PLCs and Relay

Ladder Logic
Sequence Control
Aditi Kumari 20225002
Akrati Singh 20225005
Anandi Yadav 20225007
Prashansa Sthul 20225062
Usha Nitwal​ 20225099

Submitted To: Dr . Souradip De

 1 Introduction to PLC and Relay Logic

Contents 2 Components of PLC and Relay Systems

3 Programming and Design Methods

4 Advantages and Disadvantages

5 Applications

Examples
6

7 Practical examples
 1. PLCs (Programmable Logic Controllers):

A Programmable Logic Controller (PLC) is a specialized computer used for industrial

automation and control systems. It is designed to perform specific tasks, such as controlling
machines, processes, or robots in factories. Unlike a general-purpose computer, a PLC is
rugged and can withstand harsh environments like extreme temperatures, vibrations, and
electrical noise.
Key Features of PLCs:

Input/Output (I/O) Modules: PLCs connect to sensors, switches, and other devices through
input/output modules, which collect data from the environment and send control signals to
other equipment.

Programming: PLCs are programmed using specialized languages like Ladder Logic,
Structured Text, and Function Block Diagrams.

Real-time Control: PLCs operate in real-time, meaning they execute control tasks promptly
based on input data.

Reliability and Durability: They are highly reliable for continuous operation in industrial
environments.
PLC block diagram
 Languages

Ladder Logic is a graphical Function Block Diagram (FBD) is a Structured Text (ST) is a high-level
programming language used in graphical programming programming language used in
PLC programming, resembling language used in PLCs that PLCs that resembles traditional
electrical relay diagrams. It represents functions as blocks programming languages. It allows
simplifies troubleshooting and and their relationships through for complex mathematical
understanding for engineers by interconnected lines. It allows for operations, logical functions, and
using symbols and lines to modular design, simplifying data handling, making it ideal for
represent control circuits and complex control processes, and advanced automation tasks. ST
logic functions, making it ideal for enhancing user comprehension enhances readability and simplifies
automating industrial processes. of the control logic. debugging, facilitating efficient
control system design.

Ladder Logic Function Block Diagram Structured Text

 2.Relay Ladder Logic (RLL)

Relay Ladder Logic (RLL) is one of the most common programming languages used to program PLCs. It gets its name from the
resemblance to electrical relay diagrams used in older control systems. It provides a graphical way to represent control circuits.
In Ladder Logic, the circuit is represented as a "ladder" with two vertical rails (representing electrical power lines) and horizontal
rungs (representing control circuits). It follows a left-to-right execution flow, where each rung represents a specific logic
operation.
Key Concepts in Relay Ladder Logic:

Contacts: These represent physical switches or relays in the system (e.g., normally open or normally closed).

Normally Open (NO): Allows current to flow when activated (equivalent to a switch being on).

Normally Closed (NC): Allows current to flow when deactivated (equivalent to a switch being off).

Coils: These are the output elements that get energized when the logic conditions are true. Coils typically represent relays or
devices that need to be controlled.

Rungs: Each rung in the ladder represents a logical condition. If the inputs satisfy the condition, the output coil is energized.
 3. Sequence Control using Ladder Logic

Sequence control refers to the process of executing a series of operations in a defined order based
on certain conditions. In PLCs and Ladder Logic, this is typically done using:

Relays and Contacts (in older electromechanical systems)

Timers, Counters, and Memory Bits (in modern PLCs)
 ADVANTAGES
&
DISADVANTAGES
Advantages:
01 02 03
Reduced Wiring and Faster Operation and High Reliability and Durability
Complexity Response Time

Changes can be made in PLCs use electronic switching, which is Mechanical relays wear out over
software instead of rewiring faster and more reliable . Milliseconds time due to moving parts. PLCs
circuits. response time improves control have solid-state components,
Makes the system flexible. system performance. making them more durable and
long-lasting.

04 05 06

Cost-Effective in the Long Run Communication and Integration Improved Diagnostics

Initial cost of a PLC may be higher, but PLCs can communicate with PLCs have built-in diagnostics
Fewer components, reduced wiring, other devices (HMI, SCADA, that detect faults and display
and minimal maintenance lowers sensors, etc.). errors. Relay systems require
costs. manual checking of each wire
and connection.
Disadvantages:

Problem 01 Problem 02 Problem 03

Requires Skilled Programmers &
High Initial Cost Limited Hardware Compatibility
Technicians
Between Brands
PLCs require specialized knowledge to
The cost includes hardware (PLC A program written by one
program.
unit, I/O modules, power supply) manufacturer cannot be used
Troubleshooting in PLCs can be difficult for
and software (programming tools, by another without
technicians unfamiliar with software-based
licenses, etc.). modifications. This reduces
control.
flexibility.

Problem 04 Problem 05 Problem 06

Risk of Cybersecurity Threats Limited Number of Inputs/Outputs Programming Complexity for

(I/O) Large Systems
Modern PLCs connect to networks,
and SCADA, increasing the risk of Each PLC has a fixed number of input PLC programming can become
hacking or malware attacks. and output (I/O) ports. If more I/Os are complex and difficult to manage.
Older PLCs lack built-in cybersecurity needed, additional expansion modules
features, making them vulnerable to must be installed, increasing cost.
cyber threats.
 Provide training and use user-friendly
programming interfaces.

Implement firewalls, VPNs, and access

control measures to protect PLC networks.

Solutions Use modular PLCs that allow I/O expansion

when needed.

Choose standard communication protocols (e.g

Ethernet/IP) to improve communication between
manufacturers.
 PLC controls assembly lines, robotic arms, and
1
conveyors in factories. eg : car manufacturing.

Applications Used in industries where temperature, pressure, flow,

2
and level need to be controlled. eg:Oil refineries
(distillation, flow control)

3 Monitor and control turbines, generators, and

transformers. eg :Thermal plants (boiler control)

4 Used in traffic light systems, railway signal control,

and airport automation. eg : Automatic railway
crossings and metro train automation.
 Electrical contacts
Normally Open Contact (NOC)

Definition: A contact that is open by default and closes when energized.

Example: Push-button start system.

Normally Closed Contact (NCC)

Definition: A contact that is closed by default and opens when energized.

Example: Emergency stop button in machines.
BASIC LOGIC GATE IMPLIMENTATIONS
THROUGH LADDER PROGRAMMING

AND GATE
A*B = Y
Logic: Output is ON only if both
inputs are ON.
BASIC LOGIC GATE IMPLIMENTATIONS
THROUGH LADDER PROGRAMMING

OR GATE
A+B = Y
Logic: Output is ON if at least
one input is ON.
 BASIC LOGIC GATE IMPLIMENTATIONS
THROUGH LADDER PROGRAMMING

NOT GATE
Logic: Output is the inverse of
input.
Example: Stop button in a
system.

NOTE: ALL OTHER GATES CAN BE REPRESENTED USING THESE BASIC GATES
WE WILL SEE A FEW SIMPLE IMPLIMENTATIONS OF PLC LADDER
PROGRAMMING
EXAMPLE-1 MOTOR ON AND OFF CONTROL
WITH LATCHING.

Motor latching refers to a control mechanism where a motor remains in an "on" state even after
the initiating input (like a push button) is released. This is achieved using a latching circuit,
which "remembers" the motor's state until a separate stop input is provided.
EXAMPLE-2 MOTOR ON AND OFF CONTROL
WITH LATCHING USING TIMER.

Using a timer for the start button in motor latching ensures that the motor starts after a specific
duration (EG: 2 seconds) after the start button is pressed.
 WE WILL SEE A IMPLIMENTATIONS OF
PLC LADDER PROGRAMMING IN PRACTICAL SCENARIO

Here in this practical example an automated system designed to transport and manipulate a box along a
production line by integrating mechanical and electronic components. The system operates under the
control of a Programmable Logic Controller (PLC) and executes a predefined sequence of operations to
ensure efficiency and precision.
System Components
Input Signals (Sensors)
•X0: Manual signal to turn the system ON/OFF.
•X1: Box detected on the first conveyor.
•X2: Box positioned at the exact place on the disk (platform sensor activated).
•X3: Disk rotation (CCW) completes 90°.
•X4: Box pushed out of its position on the disk.
•X5: Disk and pusher return to the initial position.

Output Signals (Motors & Actions)

•Y1: Moves the first conveyor.
•Y2: Rotates the disk (CCW).
•Y3: Pushes the box off the disk.
•Y4: Starts the second conveyor.
•Y5: Reverses the direction of Motor 2 and Motor 3.
 Operational Process
1.Box Enters the System: The first conveyor (Y1) moves the box to the positioning platform.
2.Box Positioning: A sensor (X2) detects when the box is at the correct position.
3.Disk Rotation (Counterclockwise - CCW): Motor Y2 rotates the disk platform by 90°.
4.Pushing Mechanism: The push arm (Y3) moves forward to push the box out of position.
5.Second Conveyor Activation: The second conveyor (Y4) transports the box to the end of the line.
6.System Reset: The disk and push arm return to their original position for the next box.
State Encoding Using Gray Code
To simplify programming, Gray Code is used for state representation. The state transitions are

encoded using three bits (M1, M2, M3), as shown below:

The state transitions are controlled
using the following logic functions:

1.Set M1: Activated when moving from

Stopped to Moving
or from Push to Return.
2. Reset M1: Activated when moving
from Loading to CCW or from
Return to Stopped.
3. Set M2: Activated when moving from
Moving to Loading.
4.Reset M2: Activated when moving from
Return to Stopped.
5. Set M3: Activated when moving from
CCW to Push.
6. Reset M3: Activated when moving
from Return to Stopped.
Then exchange of the primary bits with the secondary bits as follows:
The Output Functions

(Start of the first conveyor)

(Rotating the disk CCW)

(Pushing the box by jack)

(Start the second conveyer)

(Reverse relay ON).
Simplified Functions
When M2 is reset M3 is reset as well. Similarly, if M3 is set, then M2 is set as well.
One Major Source of Errors: Undefined States
The system uses three bits (M1, M2, M3) to define states.
Three bits can represent 2³ = 8 different states.
However, only 6 out of these 8 states are defined in the system.
If the system unexpectedly enters an undefined state, its behavior is unpredictable.
Ladder Programming
THANK YOU!