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Programmable Logic Controllers (PLC) : Industrial Automation Unit 3

The document provides an overview of programmable logic controllers (PLCs) including: 1. It introduces PLCs, their architecture, and definitions of discrete state process control. 2. PLCs can range in size and complexity from small modular devices to large rack-mounted systems and are designed for industrial control applications. 3. The document outlines PLC architecture including power supplies, central processing units (CPUs), input and output modules, and programming devices. It describes the purpose and functions of these core PLC components.

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Dhananjay Yelwande
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79 views14 pages

Programmable Logic Controllers (PLC) : Industrial Automation Unit 3

The document provides an overview of programmable logic controllers (PLCs) including: 1. It introduces PLCs, their architecture, and definitions of discrete state process control. 2. PLCs can range in size and complexity from small modular devices to large rack-mounted systems and are designed for industrial control applications. 3. The document outlines PLC architecture including power supplies, central processing units (CPUs), input and output modules, and programming devices. It describes the purpose and functions of these core PLC components.

Uploaded by

Dhananjay Yelwande
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Industrial Automation

Unit 3

Programmable Logic
Controllers (PLC)
Syllabus
• Introduction, architecture, definition of discrete state process control
• PLC Vs PC, PLC Vs DCS
• relay diagram, ladder diagram, ladder diagram examples, relay
sequencers
• timers/counters, high speed counter, PTO, PWM and PID blocks in PLC
• PLC design, study of at least one industrial PLC. PLC programming
methods as per IEC 61131
• PLC applications for batch process using SFC
• PLC interface to SCADA/DCS using communication links (RS232, RS485)

2
PLC
▪ A programmable logic controller (PLC) or programmable controller is an
industrial computer that has been ruggedized and adapted for the control of manufacturing
processes, such as assembly lines, machines, robotic devices, or any activity that requires high
reliability, ease of programming, and process fault diagnosis. Dick Morley is considered as the
father of PLC as he had invented the first PLC, the Modicon 084, for General Motors in 1968.
▪ 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 modular devices with thousands of I/O, and
which are often networked to other PLC and SCADA systems.
▪ They can be designed for many arrangements of digital and analog I/O, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to
control machine operation are typically stored in battery-backed-up or non-volatile memory.
▪ PLCs were first developed in the automobile manufacturing industry to provide flexible,
rugged and easily programmable controllers to replace hard-wired relay logic systems. Since
then, they have been widely adopted as high-reliability automation controllers suitable for
harsh environments.
▪ A PLC is an example of a hard real-time system since output results must be produced in
response to input conditions within a limited time, otherwise unintended operation will result.
3
PLC Architecture
PLC system contains of the following
parts
• Power supply
• CPU
• Input modules
• Output modules
• Programming Device

Power Supply :

This module supplies power to the CPU, input and output modules. It can be built
into the PLC or be an external unit. Common voltage levels required by the PLC (with
and without the power supply) are 44
24Vdc, 110Vac, 220Vac.
CPU (Central Processing Unit): I/O MODULES:
• The I/O interface section of a PLC connects it to
This module is considered as the brain of the external field devices.
PLC system and where • The main purpose of the I/O interface is to
ladder logic is stored and processed. condition the various signals received from or
• The memory contains the data and the sent to the external input and output devices
ladder program. • Inputs to, and outputs from, a PLC are necessary
• It contains an “Executive” program that to monitor and control a process. Both inputs and
tells the PLC how to: outputs can be categorized into two basic types:
• Execute the control Instructions logical or continuous.
• User’s Program
• Communicate with other devices Consider the example of a light bulb:
• Other PLCs, Programming devices, I/O If it can only be turned on or off, it is logical control. If
devices, etc. the light can be dimmed to different levels, it is
• Perform Housekeeping activities continuous. Continuous values seem more intuitive,
• Diagnostics, etc but logical values are preferred because they allow
• This program is stored in “nonvolatile” more certainty, and simplify control. As a result most
memory controls applications (and PLCs) use logical inputs and
• Meaning that the program will not be lost outputs for most applications.
if power is removed. 5
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