications: Industrial automation networks, connecting multiple PLCs.
o Brands: Belden, Alpha Wire, L-com.
❖ Profibus Cables
o Description: Used for industrial automation networks.
o Applications: Connecting PLCs to field devices in a factory.
o Brands: Siemens, Phoenix Contact, Lapp Group.
❖ Profinet Cables
o Description: Ethernet-based communication for industrial automation.
o Applications: High-speed communication between PLCs and other
devices.
o Brands: Siemens, Belden, Harting.
❖ DeviceNet Cables
o Description: Used for connecting industrial devices in a network.
o Applications: Communication between PLCs, sensors, and actuators.
o Brands: Rockwell Automation, Molex, Lumberg Automation.
❖ ControlNet Cables
 o Description: High-speed network cable for real-time control
applications.
o Applications: Connecting PLCs in control systems.
o Brands: Rockwell Automation, Belden, Panduit.
❖ Modbus Cables
o Description: Used for Modbus communication protocol.
o Applications: Connecting PLCs to various industrial devices.
o Brands: Schneider Electric, Siemens, Phoenix Contact.

❖ CAN Bus Cables

o Description: Used for Controller Area Network (CAN) communication.
o Applications: Automotive and industrial automation.
o Brands: Bosch, TE Connectivity, Belden.
❖ Fiber Optic Cables
o Description: Used for long-distance and high-speed communication.
o Applications: Connecting remote automation systems.
o Brands: Corning, Prysmian Group, OFS.

Advantages of Using Communication Cables in PLCs

• High-Speed Data Transfer: Ensures quick and efficient communication

between devices.
• Reliability: Provides stable and consistent connections, reducing downtime.
• Flexibility: Supports various communication protocols and network
configurations.
• Scalability: Allows easy expansion of the network by adding more devices.
• Long-Distance Communication: Fiber optic and RS-485 cables enable
communication over long distances without signal degradation.

The History of Automation

Early Beginnings

• 1st Century BC: The Greeks and Romans used water wheels to automate tasks
like grinding grain.
• 9th Century: Innovations in mill machinery, such as watermills and windmills,
further automated agricultural processes.
Industrial Revolution (17th-18th Century)

• Steam Engines: The introduction of steam engines revolutionized

manufacturing, enabling mechanized production and reducing reliance on
manual labor.
• Mechanized Production: Factories began using machines for tasks previously
done by hand, significantly increasing productivity.

20th Century

• 1940s: The term “automation” was coined in the automobile industry to

describe the use of automatic devices and controls in production lines.
• 1950s: Electronic industrial controllers were introduced, allowing for more
precise control of machinery and processes.

The Rise of PLCs (1970s)

• 1970: The first Programmable Logic Controller (PLC) was developed for General
Motors. PLCs replaced hard-wired relay systems, offering greater flexibility and
reliability in industrial automation.

Digital and Information Age (2000s-Present)

• Industry 4.0: The integration of the Internet of Things (IoT), artificial intelligence
(AI), and advanced robotics has led to smart manufacturing. This era is
characterized by interconnected systems that can communicate and make
decisions autonomously.

Advantages of Automation

• Increased Efficiency: Reduces the need for human intervention, leading to

faster production times.
• Improved Quality: Consistent and precise operations reduce errors and
defects.
• Cost Savings: Lowers labor costs and increases productivity.
• Enhanced Safety: Minimizes human exposure to hazardous environments.
• Flexibility: Easily adaptable to new tasks and processes.
Revolution Brought by Automation

• Industrial Revolution: Transformed manufacturing with steam engines and

mechanized production.
• Digital Revolution: Introduction of computers and PLCs revolutionized control
systems.
• Industry 4.0: Integration of IoT, AI, and advanced robotics for smart
manufacturing.

Uses of Automation in PLCs

• Manufacturing: Control of machinery and production lines.

• Material Handling: Automation of conveyor systems and robotic arms.
• Process Control: Monitoring and controlling chemical, oil, and gas processes.
• Building Automation: Managing HVAC, lighting, and security systems.
• Automotive: Assembly line automation and quality control.

SECTION-2
HARDWARE:

Typically, a PLC system has the basic functional components of processor unit,
memory, power supply unit, input/output interface section, communications
interface, and the programming device.

• The processor unit, or central processing unit (CPU) is the unit containing the
microprocessor. This unit interprets the input signals and carries out the control
actions according to the program stored in its memory, communicating the
decisions as action signals to the outputs.
• The power supply unit is needed to convert the mains AC voltage to the low DC
voltage (5 V) necessary for the processor and the circuits in the input and output
interface modules.
• The programming device is used to enter the required program into the memory
of the processor. The program is developed in the device and then transferred to
the memory unit of the PLC.
• The memory unit is where the program containing the control actions to be
exercised by the microprocessor is stored and where the data is stored from the
input for processing and for the output.
• Communications Interface:
 Receives and transmits data on communication networks.
Manages device verification, data acquisition, synchronization, and connection
management.
• Input/Output (I/O) Interface Section:
o Inputs: Receives information from external devices (e.g., switches, sensors).
o Outputs: Communicates information to external devices.
Input/Output devices can be:
→ Discrete/Digital: Signals are either on or off (e.g., switches).
→ Analog: Signals proportional to the monitored variable (e.g., temperature
sensors)

INTERNAL ARCHITECTURE:
The above figure shows the basic internal architecture of a PLC. It consists of a central
processing unit (CPU) containing the system microprocessor, memory, and
input/output circuitry.

1. CPU
• The CPU controls and processes all the operations within the PLC. It is supplied
with a clock that has a frequency of typically between 1 and 8 MHz. This
frequency determines the operating speed of the PLC and provides the timing
and synchronization for all elements in the system. Information within the PLC is
carried by digital signals.
• An arithmetic and logic unit (ALU) that is responsible for data manipulation and
carrying out arithmetic operations of addition and subtraction and logic
operations of AND, OR, NOT, and EXCLUSIVE-OR.
• Memory, termed registers is located within the microprocessor and used to
store information involved in program execution.
• A control unit that is used to control the timing of operations.

2. BUSES:

-Buses: internal paths for digital signals, consisting of conductors like tracks on a
printed circuit board or wires in a ribbon cable.

• The buses are the paths used for communication within the PLC. The information is
transmitted in binary form, that is, as a group of bits, with a bit being a binary digit of
1 or 0, indicating on/off states. The system has four buses:

→ The data bus carries the data used in the processing done by the CPU. A
microprocessor termed as being 8-bit has an internal data bus that can handle
8-bit numbers. It can thus perform operations between 8-bit numbers and
deliver results as 8-bit values.
→ The address bus
Purpose: Carries addresses of memory locations.
Unique Addresses: Each memory location has a unique address,
CPU Access: Allows the CPU to read from or write to specific memory locations.
Address Information: The address bus carries information indicating which
address is to be accessed.
→ The control bus carries the signals used by the CPU for control, such as to
inform memory devices whether they are to receive data from an input or output
data and to carry timing signals used to synchronize actions.
 → The system bus is used for communications between the input/output ports
and the input/ output unit.

3.MEMORY:

operate the PLC system there is a need for it to access the data to be processed and
instructions, that is, the program, which informs it how the data is to be processed.
Both are stored in the PLC memory for access during processing. There are several
memory elements in a PLC system:

• System read-only-memory (ROM) gives permanent storage for the operating

system and fixed data used by the CPU..
• Random-Access Memory (RAM):
o Stores the user’s program, status of input/output devices, values of timers,
counters, and other internal devices.
o Data RAM is sometimes referred to as a data table or register table.
o Divided into blocks for input/output addresses, preset data, counter values,
timer values, etc.
o Programs and data in RAM can be changed by the user.
o Battery-backed to maintain contents when power is off.
• Erasable Programmable Read-Only Memory (EPROM):
o Used to store programs permanently.
o Often a bolt-on module to the PLC.
• Temporary Buffer Stores:
o Used for input/output channels.

• Memory Capacity:
o Determined by the number of binary words it can store.
o Example: 256 words can store 2048 bits (8-bit words) or 4096 bits (16-bit
words).
o Memory sizes often specified in terms of storage locations (e.g., 1K = 1024
bytes).
o Example: 4K * 8 memory can store 4096 bytes.
o With a 16-bit address bus, 2^16 different addresses can be used, allowing for
64K * 8 memory size.
4. INPUT/OUTPUT UNITS:

• The I/O unit connects the PLC to external devices, such as sensors (inputs)
and actuators like motors and solenoids (outputs).
• Unique Addressing: Each I/O point has a unique address, allowing the CPU
to identify and interact with specific inputs and outputs.
 • Isolation and Signal Conditioning: I/O channels provide electrical isolation
and signal conditioning, often using optoisolators (or optocouplers) to
ensure safe and reliable connections between the PLC and external devices.
• Compatibility with Microprocessors: The digital signals compatible with
the PLC’s microprocessor are typically 5 V DC. However, signal conditioning
allows for a wide range of input signals, such as 5 V, 24 V, 110 V, and 240 V
digital/discrete signals.
• Output Signal Conditioning: The output from the I/O unit is conditioned to
match the requirements of the connected devices, which might include
various voltage levels and current capacities, such as 24 V, 100 mA switching
signals, or 240 V, 2 A AC signals.

 Relay Outputs

o Function: Uses a relay to switch currents in an external circuit.

• Advantages:
o Can switch both AC and DC currents.
o Can handle high surge currents and voltage transients.
o Provides isolation between the PLC and the external circuit.
• Disadvantages:
o Relatively slow to operate.

 Transistor Outputs

• Function: Uses a transistor to switch current through the external circuit.

• Advantages:
o Provides faster switching action.
o Suitable for DC switching.
• Disadvantages:
o Strictly for DC operation.
o Can be destroyed by overcurrent and high reverse voltage.
o Requires protection such as fuses or built-in electronic protection.
o Optoisolators are used for isolation.

 Triac Outputs

• Function: with Optoisolators for isolation can be used to control external

loads connected to the AC power supply.
• Advantages:
o Suitable for AC operation.
• Disadvantages:
 o Strictly for AC operation.
o Easily destroyed by overcurrent.
o Fuses are typically included for protection.

➢ Type- The type determines if an input or output is being addressed.

• Slot- The slot number is the physical location of the I/O module. This may be a
combination of the rack number and the slot number when using expansion
racks.
• Word and Bit-The word and bit are used to identify the actual terminal
connection in a particular I/O module. A discrete module usually uses only one
word, and each connection corresponds to a different bit that makes up the
word.

With a rack/slot address system the location of a module within a rack and the terminal
number of a module to which an input or output device is connected will determine the
device's address.