Manufacturing Automation (MTS 451)

2 Credits – Lectures

Lecture 1

Dr. Syed Hammad Nazeer

Associate Professor
Office: A Block
Email: [email protected]
 Introduction to PLC’s

• Up till 1960- 1968  Analog Controllers & Electro

Mechanical relays to implement Discrete Control
• Initially it was called PC, but later IBM introduced
Personnel Computers
• PLC was coined by Allen Bradley
• 1968  PLC’s came into being
– GM (General Motors) Hydramatics requested a proposal for
replacement of Hardwired systems
– Best proposal came from Bedford Associated
• It was called 084 since it was their 84th Project
– Bedford developed a new company to develop this new device 
MODICON (Modular Digital Controller)

• Up till now most PLC components (I/O etc) are

proprietary
 Basic Requirements

• Initially when the proposal was put forward the following

requirements had to be achieved by PLC’s
– Reprogrammable

– Operable in Industrial environments

– Outputs designed to operate loads such as motors and relays

– Price & Installation cost competitive compared to relay and solid

state logic devices
 Capabilities

• Capabilities of PLC’s were similar to relay controllers back in 1970’s

• With time passage enhancements took place such as Operator

Interfaces, Arithmetic Capability, Data Manipulation, Analog Inputs,
Remote I/O’s

• All the advancements were based on the microprocessor industry.

• With increase in computing power the capabilities and functionalities of

PLC’s Improved
 PLC Programming

• PLC’s can be programmed using different techniques.

These include 3 Graphical & 2 Text based diagrams:
– Ladder Logic
– Functional Block Diagrams
– Sequential Functions Charts or Grafcet Method
– Instruction List
– Structured Text
 Advantages of PLC’s
• Built specifically for the Industrial Conditions
• Takes less space compared to conventional control panels
• Can be interface with Computers easily
• Date Processing & Reporting Capabilities
• Flexibility in terms of I/O modules
• Easier to program (using ladder logic) & Reprogrammable as well
• Built to last in industry (under rough conditions)
• Highly Reliable
– 1 PLC fails in 1000
 Basic Control Diagram

• The computer communicates with PLC through

Serial, Parallel or Ethernet port
 Allen Bradley Series
• Allen Bradley Offers a wide range of series for automation at different
levels:
– Control logix  for Large Scale Automation
– Small Logic Controller (SLC)  for Medium Scale Automation
– Micro logix  for Small Scale Automation
– Pico

• Some Micro Logix series (or in general some PLC’s) have fixed I/O’s,
thus they are low cost but inflexible

• All series require different controllers which have different

specifications (in terms of I/O interfaces, connectivity
options(DH+,RS232 etc))

• Depends on the scale of automation and requirements which series &

controller has to be chosen
 PLC Components
• Essential Components of a PLC:
– Central Processing Unit (CPU)  Basic Control Unit
– Power Supply
– PLC Racks
– I/O Modules

• Central Processing Unit:

– One or more Micro processor’s for all computations
– Holds the entire operating system and the user code
– Manages memory, monitor inputs & evaluates outputs
– Memory checking routines
Architecture of PLC’s
Allen Bradley SLC CPU

SLC (Small Logic Controller)

 Operation Modes of CPU
• The controller can run is 3 different modes which are specified below:
– Program Mode
– Run Mode
– Remote Program
• Program Mode:
– In program mode all outputs are forced to be off and this specific mode can
be used to:
• Develop or Change existing logic
• Transfer program files (firmware) to the memory modules
• Run Mode:
– The PLC continuously scans the inputs & outputs and evaluates logic
• Remote Program:
– A remote computer attached to the PLC can switch the mode in which the
processor is operating.
 SLC CPU Models
• 5/01
– Program memory option of 1K or 4K Instruction words
– Address up to 256 I/O’s
– DH485 Communication
• 5/02
– Program memory of 4K
– Address up to 480 local I/O and up to 4000 remote inputs & outputs can be
addressed
– DH 485 Communication
• 5/03
– 12K word and some additional word capacity
– 960 Local I/O can be addressed
– DH485 & RS232/DF1 ports
– Online programming, additional math blocks etc
SLC CPU Models
• 5/04
– It can have 12K, 28K or 60K words of memory
– All features of 5/03
– Additional DH+ (Data Highway) port
– Real time clock and Math coprocessor
• 5/05
– All aspects of 5/04 plus Ethernet communication ability.
 Memory
• Memories in PLC can be of various types:
– Operating System Memory (ROM)
• Operating system is burned into this memory
• Essentially holds all control function  Ladder logic is a high level
language, it has to converted into machine language
• Non Volatile Memory  memory is retained even when PLC is turned
off
– Random Access Memory:
• Essentially all status bits are stored in this memory (status bits
corresponding to Processor , I/O’s (I/O image tables))
• User’s program, Timer & Counter Values are all stored in RAM
• Volatile memory  data is lost once turned off (that’s why Lithium
batter is used)  also provide capacitors in case battery is being
replaced (provides 30 min backup)
• Most PLC’s use CMOS-RAM which draws low current (can remain
functional for 2-5 years)
 Allen Bradley SLC

Power Supply
Allen Bradley Control Logix

Power Supply
Control Logix Controllers

• Like SLC’s they have a lot of

controllers which vary in
different aspects
• Depends on requirements
which controller has to be
used
Micro Logix Series

• Mainly used for Small Scale

Automation
• Some series allow flexible
I/O’s
Hand Held Programmer’s

• Were used back in the Eighties (1980’s)

• Now replaced by cheap Personal Computers
• Can show only a small part of Ladder Logic
• Can be used to monitor I/O and force them
 Allen Bradley PLC Rack

• Physical Housing for the CPU, I/O modules and Power Supply
• The back plane provides the paths and electrical connections to
connect modules, power supply and CPU
• Modules can be plugged in and out easily. The ability to quickly
change I/O modules make PLC’s very robust and useful
• Can also handle remote I/O
 I/O Modules
• Input Modules:
– Either Analog or Digital (available for DC, TTL Logic and AC) 
however AC modules are not commonly used (in case of AC the
PLC converts it into low voltage DC)

– Modules can have 4,8,16 or 32 input channels

– Analog modules can operate on Current or Voltage (4-20mA or 0-

10V)

– Common inputs are switches & sensors, often called field

devices.

– Specific modules for RTD’s, Thermocouples etc

I/O Modules
– Input modules rarely provide power to sensors, so most sensors
in field are externally powered
– All input modules have Opto Isolation (Opto coupler) in order to
protect in case of electrical surge
 Output Modules
• Output Modules:
– Either Analog or Digital (available for DC, TTL Logic and AC)  however
AC modules are not commonly used
– Modules can have 4,8,16 or 32 output channels
– Output modules as well rarely provide power so they must be powered
externally as well.

Input Output
Module Module
 Siemens

S7 Simatic S5 Simatic
Omron & Yokogawa
 Applications
• Mainly to replace old hard wired systems with systems
which are more flexible
• Reduce downtime of Process plant.

• Effectively control Large process plants with thousands of

inputs & outputs
• Develop generalized & cost effective control equipment for
industries

• Develop effective and accurate control equipment (PLC’s

can control (position or velocity) more accurately then any
CAM Shaft mechanism)
• No wear and tear as in Mechanical equipment
Ladder Logic
 Ladder Logic

• Ladder Logic
– A symbolic representation of an Circuit Diagram of
Relay logic hardware
– Mimics Relay logic
• Quite popular because it is quite easy to understand and
requires minimum training of Engineers

• What is a Relay?
– How does a relay operate?
 Relays
• An electrically operated switch
– Old relays were based on electromagnet

• Solid state relays use solid state

electronic switching device based on
some sensor (opto coupler)
– Switching devices could be Transistors,
MOSFET’s or Thyristors

• All relays have two states NO (Normally Open)

and NC (Normally Closed)

• Mainly used for isolation of High Power Source from Low

power source or where some signal needs to be controlled
Ladder Logic
 Basic Terminologies
• Contacts:
– Contacts are inputs symbols
– Most inputs to the PLC’s are discrete binary in nature (sensors &
switches)
– Contacts can be of two types
• Normally Closed Contact (XIO)
• Normally Open Contact (XIC)
• Transitional Contacts (OSR)

– Normally Open contact only allows current when there is input

– Normally Closed contact allows current to pass in the case when

there is no input
– Contacts always appear on the left side of the ladder diagram
 Examples of Contacts

• Which contact & switch would you use for a Doorbell?

– Normally Open

• Which contact & switch would you use for counting boxes
on a conveyer?
– Normally Open

• Which contact & switch would you use for Home Alarm
system?
– Normally Closed
– Why Normally Closed???
 Contacts

Real Input ON Output?

Real Input ON Output?

Real Input OFF Output?

Real Input OFF Output?

 Transitional Contacts

• Special types of Contacts also called one shot contacts

• An input instruction that can trigger an event to occur only once

• When the rung condition changes from false to true, OSR will be true for once
scan only

• Often used for pulse, timings and to perform operation only in one cycle

– Addition of numbers based on OSR (the numbers will be added only once)
 Basic Terminologies

• Coils (Outputs):
– Coils are output symbols
– Output can be off different forms (motor, valves, counters, timers)
– Ladder logic evaluates the inputs and operates the coils based on the
evaluation
– Coils (binary) are of different types:
• Output Energize

• Output latch

• Output Unlatch

– Coils always appear on the right side of the ladder diagram

– The output that the coil represents can appear on the left side of the
diagram
 Ladder Logic

• Contacts appear on the left hand side and Coils on the

right
Contacts
 Ladder Diagram
• Looks quite similar to a step ladder
• Uprights (power rails  because they represent power) hold together
different rungs
• Power can flow from left to the right
• PLC will continuously monitor the inputs and generate outputs based on
evaluation

• Consider the following rung, two normally open switches control the
output ‘light’. Explain the operation!!!!
 Ladder Diagram

• Multiple Contacts:
– A ladder can have multiple contacts put on the same rung

• Branching:
– Contacts can also be added in parallel to already existing contacts
 Scan Times
• This process of monitoring inputs and generating outputs is called scanning
• Scan Cycle:
– First checks all the inputs before it enters the ladder
– Evaluates the logic to decide which outputs have to be changed (however doesn't
toggle them yet)
– Finally changes all the outputs by copying the output image tables to the
corresponding output channel

• The amount of time it takes the PLC to check input, evaluate logic and then update I/O
tables is called scan times
 Scan Times
• Scan times can be divided into two parts:
– I/O scan
– Program scan

• Generally scan times of PLC’s are in the order of milliseconds

• Scan times differ in different models and manufacturers of PLC’s but generally
its given in Fraction of Milliseconds per K of memory

• Increasing the size and complexity (math operations) increases scan times
• Rockwell Scan Order:
– Input Scan
– Program Scan
– Output Scan
– Service Communication
– Overheads (timers, bits, counters)
 Boolean Logic Design
• Objectives:
– Boolean Algebra and Conversion to Ladder Logic

• Conversion of Control requirements to Ladder Logic requires structured

thought and Boolean Algebra provides the tools

• Boolean Algebra:
– Was developed in 1800 by an Irish Mathematician James Bool
– Found to be very useful in designing digital circuits and is still very commonly
used
• Basic Operators:
– AND, NOT, OR
• Other Operators:
– Exclusive OR, NAND, NOR
 Boolean Algebra

• Solution of a Boolean Equation

Axioms of Boolean Algebra
Axioms of Boolean Algebra
 Boolean Manipulation

• An Example of Boolean Manipulation

Boolean Logic  Ladder Logic

Stop button in industries is

generally Normally Closed
Boolean Logic  Ladder Logic

• How to convert NAND, NOR and EOR (which don’t have equivalent
descriptions in Ladder logic) to Basic operations
Boolean Logic  Ladder Logic
Boolean Logic  Ladder Logic
Boolean Logic  Ladder Logic
Example with Given Circuit
 Example with Given Circuit
• Simplified circuit is then drawn as Ladder logic.
• This ladder logic generates the same outputs and the original complex
function
Multiplexer in Ladder Logic
 Rockwell Memory & File Organization

• Understanding File Organization and Addressing is very essential to

program a PLC

– There exists two types of memories in Rockwell PLC’s (RAM)

• Program Memory
• Data Memory
– Each contains 256 files (0-255)

• Program Memory:
– File 0 contains processor type, I/O Configurations etc
– File 1 is reserved
– File 2 contains the main ladder logic
– File 3-255 are user created according to subroutines in the main ladder
 Rockwell Memory & File Organization
• Data Memory:
– Data Memory also has 256 files
– Mainly contains the status of I/O and other instructions used in the main
ladder and subroutine ladders
– There exists different files with different functions:
• File 0 (O) : Stores the status of outputs. If you want to change the status of the
output you could put 0 or 1 in the correct bit
• File 1 (I) : Stores the status of the inputs. You can check the status of any input
by looking in the file
• File 2 (S): Mainly stores status bits corresponding to the processors state.
• File 3 (B): Used to store bit information. You can store different information
relating to contacts and coils.
• File 4 (T): Used to store Timer information.
• File 5 (C): Used to store data corresponding to Counters
• File 6 (R): Used for control, example when working with Sequencers & Shift
registers
Rockwell Memory & File Organization

• File 7 (N): Used to store Integers or Bit information

• File 8 (F): Used to store floating point numbers. These numbers

could be gains for PID blocks or outputs corresponding to them.

• File 9-255: These files are user defined. The user can define them
according to his requirements. They can be used to store integers,
floating points etc
 Memory Addressing
• Memory addressing is the processing of reading or writing data to
the files
– The first letter in the input address is called the identifier
– The second letter is the file number (the default number is 1)
– The next item is the delimiter (colon)
– The next item after limiter is the slot number (in the chassis) and after
that the Bit number Slot 0

I1:0/1 Channel 1
Input Register (File 1)
 Memory Addressing

File Type Identifier File Number

Output O 0
Input I 1
Status S 2
Bit B 3
Timer T 4
Counter C 5
Control R 6
Integer N 7
Float F 8
 Memory Addressing

Power CPU Output Input Output Output

Supply Input

SLOT NO. 0 1 2 3 4 5

• How would you address different slots and channels within those
slots??????
 Memory Addressing
• Similarly Timer and Counter Files can also be addressed however they
contain additional parameters that can be addressed

• Timers & Counters and additional parameters that can be addressed in

them will be discussed in upcoming lectures
Boolean Representation - Example
 Example
• Make Boolean Function & Simplify!!!
Example
 Exercise

• Convert to Boolean Logic  Simplify and then write the ladder logic
 Karnaugh Maps

• Given a Truth table it can be used to get a (Simple) Boolean Function

Karnaugh Maps – Example