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PLC's & Its Applications: BY Anil Kumar

This document provides an overview of programmable logic controllers (PLCs) including their history, components, programming, and applications. It describes that PLCs were first developed in 1968 as programmable replacements for hardwired relay logic. The document then discusses the basic components of a PLC including the central processing unit, power supply, and input/output modules. It also covers common PLC programming methods like ladder logic and provides examples of industrial applications for PLCs such as controlling tank levels, mixing processes, robotics, and automatic sprinkler systems.

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223 views51 pages

PLC's & Its Applications: BY Anil Kumar

This document provides an overview of programmable logic controllers (PLCs) including their history, components, programming, and applications. It describes that PLCs were first developed in 1968 as programmable replacements for hardwired relay logic. The document then discusses the basic components of a PLC including the central processing unit, power supply, and input/output modules. It also covers common PLC programming methods like ladder logic and provides examples of industrial applications for PLCs such as controlling tank levels, mixing processes, robotics, and automatic sprinkler systems.

Uploaded by

srini_kalmula
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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PLC’s & Its Applications

BY
Anil Kumar
Contents
 What is PLC?
 Historical background & Origin
 Why PLC?
 Block Diagram
 Components & Systems
 Principle of operation

 Types of PLC’s
 Different Manufactures of PLC’s
 Characteristics
 Advantages & Disadvantages
 Programming
 Applications
PLC = Programmable Logic Controller
Def:-
NEMA (National Electrical Manufacturers Association):
A digitally operating electronic apparatus which
uses a programmable memory for the internal storage of
instructions for implementing specific functions, such as
logic, sequencing, timing, counting and arithmetic, to
control through digital or analog input/output, various
types of machines or process.
Historical Background & Origin
The first programmable controller in 1968 developed by
General Motors Corporation.
The first PLCs offered relay functionality, thus replacing
the original hardwired relay logic.
PLC began in the 1970s, and has become the most
common choice for manufacturing controls.
Costs dropped and became popular by 1980s
Now used in many industrial designs
Why & Where PLC is used?
Block Diagram of a PLC
Input wiring and Devices
Push buttons
Selector Switches
Limit Switches
Level Switches
Proximity Sensors
Photoelectric Sensors
Relay Contacts
Motor Starter Contacts
Etc…….
Output wiring & Devices
Valves
Motor Starters
Solenoids
Control Relays
Alarms
Lights
Fans
Horns
Transistors
Etc………….
Central Processing Unit:
It is the unit containing Microprocessor for logical
operations
Power Supply Unit:
It is needed to convert mains High A.C voltage to Low D.C
voltage
Input & Outputs:
Operation Cycle of the PLC
The signal chain within PLC
Types of PLC’s
Compact
Modular PLC
Soft PLC
Micro
Medium
Large
Nano
Modular PLC
• tailored to the needs of an application development
environment
• housed in a 19" (42 cm) rack RS232
(height 6U ( = 233 mm) or 3U (=100mm)
• high processing power (several CPU)
LAN
• large choice of I/O boards
backplane
• concentration of a large number of I/O parallel bus
courtesy ABB

• interface boards to field busses fieldbus

• requires marshalling of signals Power Supply

• primitive or no HMI
CPU CPU Analog I/O Binary I/O
• cost effective if the rack can be filled fieldbus
• supply 115-230V~ , 24V= or 48V= (redundant)
• cost ~ €10’000 for a filled crate
Small modular PLC

courtesy ABB
courtesy Backmann

Supply 24 V
Cheaper (€5000)
Not water-proof,
No ventilator
extensible by a parallel bus (flat cable or rail)
Industrial PLC’s
Soft-PLC (PC as PLC)
• PC as engineering workstation
• PC as human interface (Visual Basic, Intellution, Wonderware)
23 12 • PC as real-time processor (Soft-PLC)
4 2 2 • PC assisted by a Co-Processor (ISA- or PC104 board)
3
3 • PC as field bus gateway to a distributed I/O system

I/O modules
Compact PLC

courtesy ABB courtesy ABB courtesy ABB

Monolithic (one-piece) construction


Fixed casing
Fixed number of I/O (most of them binary)
No process computer capabilities (no MMC)
Can be extended and networked by an extension (field) bus
Sometimes LAN connection (Ethernet, Arcnet)
Monoprocessor
Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7
costs: € 2000
Market share
% installed PLCs

Micro: 15 to 128 I/O points 32%


Medium: 128 - 512 I/O points 29%
Large: > 512 I/O points 20%
Nano: < 15 I/O points 7%
PC-based 6%
Software PLC 4%
Embedded control 2%
Different Manufactures of PLC’s
Siemens----------------------------------29.6%
Rockwell Automation------------------20.8%
Mitsubishi--------------------------------15.1%
Schneider Electric----------------------8.3%
Omron------------------------------------7.4%
GE Fanuc---------------------------------3.7%
B&R Industrial--------------------------2.1%
ABB (Asea Brown Boveri) -----------1.7%
Moller-------------------------------------1.4%
Hitachi ------------------------------------1.3%
PLC: Characteristics
• large number of peripherals: 20..100 I/O per CPU, high density of wiring, easy assembly.
• binary and analog Input/Output with standard levels
• located near the plant (field level), require robust construction, protection against dirt,
water and mechanical threats, electro-magnetic noise, vibration, extreme temperature
range (-30C..85C)
• programming: either very primitive with hand-help terminals on the target machine itself, or

with a lap-top able to down-load programs.


• network connection is becoming common, allowing programming on workstations.
• field bus connection for remote I/Os
• primitive Man-Machine interface, either through LCD-display or connection of a laptop
over serial lines (RS232).
• economical - €1000.- .. €15'000.- for a full crate.
Advantages:
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.
Relay Logic Vs Ladder Logic
Disadvantages
Too much work required in connecting wires
Difficulty with changes or replacements
Difficulty in finding errors, which leads to skillful work
force.
Programming a PLC
Function Block Diagram (FBD)
Sequential Flow Chart (SFC)
Ladder Diagram (LD)
Structured Text (ST)
Instruction List (IL)
Ladder Diagram Programming
Normally Open
Normally Closed
Energize Coil
Set the Coil
Reset the Coil
Timers
ON-Delay
Off –Delay
Retentive
Extended Pulse
Counters
Up
Down
UP/Down
Basic of Ladder Diagram
Simple “OR” gate
Applications
Level Controlling in a Tank
Aim:
We are controlling
lubricating oil being
dispensed from a tank.
This is possible by using
two sensors. And we
need to develope a
ladder logic program to
achieve this.
Program
The Ladder Diagram
Tank Level control using a PLC
Typical PLC Application (CSTR)
Operation of Mixer
(Sequence of Control)
Application of PLC’s in Robotics
Automatic water
sprinkler system of a garden
Queries?
Thank You

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