CONTENTS

Topic Page no.

1. Abstract 6

2. Introduction to Programmable Logic Controllers ............................ 7

3. History of PLCs… .......................................................................... 7-8

4. Characteristics… ............................................................................... 8

5. System Scale… ................................................................................ 9

6. Programming in PLCs… ................................................................ 9-10

7. User Interface… ............................................................................... 10

8. How does a PLC operate?. ............................................................... 10-11

9. Other auxiliary devices connected to a PLC…................................ 12-13

10. PLCs as compared to other control systems ..................................... 14

11. Digital and Analog signals… .......................................................... 15-16

12. PLC Software… ................................................................................ 16

13. PLC Applications… ........................................................................ 17-20

14. Lift Control Module

Introduction................................................................................ 21
Hardware................................................................................ 22-24
Lift control Using PLC With Explanation….......................... 24-29

15. Temperature Control Trainer

Introduction............................................................................. 30-31
ABSTRACT

This project work is divided into two parts. The first part deals with the history and
development of Programmable Logic Controllers and its subsequent applications in
different industries. In The second part PLC was implemented to control 3 different
processes namely lift car controller, Liquid level controller, Temperature controller.

Automation of many different processes, such as controlling machines or factory

assembly lines, is done through the use of small computers called a programmable logic
controller (PLC). This is actually a control device that consists of a programmable
microprocessor, and is programmed using a specialized computer language.

Before, a programmable logic controller would have been programmed in ladder logic,
which is similar to a schematic of relay logic. A modern programmable logic controller is
usually programmed in any one of several languages, ranging from ladder logic to Basic
or C. Typically, the program is written in a development environment on a personal
computer (PC), and then is downloaded onto the programmable logic controller directly
through a cable connection. The program is stored in the programmable logic controller
in non-volatile memory.

The programmable logic controller has made a significant contribution to factory

automation. Earlier automation systems had to use thousands of individual relays and
cam timers, but all of the relays and timers within a factory system can often be replaced
with a single programmable logic controller. Today, programmable logic controllers
deliver a wide range of functionality, including basic relay control, motion control,
process control, and complex networking, as well as being used in Distributed Control
Systems.

There are several different types of interfaces that are used when people need to interact
with the programmable logic controller to configure it or work with it. This may take the
form of simple lights or switches or text displays, or for more complex systems, a
computer of Web interface on a computer running a Supervisory Control and Data
Acquisition (SCADA) system.

Programmable logic controllers were first created to serve the automobile industry, and
the first programmable logic controller project was developed in 1968 for General Motors
to replace hard-wired relay systems with an electronic controller.

The lift controller controls the movement of the lift. The program is designed to make the
lift car move to the correct floor based on floor request. The temperature controller
controls the temperature of the fluid based on a set point. The level controller controls the
level of a liquid in a tank.
 Introduction

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History

The PLC was invented in response to the needs of the American automotive industry.
Before the PLC, control, sequencing, and safety interlock logic for manufacturing
automobiles was accomplished using relays, timers and dedicated closed-loop controllers.
The process for updating such facilities for the yearly model change-over was very time
consuming and expensive, as the relay systems needed to be rewired by skilled
electricians. In 1968 GM Hydramatic (the automatic transmission division of General
Motors) issued a request for proposal for an electronic replacement for hard-wired relay
systems.

The winning proposal came from Bedford Associates of Bedford, Massachusetts. The
first PLC, designated the 084 because it was Bedford Associates eighty-fourth project,
was the result. Bedford Associates started a new company dedicated to developing,
manufacturing, selling, and servicing this new product: Modicon, which stood for
Modular Digital Controllers. One of the people who worked on that project was Dick
Morley, who is considered to be the "father" of the PLC. The Modicon brand was sold in
1977 to Gould Electronics, and later acquired by German Company AEG and then by
French Schneider Electric, the current owner.

One of the very first 084 models built is now on display at Modicon's headquarters in
North Andover, Massachusetts. It was presented to Modicon by GM, when the unit was
retired after nearly twenty years of uninterrupted service.

The automotive industry is still one of the largest users of PLCs, and Modicon still
numbers some of its controller models such that they end with eighty-four. PLCs are used

in many different industries and machines such as packaging and semiconductor

machines. Well known PLC brands are Siemens, Allen-Bradley, ABB, Mitsubishi,
Omron, and General Electric.
Characteristics

The main difference from other computers is that PLCs are armored for
severe condition (dust, moisture, heat, cold, etc) and have the facility for
extensive input/output (I/O) arrangements. These connect the PLC to sensors
and actuators. PLCs read limit switches, analog process variables (such as
temperature and pressure), and the positions of complex positioning systems.
Some even use machine vision. On the actuator side, PLCs operate electric
motors, pneumatic or hydraulic cylinders, magnetic relays or solenoids, or
analog outputs. The input/output arrangements may be built into a simple
PLC, or the PLC may have external I/O modules attached to a computer
network that plugs into the PLC.

PLCs were invented as replacements for automated systems that would use
hundreds or thousands of relays, cam timers, and drum sequencers. Often, a
single PLC can be programmed to replace thousands of relays.
Programmable controllers were initially adopted by the automotive
manufacturing industry, where software revision replaced the re-wiring of
hard-wired control panels when production models changed.

Many of the earliest PLCs expressed all decision making logic in simple
ladder logic which appeared similar to electrical schematic diagrams. The
electricians were quite able to trace out circuit problems with schematic
diagrams using ladder logic. This program notation was chosen to reduce
training demands for the existing technicians. Other early PLCs used a form
of instruction list programming, based on a stack-based logic solver.

The functionality of the PLC has evolved over the years to include
sequential relay control, motion control, process control, distributed control
systems and networking. The data handling, storage, processing power and
communication capabilities of some modern PLCs are approximately
equivalent to desktop computers. PLC-like programming combined with
remote I/O hardware, allow a general-purpose desktop computer to overlap
some PLCs in certain applications.

Under the IEC 61131-3 standard, PLCs can be programmed using

standards-based programming languages. A graphical programming
notation called Sequential Function Charts is available on certain
programmable controllers.
System Scale:

A small PLC will have a fixed number of connections built in for inputs
and outputs. Typically, expansions are available if the base model does
not have enough I/O.

Modular PLCs have a chassis (also called a rack) into which is placed
modules with different functions. The processor and selection of I/O
modules is customised for the particular application. Several racks can be
administered by a single processor, and may have thousands of inputs and
outputs. A special high speed serial I/O link is used so that racks can be
distributed away from the processor, reducing the wiring costs for large
plants.

PLCs used in larger I/O systems may have peer-to-peer (P2P)

communication between processors. This allows separate parts of a complex
process to have individual control while allowing the subsystems to co-
ordinate over the communication link. These communication links are also
often used for HMI (Human-Machine Interface) devices such as keypads or
PC-type workstations. Some of today's PLCs can communicate over a wide
range of media including RS-485, Coaxial, and even Ethernet for I/O
control at network speeds up to 100 Mbit/s.

Programming in PLCs

Early PLCs, up to the mid-1980s, were programmed using proprietary programming

panels or special-purpose programming terminals, which often had dedicated function
keys representing the various logical elements of PLC programs. Programs were stored
on cassette tape cartridges. Facilities for printing and documentation were very minimal
due to lack of memory capacity. More recently, PLC programs are typically written in a
special application on a personal computer, then downloaded by a direct-connection cable
or over a network to the PLC. The very oldest PLCs used non-volatile magnetic core
memory but now the program is stored in the PLC either in battery-backed-up RAM or
some other non-volatile flash memory.

Early PLCs were designed to replace relay logic systems. These PLCs were programmed
in "ladder logic", which strongly resembles a schematic diagram of relay logic. Modern
 PLCs can be programmed in a variety of ways, from ladder logic to more traditional
programming languages such as BASIC and C. Another method is State Logic, a Very
High Level Programming Language designed to program PLCs based on State Transition
Diagrams.
Recently, the International standard IEC 61131-3 has become popular. IEC 61131-3 currently
defines five programming languages for programmable control systems: FBD (Function block
diagram), LD (Ladder diagram), ST (Structured text, similar to the Pascal programming
language), IL (Instruction list, similar to assembly language) and SFC (Sequential function
chart). These techniques emphasize logical organization of operations.

While the fundamental concepts of PLC programming are common to all manufacturers,
differences in I/O addressing, memory organization and instruction sets mean that PLC
programs are never perfectly interchangeable between different makers. Even within the same
product line of a single manufacturer, different models may not be directly compatible.

User Interface

PLCs may need to interact with people for the purpose of configuration,
alarm reporting or everyday control. A Human-Machine Interface (HMI) is
employed for this purpose. HMI's are also referred to as MMI's (Man
Machine Interface) and GUI (Graphical User Interface).

A simple system may use buttons and lights to interact with the user. Text
displays are available as well as graphical touch screens. Most modern
PLCs can communicate over a network to some other system, such as a
computer running a SCADA (Supervisory Control And Data Acquisition)
system or web browser.

How does a PLC operate?

There are four basic steps in the operation of all PLCs; Input Scan, Program
Scan, Output Scan, and Housekeeping. These steps continually take place in a
repeating loop.
Four Steps In the PLC
Operations 1.) Input Scan
Detects the state of all input devices that are connected
to the PLC 2.) Program Scan
Executes the user created program logic.
3.) Output Scan
Energizes or de-energize all output devices that are connected to the PLC.
4.) Housekeeping
This step includes communications with programming
terminals, internal diagnostics, etc
Fig. Operation of a PLC in basic stages
Other Auxiliary devices connected To a PLC:

Input devices:

– Condition Sensors

– Encoders
• Pressure Switches
• Level Switches
• Temperature Switches
• Vacuum Switches
• Float Switches

- Switches and Pushbuttons

– Sensing Devices
• Limit Switches
• Photoelectric Sensors and proximity sensors
 Output Devices

– Valves
– Motor Starters
– Solenoids
– Actuators

– Horns and Alarms

– Stack lights
– Control Relays
– Counter/Totalizers
– Pumps
– Printers
– Fans
PLCs as compared to the other control Systems:

PLCs are well-adapted to a range of automation tasks. These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation
system is high relative to the total cost of the automation, and where changes to the
system would be expected during its operational life. PLCs contain input and output
devices compatible with industrial pilot devices and controls; little electrical design is
required, and the design problem centers on expressing the desired sequence of
operations in ladder logic (or function chart) notation. PLC applications are typically
highly customized systems so the cost of a packaged PLC is low compared to the cost of
a specific custom-built controller design. On the other hand, in the case of mass-produced
goods, customized control systems are economic due to the lower cost of the
components, which can be optimally chosen instead of a "generic" solution, and where
the non-recurring engineering charges are spread over thousands of places.

For high volume or very simple fixed automation tasks, different techniques are used. For
example, a consumer dishwasher would be controlled by an electromechanical cam timer
costing only a few dollars in production quantities.

A microcontroller-based design would be appropriate where hundreds or thousands of

units will be produced and so the development cost (design of power supplies and
input/output hardware) can be spread over many sales, and where the end-user would not
need to alter the control. Automotive applications are an example; millions of units are
built each year, and very few end-users alter the programming of these controllers.
However, some specialty vehicles such as transit busses economically use PLCs instead
of custom-designed controls, because the volumes are low and the development cost
would be uneconomic.

Very complex process control, such as used in the chemical industry, may require
algorithms and performance beyond the capability of even high-performance PLCs. Very
high-speed or precision controls may also require customized solutions; for example,
aircraft flight controls.

PLCs may include logic for single-variable feedback analog control loop, a "proportional,
integral, derivative" or "PID controller." A PID loop could be used to control the
temperature of a manufacturing process, for example. Historically PLCs were usually
configured with only a few analog control loops; where processes required hundreds or
thousands of loops, a distributed control system (DCS) would instead be used. However,
as PLCs have become more powerful, the boundary between DCS and PLC applications
has become less clear-cut
Digital and Analog Signals:

Digital or discrete signals behave as binary switches, yielding simply an On

or Off signal (1 or 0, True or False, respectively). Pushbuttons, limit
switches, and photoelectric sensors are examples of devices providing a
discrete signal.

Discrete signals are sent using either voltage or current, where a specific
range is designated as On and another as Off. For example, a PLC might
use 24 V DC I/O, with values above 22 V DC representing On, values
below 2VDC representing Off, and intermediate values undefined.
Initially, PLCs had only discrete I/O.

Analog signals are like volume controls, with a range of values between zero
and full- scale. These are typically interpreted as integer values (counts) by
the PLC, with various ranges of accuracy depending on the device and the
number of bits available to store the data. As PLCs typically use 16-bit
signed binary processors, the integer values are limited between -32,768 and
+32,767.

Pressure, temperature, flow, and weight are often represented by analog

signals. Analog signals can use voltage or current with a magnitude
proportional to the value of the process signal. For example, an analog 4-
20 mA or 0 - 10 V input would be converted into an integer value of 0 -
32767.

Current inputs are less sensitive to electrical noise (i.e. from welders or
electric motor starts) than voltage inputs.As an example, say the facility
needs to store water in a tank. The water is drawn from the tank by another
system, as needed, and our example system must manage the water level in
the tank.

Using only digital signals, the PLC has two digital inputs from float
switches (tank empty and tank full). The PLC uses a digital output to open
and close the inlet valve into the tank. When the water level drops enough so
that the tank empty float switch is off (down), the PLC will open the valve
to let more water in. Once the water level raises enough so that the tank full
switch is on (up), the PLC will shut the inlet to stop the water from
overflowing.
| |
| Low Level High Level Fill Valve |
| [/] | [/] (OUT) |
| | |
| | |
| | |
| Fill Valve | |
|------[ ]------| |
| |
|

An analog system might use a water pressure sensor or a load cell, and an
adjustable (throttling)dripping out of the tank, the valve adjusts to slowly drip
water back into the tank.

In this system, to avoid 'flutter' adjustments that can wear out the valve,
many PLCs incorporate "hysteresis" which essentially creates a "deadband"
of activity. A technician adjusts this dead band so the valve moves only for
a significant change in rate. This will in turn minimize the motion of the
valve, and reduce its wear.

A real system might combine approaches, using float switches and simple
valves to prevent spills, and a rate sensor and rate valve to optimize refill
rates and prevent water hammer. Backup and maintenance methods can
make a real system very complicated.

PLC Software:

The PLC software is manufacturer dependent and even when the

manufacturer is the same, it may vary for the different models of the
same brand.

For, instance for a manufacturer like Allen Bradley the software may vary
for its PICO Controller models and other models. For example, the software
used for these controllers is PICOSoft whereas for its higher models it is
RSLogix.

Moreover, the HMI Interface may also vary for the different controllers.
 PLC APPLICATIONS:

Automotive Industry

Reducing Time-To-Customer and Other Costs

The automotive landscape is changing. Emerging markets are forcing you

to re-think production strategies. The effects of a tight economy and
intense competition means you need suppliers to play a larger role in
successfully executing the supply chain.

Our industrial automation and control solutions span the entire

automotive supply chain and can help you address these challenges while
staying focused on improving quality, reducing costs, increasing
responsiveness and ultimately improving time-to-customer throughout
your supply chain.

By combining our integrated architecture with proven automotive

manufacturing solutions, you get accurate, event-driven information
about materials, operations and finished-product requirements — and the
ability to deliver and receive the right components, in the right quantities,
at exactly the right time and place. The result: faster time-to-customer for
the entire industry.

Your requirements are unique. So are our solutions. We listen to you then
apply our resources to build cost-effective, results-based solutions for the
automotive industry. We are committed to your success. Whatever your
automation challenges, you'll find the answer by partnering with us.

Beverage Industry

Improving Production Flexibility and Agility

You are striving for consistent quality regardless of where your product is
manufactured or distributed, while under continuous pressure to respond
quicker than your competitors to changes in consumer demand during
continued consolidation in the industry.

Our focus on beverage production optimization addresses these issues and

17
 every phase of your operation so you can meet cost, quality, flexibility and
regulatory challenges across the entire life cycle - from raw materials
through final shipment.
Because of the diversity of beverage production processes, it can be
challenging for you to meet customer demand, document regulatory
compliance and identify production inefficiencies. Through our domain
knowledge and production experience, we offer a variety of solutions to
help you satisfy your demanding consumers and retailers.

We understand the beverage industry, and can help you turn our
solutions and services into a competitive advantage. Your requirements
are unique, so whatever production challenges you have, partnering
with us will help you overcome them.

Entertainment Industry
Marine Industry
Optimize Equipment Performance and ImproveReliability

Operational demands are placing enormous pressure to optimize reliability and safetywhile
reducing the size and weight of equipment.

Increasing the Safety, Reliability and Profitability ofYour Venue

Whether we're controlling a roller coaster racing at 120 miles per hour,
protecting an investment in valuable exotic creatures, or providing secure
transportation to ski runs, our components and systems meet your
automation challenges to increase your safety, reliability and profitability.

From the initial conceptualization of the system architecture through the

implementation and commissioning of a specific solution, we will receive
the skills and experience to fulfill your project requirements through:

• Superior support, everything from integrated engineering and

support solutions on multi-vendor platforms, to software and MRO
asset management services.
• Global parts availability for localized support.
• Depth and breadth of products.
• Migration with easy upgrades to the newest technology to protect

18
 Conclusion
PLCs are well-adapted to a range of automation tasks. These are
typically industrial processes in manufacturing where the cost of
developing and maintaining the automation system is high
relative to the total cost of the automation, and where changes to
the system would be expected during its operational life. PLCs
contain input and output devices compatible with industrial pilot
devices and controls; little electrical design is required, and the
design problem centers on expressing the desired sequence of
operations in ladder logic (or function chart) notation. PLC
applications are typically highly customized systems so the cost
of a packaged PLC is low compared to the cost of a specific
custom-built controller design. On the other hand, in the case of
mass-produced goods, customized control systems are economic
due to the lower cost of the components, which can be optimally
chosen instead of a "generic" solution, and where the non-
recurring engineering charges are spread over thousands of
places.

19