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Programmable Logic Controller (PLC)
Programmable Logic Controller (PLC)
Controller (PLC)
Prof. Vinay J. Patel
Professor, Mechanical Engineering Department
Birla Vishvakarma Mahavidyalaya (Engineering College)
Vallabh Vidyanagar – 388120. Gujarat, INDIA
Programmable Logic Controller (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
Introduction
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.
• Less wiring.
• Wiring between devices and relay contacts are done in the PLC
program.
• Easier and faster to make changes.
• Trouble shooting aids make programming easier and reduce
downtime.
• Reliable components make these likely to operate for years
before failure.
Advantages
EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
• Manufacturing/Machining
• Food/Beverages
• Metal industries
• Power industries
• Mining
• Petrochemical industries
• Process industries
• Many more…
Applications
MOTOR
A
FS FLOAT SWITCH
SOLENOIDS B
Typical application
SOLENOID
C
TIMER
POWER
SUPPLY
I M O M
N O U O
P D T D
U U PROCESSOR P U
T L U L
Major components
From E T E To
SENSORS OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE
Power supply
• Provides the voltage needed to run the primary PLC components
I/O MODULES
• Provides signal conversion and isolation between the internal logic- level
signals inside the PLC and the field’s high level signal.
PROCESSOR
Major components
I/O Module
• The I/O interface section of a PLC connects it to external field devices.
• The main purpose of the I/O interface is to condition the various signals
received from or sent to the external input and output devices.
• Input modules converts signals from discrete or analog input devices to
logic levels acceptable to PLC’s processor.
Major components
I/O Module
DC INPUT MODULE
IS NEEDED TO:
USE TO Prevent voltage
DROP THE transients from
VOLTAGE damaging the
TO LOGIC processor.
LEVEL Helps reduce the
effects of electrical
noise
Major components
Current Buffer,
FROM Limiting Filter,
OPTO- TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits
I/O Module
AC INPUT MODULE
IS NEEDED TO:
CONVERTS THE AC Prevent voltage
INPUT TO DC AND transients from
DROPS THE VOLTAGE damaging the
TO LOGIC LEVEL processor.
Helps reduce the
effects of electrical
noise
Major components
Rectifier, Buffer,
FROM Resistor Filter,
OPTO- TO
INPUT Network ISOLATOR Hysteresis
PROCESSOR
DEVICE Circuits
I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise
Major components
Amplifier
FROM RELAY
TTL OPTO- TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE
• Memory
The logic or application program is stored
in memory. As the PLC executes logic, it
may also read and store values to memory.
The values may be referenced by the
application program.
Commutatitve
𝑋+𝑌 =𝑌+𝑋
𝑋𝑌 = 𝑌𝑋
Associative
𝑋 + 𝑌 + 𝑍 = 𝑋 + 𝑌 + 𝑍 = 𝑋 + (𝑌 + 𝑍)
𝑋𝑌𝑍 = 𝑋𝑌 𝑍 = 𝑋(𝑌𝑍)
Distributive
Boolean Algebra
𝑋 𝑌 + 𝑍 = 𝑋𝑌 + 𝑋𝑍
De Morgan’s
𝑋 + 𝑌 = 𝑋ത 𝑌ത
𝑋𝑌 = 𝑋ത + 𝑌ത
AND gate
Solenoid
A B
Output
Input 1 Input 2
Logic functions
AND Gate
OR gate Solenoid
B
Output
Input 1
Logic functions
Input 2
OR Gate
NOR gate
Solenoid
A B
Output
Input 1 Input 2
Logic functions
NOR Gate
B
Output
Input 1
Logic functions
Input 2
NAND Gate
B
Output
Input 1 Input 2
Logic functions
Input 1 Input 2
XOR Gate
The term internal relay, auxiliary relay or marker is used for what can be
considered as an internal relay in the PLC.
These behave like relays with their associated contacts, but in reality are not
actual relay but simulations by the software of the PLC.
Some have battery back-up so that they can be used in circuits to ensure a
safe shut-sown of plant in the event of a power failure.
Internal relays can be very useful aids in the implementation of switching
sequences.
Internal Relays
Internal relays are often used when there are programs with multiple input
conditions.
IR 1
internal relay IR 2.
The contacts of the two relays are then
put in an OR situation to control the IR 2
output. END
IR Input
Output 3
IR Input
END
There are often control situations where sequences of outputs are required.
Figure in next slide shows a pneumatic system with double-solenoid valves
controlling two double-acting cylinders A and B if limit seiches a-, a+, b-, b+
are used to detect the limits of the piston rod movements in the cylinders
and the cylinder activation sequence A+, B+, A-, B- is required.
Sequencing
A+
Start b-
B+
A B
a- a+ b- b+ a+
A-
b+
A+ A- B+ B- B-
Sequencing
a-
END
Other treat the counter as an intermediate block in a rung from which signals emanate
when the count is attained, e.g. Siemens.
circuit. RST
RST
In 1
In 1
When there is pulse input to In 1, the Counter
CU
counter is reset. CU In 2
In 2 Out 1
When there is an input to In 2, the Out 1
counter starts counting. If the counter Counter
Counter
is set for, say, 10 pulses, then when 10
pulse inputs have been received at In 2, (a) (b)
Timer
the counter’s contacts will close and CTU Q
Out 1
there will be an output from Out 1. In 2
CU