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Inst PPT

The document discusses Programmable Logic Controllers (PLCs) and their application in industrial automation, focusing on ladder logic programming and Sequential Function Charts (SFC). It outlines the advantages and disadvantages of PLCs, as well as provides examples of relay logic functions and troubleshooting scenarios. Additionally, it presents a research paper abstract on using PLCs for motor control in various sequence modes.

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Suryansh Singh
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14 views22 pages

Inst PPT

The document discusses Programmable Logic Controllers (PLCs) and their application in industrial automation, focusing on ladder logic programming and Sequential Function Charts (SFC). It outlines the advantages and disadvantages of PLCs, as well as provides examples of relay logic functions and troubleshooting scenarios. Additionally, it presents a research paper abstract on using PLCs for motor control in various sequence modes.

Uploaded by

Suryansh Singh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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PLCs and Relay Ladder Logic

Sequence Control

Submitted by:
Hemant Kumar Yadav (20225037)
Ishan Singh(20221047)
Sudarshan Singh Yadav(20225091) Submitted to:
Anurag Singh(20225012) Dr. Souradip De
Eklavya Gupta(20225032)
Introduction:
A Programmable Logic Controller, or PLC, is a
ruggedized computer used for industrial
automation. These controllers can automate a
specific process, machine function, or even an
entire production line.
PLCs can range from small modular devices with
tens of inputs and outputs (I/O), in a housing
integral with the processor, to large rack-mounted Fig 1: Compact PLC with 8
inputs and 4 outputs
modular devices with thousands of I/O, and which
are often networked to other PLC and SCADA
systems.
Development of PLC:
PLCs were first developed in the automobile manufacturing industry to provide
flexible, rugged and easily programmable controllers to replace hard-wired
relay logic systems. Dick Morley, who invented the first PLC, the Modicon 084,
for General Motors in 1968, is considered the father of PLC.
Many early PLC programming applications were not capable of graphical
representation of the logic, and so it was instead represented as a series of
logic expressions in some kind of Boolean format, similar to Boolean algebra. As
programming terminals evolved, because ladder logic was a familiar format
used for electro-mechanical control panels, it became more commonly used.
How does a PLC work?

Fig 2: Block diagram of Working Of PLC


Ladder logic programming
Ladder logic programming is a visual representation used in programmable
logic controllers to control machinery and processes. For example, it can
manage a conveyor belt system by controlling motor start/stop operations
based on sensor inputs.

Its name comes from it’s the visual resemblance to a ladder, with horizontal
rungs and vertical rails.

PLC ladder rungs should have logical continuity in order for the output to
be energized. PLC ladder program uses familiar terms like “rungs”,
“normally open” and “normally closed” contacts
Working of ladder logic programming
In a ladder logic program, there is no physical conductor that carries the input
signal through to the output. Each rung in the ladder diagram is a program
statement. This program statement consists of a condition or sometimes
conditions, along with some type of action.
Inputs are the conditions, and the action, or output, is the result of the
conditions. As in case of physical wiring hardware devices connected in series or
parallel, PLC also combines ladder program instructions in series or parallel.
However, rather than working in series or parallel, the PLC combines instructions
logically using logic operators like: AND, OR, and NOT. These operators are used
to combine the instructions on PLC rung to make the outcome of each rung
either true or false.
Sequential Function Chart (SFC)
Sequential Function Chart (SFC) is a graphical programming language among
the languages identified by IEC 61131-3 programming languages and standard
for PLC programming using ladder logic.
Sequential control refers to a process where operations occur in a specific
predefined order.

SFCs, or sequential functions charts, are not text-based programming languages,


but rather visual programming languages, similar to the flow charts for computer
science algorithms.
How Does SFC Programming Work?
In this, the operations are described as separate steps that are sequentially
connected. In SFC programming, states or steps are represented by rectangular
boxes.
The first box represents the start of the operation. Two states are connected
with a vertical line. The horizontal lines between boxes represent transition
conditions.

After a step is completed, the process moves on to the next state only if the
transition condition(s) is also satisfied.

Each of the states also has corresponding outputs. Outputs are represented as
rectangular boxes linked horizontally to their respective state.
Two conditions must be followed for every SFC:
There should be a transition condition between two steps.
A step should always separate two transition conditions.

Fig 4: SFC diagram representated by an equivalent ladder logic.


Advantages of PLC:
1. Easy Programming and Modification
Uses user-friendly languages like Ladder Logic.
Programs can be updated without changing hardware.

2.High Reliability
Designed for industrial environments.
Can operate 24/7 with minimal maintenance

3.Compact and Space-Saving


Replaces large relay panels.
Occupies less physical space in control panels.

4.Easy Troubleshooting and Diagnostics


Built-in error detection and monitoring tools.
Disadvantages of PLC:
1. Higher Initial Cost
More expensive than traditional relay-based systems.
Requires investment in hardware and software.

2.Complex Maintenance
Requires trained personnel for programming and troubleshooting
Not as straightforward as relay-based systems

3.Compatibility Issues
Different PLC brands have different programming environments.
Not all PLCs are interchangeable.

4.Dependence on Software and Programming


Failure in the software can stop operations.
Problem 1:
Identify each of these relay logic functions by name (AND, OR, NOR, etc.) and
complete their respective truth tables:
Problem 1:
Identify each of these relay logic functions by name (AND, OR, NOR, etc.) and
complete their respective truth tables:
Problem 1:
Identify each of these relay logic functions by name (AND, OR, Neg-AND, etc.) and
complete their respective truth tables:
Problem 1:
Identify each of these relay logic functions by name (AND, OR, NOR, etc.) and
complete their respective truth tables:
Problem 2:
Predict how the operation of this relay logic circuit will be affected as a result of
the following faults. Consider each fault independently (i.e. one at a time, no
multiple faults):

Pushbutton switch A fails open:


Relay coil CR2 fails open:
Relay contact CR1-1 fails open:
Relay contact CR2-1 fails shorted:
Relay contact CR2-2 fails shorted:
For each of these conditions,
explain why the resulting effects
will occur.
Solution 2:
1.Push button switch A fails open:
lamp 1 always energized, lamp 2 simply becomes
inverse status of push button switch B.

2. Relay coil CR2 fails open: Both lamp 1 and lamp 2


simply become inverse status of push button switch A

3. Relay contact CR1-1 fails open: lamp 1 simply


becomes same status as push button switch B.

4. Relay contact CR2-1 fails shorted: lamp 1 always


energized.

5. Relay contact CR2-2 fails shorted: lamp 2 simply


becomes inverse status of push button switch A.
Research Paper:
Abstract: Today, programmable logic controllers (PLCs) is the dominant
technology deployed in control automation systems in modern factories. The
main modeling method of the PLC is based on ladder logic diagrams (LLDs).
However, as a system gets more complex, LLD implementations poses a
stumbling block in the design of more complex and real-time PLCs.the main
objective of this paper is to run a motor in different sequence mode and
simultaneously run the light .
Follow the two steps required to draw the relay logic
diagram of the following motor control problem.

Step 1: Define the problem. In a motor control


system, one master stop pushbutton (Stop_PB) is
available for stopping the operation at any time. If
the temperature switch (TSW) is closed, pressing the
red pushbutton (Red_PB) will turn on both motors
one (M1) and two (M2). If TSW is open, pressing
Red_PB will only turn on M2. If TSW is closed and the
green pushbutton (Green_PB) is pressed once, M1
will run. Closing the temperature switch turns on the
white pilot light.
Fig 5: Close the temperature switch to turn on the white pilot light. Then,
Step 2: Draw the relay logic diagram. press the red pushbutton to turn on both motors. Press the green
pushbutton to turn on only motor one (M1). Open the temperature switch
and then press the red pushbutton to turn on only motor two (M2).
Figure 7 displays the relay logic diagram of the
circuit described in the first step. The normally
closed stop pushbutton (Stop_PB) is the master stop
pushbutton. If we press the normally open red
pushbutton (Red_PB), motor two (M2) turns on. If the
normally open temperature switch (TSW) is closed,
then pressing the Red_PB will also turn on motor one
(M1). Also, when TSW is closed, pressing the green
pushbutton (Green_PB) will only turn on M1. When
TSW is closed, the white pilot light (White_PLT) turns
on. Fig 5: Close the temperature switch to turn on the white pilot light. Then,
press the red pushbutton to turn on both motors. Press the green
pushbutton to turn on only motor one (M1). Open the temperature switch
and then press the red pushbutton to turn on only motor two (M2).
Thank You

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