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Intro To PLC

The document discusses programmable logic controllers (PLCs). It describes PLCs as specialized industrial computers that accept inputs from sensors, evaluate them based on a programmed logic, and change outputs to control machines or processes. PLCs are optimized for control tasks in industrial environments. The document outlines different types of PLCs and provides examples of major PLC manufacturers.

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Nicholas Shelton
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0% found this document useful (0 votes)
143 views43 pages

Intro To PLC

The document discusses programmable logic controllers (PLCs). It describes PLCs as specialized industrial computers that accept inputs from sensors, evaluate them based on a programmed logic, and change outputs to control machines or processes. PLCs are optimized for control tasks in industrial environments. The document outlines different types of PLCs and provides examples of major PLC manufacturers.

Uploaded by

Nicholas Shelton
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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 Introduction

1
Programmable logic controller
 A programmable logic controller (PLC) is
 a special form of microprocessor - based
controller
 uses a programmable memory to store
instructions
 to implement functions such as logic,
sequencing, timing, counting and arithmetic in
order to control machines and processes

2
Programmable Logic Controllers
 Programmable Logic Controllers, programmable
controllers, or PLCs are specialized industrial
computers.
 The PLC,
 accepts inputs from switches and sensors (measures
or senses the system),
 evaluates these based on a program (logic), and
 changes the state of outputs to control a machine or
process.

3
Programmable logic controller
 The term logic is used because programming is primarily
concerned with implementing logic and switching
operations,
 e.g. if A or B occurs switch on C, if A and B occurs switch
on D.
 Input devices,
 e.g. sensors such as switches, and
 output devices in the system being controlled,
 e.g. motors, valves, etc.,
 are connected to the PLC.

 The operator then enters a sequence of instructions, i.e.


a program, into the memory of the PLC.
4
PLC with Input and Output

5
Programmable logic controller
 The controller then,
 monitors the inputs and outputs according to
this program and carries out the control rules
for which it has been programmed.

6
Programmable logic controller

7
Programmable logic controller
 PLCs are similar to computers
 but whereas computers are optimised for
calculation and display tasks,

 PLCs are optimised for control tasks


and the industrial environment.

8
Programmable logic controller
 Thus PLCs are:
 rugged and designed to withstand vibrations,
temperature, humidity and noise.
 have interfacing for inputs and outputs already
inside the controller
 are easily programmed
 have an easily understood programming language
which is primarily concerned with logic and
switching operations.

9
PLC: manufacturers
Switzerland
SAIA, Weidmüller
Europe:
Siemens (60% market share) [Simatic],
ABB (includes Hartmann&Braun, Elsag-Bailey, SattControl,…)
[IndustrialIT],
Groupe Schneider [Télémécanique],
WAGO,
Phoenix Contact ...
World Market:
GE-Fanuc,
Honeywell,
Invensys (Foxboro)
Rockwell, (Allen-Bradley,…)
Emerson (Fisher Control, Rosemount, Westinghouse)
Hitachi, Toshiba, Fujitsu, Yokogawa

10
(1) Compact
Monolithic construction
Kinds of PLC
Monoprocessor
Fieldbus connection
Fixed casing
Fixed number of I/O (most of them binary)
No process computer capabilities
Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7
(2) Modular PLC
Modular construction (backplane)
One- or multiprocessor system
Fieldbus and LAN connection
3U or 6U rack, sometimes DIN-rail
Large variety of input/output boards
Connection to serial bus
Typical products: SIMATIC S5-115, Hitachi H-Serie, ABB AC110

(3) Soft-PLC
Windows NT or CE-based automation products
Direct use of CPU or co-processors

11
Small modular PLC

courtesy ABB
courtesy Backmann

mounted on DIN-rail, 24V supply


cheaper (€5000)
not water-proof,
no ventilator
extensible by a parallel bus (flat cable or rail)

12
Specific controller (railways)

data bus

three PLCs networked by a data bus.


special construction: no fans, large temperature range, vibrations
13
Compact or modular ?
field bus
€ extension

compact PLC
(fixed number of I/Os)

modular PLC (variable number of I/Os

Limit of local
I/O

# I/O modules

14
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

15
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%

Source: Control Engineering, Reed Research, 2002-09

16
Global players

Total sales in 2004: 7’000 Mio € Source: ARC Research, 2005-10

17
Comparison Criteria – Example
Brand Siemens Hitachi
Number of Points 1024 640
Memory 10 KB 16 KB
Programming Language • Ladder logic • Ladder Logic
• Instructions • Instructions
• Logic symbols • Logic symbols
• Basic
• Hand-terminal
• Hand-terminal
Programming Tools • Graphic on PC • Graphic on PC
Download no yes
Real estate per 250 I/O 2678 cm2 1000 cm2

Label surface 5.3 mm2 6 mm2


per line/point 7 characters 6 characters

Network 10 Mbit/s 19.2 kbit/s

Mounting DIN rail cabinet


18
General PLC architecture
RS 232 Ethernet

Real-Time flash serial port ethernet


CPU ROM
Clock EPROM controller controller
extension
bus
parallel bus buffers

fieldbus analog- digital- external


Digital
controller digital analog Digital Output I/Os
Input
converters converters

signal power signal


relays
conditioning amplifiers conditioning

field bus direct Inputs and Outputs

19
The signal chain within a PLC
y y(i) y(i)

time time time

analog filtering analog- 011011001111


digital- analog
variable & sampling digital analog amplifier variable
(e.g. 4..20mA) scaling converter converter e.g. -10V..10V

processing
1
binary transistor
binary
variable filtering sampling or
(e.g. 0..24V) relay variable
0001111

non-volatile
counter memory
y

time
20
Hardware

 Processor unit or central processing unit (CPU) is


the unit containing the microprocessor,
 Power supply unit is needed to convert the mains
a.c. voltage to the low d.c. voltage (5 V)
 Programming device is used to enter the required
program into the memory of the processor

21
Hardware

 Memory unit is where the program is stored


that is to be used for the control actions

22
NVRAM – Non Volatile RAM

23
Hardware

 Input and output sections are where the


processor receives information from external
devices and sends information to external
devices
 The inputs
 switches, other sensors such as photo-electric
cells, temperature sensors, or flow sensors, etc.
 The outputs
 motor starter coils, solenoid valves, etc.
 Input and output

24
Hardware

 Input and output devices can be classified


based on signals
 Discrete/digital
 analogue

 Devices giving discrete or digital signals are


ones where the signals are either off or on.
 switch is an example for this.

25
Hardware

 Digital devices can be considered to be essentially


discrete devices which give a sequence of on−off
signals.
 Rotary encoder is an example

 Analogue devices give signals whose size is


proportional to the size of the variable being
monitored.
 For example, a temperature sensor may give a voltage
proportional to the temperature.

26
Hardware

 Communications interface is used to receive and


transmit data on communication networks from or to
other remote PLCs .

 Used for,
 device verification,

 data acquisition,

 synchronization between user applications and

 connection management

27
Hardware

Basic communications model

28
Hardware

 CPU, Buses and Memory will be same as


any of the other microprocessor based
systems

 The difference is found in the Input and


output units

29
Hardware

 The input/output unit provides the interface between


the system and the outside world
 connections to be made through input/output channels to
input devices such as sensors and output devices such as
motors and solenoids.
 programs are entered from a program panel
 Every input and output has a unique address

30
Hardware

 Provide isolation and signal conditioning


functions so the sensors and actuators can be
directly connected to them without the need for
other circuitry.
 Electrical isolation from the external world is
usually by means of optoisolators
(optocouplers)

31
Hardware

Optoisolator

32
Hardware
 The digital signal that is generally compatible with the
microprocessor in the PLC is 5 V d.c.
 Signal Conditioning:
 However, signal conditioning in the input channel, with
isolation, enables a wide range of input signals to be
supplied to it
 A range of inputs might be available with a larger PLC,
 e.g. 5 V, 24 V, 110 V and 240 V digital/discrete, i.e.
on−off, signals.
 A small PLC is likely to have just one form of input,
 e.g. 24 V.

33
Hardware

Input levels
34
Output
 The output from the input/output unit will be
digital with a level of 5 V.
 After signal conditioning with relays, transistors
or triacs, the output from the output channel
might be
 24 V, 100 mA switching signal,
 d.c. voltage of 110 V, 1 A or
 240 V, 1 A a.c., or
 240 V, 2 A a.c., from a triac output channel (Figure
1.10).
 With a small PLC, all the outputs might be of one
type,
 e.g. 240 V a.c., 1 A.
35
Output

36
PLC Systems

 There are two common types of


mechanical design for PLC systems;
 A single box, and
 the modular/rack types.

37
Single Box

 The single box type (or, as sometimes termed,


brick) is commonly used for
 small programmable controllers and
 is supplied as an integral compact package complete
with power supply, processor, memory, and
input/output units.

 Typically such a PLC might have


 6, 8, 12 or 24 inputs and
 4, 8 or 16 outputs and
 a memory which can store some 300 to 1000
instructions.
38
Modular/rack types

 Systems with larger numbers of inputs and


outputs are likely to be modular and designed
to fit in racks.

 The modular type consists of separate


modules for power supply, processor, etc.,
which are often mounted on rails within a
metal cabinet.

39
Modular/rack types

 The rack type can be used for all sizes of


programmable controllers and has the various
functional units packaged in individual
modules which can be plugged into sockets in
a base rack.

 The mix of modules required for a particular


purpose is decided by the user and the
appropriate ones then plugged into the rack.

40
Programming PLC

 Programming PLCs
 Programming devices can be
 a hand-held device,
 a desktop console or
 a computer.

41
Siemens - SIMATIC STEP 7

 Fully complies with the international standard


IEC 61131-3 for PLC programming languages.
 With STEP 7, programmers can select between
different programming languages.
 ladder diagram (LAD) and
 function block diagram (FBD),
 Instruction List (STL) programming language
 a Sequential Function Chart (SFC) called
 SIMATIC S7-Graph which provides an efficient way to
describe sequential control systems graphically.
42
Siemens - SIMATIC STEP 7
 Features of the whole engineering system
include,
 system diagnostic capabilities,
 process diagnostic tools,
 PLC simulation,
 remote maintenance, and
 plant documentation.
 S7-PLCSIM is an optional package for STEP 7
that allows,
 simulation of a SIMATIC S7 control platform and
testing of a user program on a PC, enabling testing
and refining prior to physical hardware installation.
43

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