25-11-2024

Programmable Logic Controllers

MECHATRONICS & AUTOMATION

Dr. Arshad Javed

BITS Pilani Asst. Prof.
Department of Mechanical Engineering
Hyderabad Campus

PLC

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How to inbuilt the logic in

automation systems?
• Mechanical Systems
• Hydraulics and pneumatics
• Relay logic
• Digital logic
• Coding (programming)
– Micro controller/
– PLC

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What is PLC?
A PROGRAMMABLE LOGIC CONTROLLER (PLC) is
an industrial computer control system that
continuously monitors the state of input devices
and makes decisions based upon a custom program
to control the state of output devices.
Digital electronic device
Uses a programmable memory
Store instructions (logic)
Sequencing
Timing
Counting
Arithmetic operations
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Advantage of PLC
Cost effective for controlling complex systems.
Flexible and can be reapplied to control other systems
quickly and easily.
Computational abilities allow more sophisticated
control.
Trouble shooting aids make programming easier and
reduce downtime.
Reliable components make these likely to operate for
years before failure.

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Main Units of PLC

The program memory
Instruction for the logic control are stored
The Data memory
The status of switches, interlocks, past values of data and other working data stored
The output device
Drivers for the industrial process actuators (solenoid switch, motor, valves)
The input Device
Status sensors, proximity detectors, interlock settings

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PLC
PLC HARDWARE
 Small self contained – 20 digital i/o
 Modular – large I/o, digital/analogue, 20 A current on
output
 programming device: key pad/key board/link with PC
 Display: digital/LCD/VDU
SIGNAL CONDITIONING
 AD-DA
 Multiplex
 Input: optocoupler/safety
 Output: optocoupler/Fuse/MCB

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Programming in PLC

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LD

• Ladder Diagram (LD) Traditional ladder logic is graphical

programming language. Initially programmed with simple
contacts that simulated the opening and closing of relays,
Ladder Logic programming has been expanded to include such
functions as counters, timers, shift registers, and math
operations.

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FBD

• Function Block Diagram (FBD) - A graphical language for

depicting signal and data flows through re-usable function
blocks. FBD is very useful for expressing the interconnection of
control system algorithms and logic

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ST

• Structured Text (ST) – A high level text language that encourages

structured programming. It has a language structure (syntax)
that strongly resembles PASCAL and supports a wide range of
standard functions and operators. For example;

If Speed1 > 100.0 then

Flow_Rate: = 50.0 + Offset_A1;
Else
Flow_Rate: = 100.0; Steam: = ON
End_If;

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IL

• Instruction List (IL): A low level “assembler like”

language that is based on similar instructions list
languages found in a wide range of today’s PLCs.

LD R1
MPC RESET
LD PRESS_1
ST MAX_PRESS
RESET: LD 0
ST A_X43

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SFC

• Sequential Function Chart (SFC) A method of programming complex control

systems at a more highly structured level. A SFC program is an overview of
the control system, in which the basic building blocks are entire program
files. Each program file is created using one of the other types of
programming languages. The SFC approach coordinates large, complicated
programming tasks into smaller, more manageable tasks.

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Ladder Diagram (LD)

Simple illustration
Similar to the circuit diagram of the relay
technology
Symbol based programming
Symbolized current flow from left to right
I/O states are mapped onto switch-states
The program is read from top to bottom
Disadvantage: difficult representation of
complex mathematic functions
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PLC PROGRAMMING

LADDER PROGRAMMING – a graphical

programming language
Identify all elements of a mechatronic system and
represent graphically
Elements
Rails
Rungs
Input
Output
Branches
Timer
counter
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PLC

SYMBOLS
PLC LADDER PROGRAMMING
Input (NO/Close on input)

Input (NC/Open on input)

Output (Motor/timer/alarm/..)

Special Instruction (e.g. END)

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Hardware

Allen Bradley

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Hardware

Siemens Fatek

Delta
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Hardware

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Programming (Ladder Diagram)

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OR

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AND

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NOR

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NAND

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NOR

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Exclusive-OR

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Interlock Circuit

OL: Over Load

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Latching: Motor control

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Timer, Internal Relays and Counter

Tasks involved time delay
TIMER
•Waits a set amount of time before doing INPUT TIMER

something (control time)

•Count fractions of seconds or seconds TIMER OUTPUT

using the internal CPU clock.

•The time duration for which a timer has

been set is termed the preset and is set in
multiples of the time base used.

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Timer, Internal Relays and Counter

Timers Types

• On-Delay timer- simply “delays turning on”. It is

called TON, TIM or TMR.

• Off-Delay timer- simply “delays turning off”. It is

called TOF and is less common than the on-
dellay type.

• The on/off delay timers above would be reset if

the input sensor wasn’t on/off for the complete
timer duration.

• Retentive or Accumulating timer- holds or

retains the current elapsed time when the
sensor turns off in mid-stream. It is called RTO or
TMRA. This type of timer needs 2 inputs.

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Large delay, cascaded timers

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• In the example above, when the operator pushes button 0001 the timer
starts ticking.
• When the accumulated value reaches 0 the timer contacts (T000) will close
and output 0500 becomes true.
• When the operator releases the button (0001) the accumulated value
changes back to the preset value.(i.e. it resets)

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• In the example above, when the operator pushes button 0002 the timer
starts ticking.
• When the accumulated value reaches 0 the timer contacts (T000) will close
and output 0500 becomes true.
• When the operator releases the button (0002) the accumulated value is
held(i.e. retained).
• Only when the operator pushes the reset button(0001) does the timer reset.

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Timer, Internal Relays and Counter

1 IR 1
INTERNAL RELAYS
Marker or Auxiliary relay,
2
Simulation by software of PLC
May have battery back up IR 2
3 4

IR 1 OUTPUT

IR 2
END

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Timer, Internal Relays and Counter

COUNTER
Counter changes its stage after a preset no. of pulse
Up Counter
1
Down Counter RESET

Counter
2 K10

OUT

Counter OUTPUT

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Cylinder sequencing

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Cylinder sequencing

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