Programmable Logic Controller

INTRODUCTION :-
PLC is a digitally operating electronic apparatus which uses a
programmable (through dedicated language such as Relay Ladder Programming) 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 modules, various types of machines and processes.
he programmable controllers (PC) have developed as the heart of the
automation of the industries. he PCs offer a number of advantages over the
conventional relay control logic in many aspects li!e reliability, repeatability,
programmability, compact design etc. "mall controllers play an important role in the
automation where such controllers are implemented in huge and complicated
processes and plants. #n such situations the communication among the PCs is of vital
importance along with other aspects.
1
Programmable Logic Controller
TYPICAL SPECIFICATIONS OF THE PROJECT :-
$. %ain module based around &'($ microcontroller.
). $* digital #nputs and digital outputs with proper isolation and signal conditioning.
(. wenty+five he, !eyboard and -+segment display interface.
.. Closed loop P# controller for /C motor of )' 0P.
HARDWARE DESIGN :-
he general bloc! diagram of the system is shown in fig$. he system
is divided in following different cards1 $. &'($ CP2 card ). /isplay and 3eyboard
card (./igital input card ../igital output Card 4.Closed Loop P# Controller which
includes 5/C and /5C. hese cards are fitted on the bac! plane through 6*+pin
72R8 connector. hus it is completely modular and open ender for future e,pansion.
1. 8031 CPU CARD
#ts general bloc! diagram is shown in fig.
1.1 SELECTION OF PROCESSOR
he 7PR8% requirement for monitor program is less than .3 bytes but
additional .3 bytes of R8% memory space are given for future e,pansion of the
system. 9o. of digital inputs and outputs is $*. his has caused to select #ntel &'($
microcontroller as the CP2.
1.2 CONFIGURATION OF THE CARD
he #ntel &'($ microcontroller is interfaced to two 7PR8%s (total &3
bytes), a "R5% *$$* ()3 bytes), !eyboard and display controller &)-6 two
2
Programmable Logic Controller
programmable peripheral interface chips &)44 alongwith necessary Reset, Cloc!, and
Chip "election logic circuit.
2. DISPLAY AND KEYBOARD CARD
#ts bloc! diagram is shown in fig.).) . :ive !eys he, !eyboard a
common cathode -+segment displays are interfaced to corresponding control signals
of &)-6 from 72R8 connector.
3. DIGITAL INPUT CARD
#ts bloc! diagram is shown in fig.). /igital inputs are sensed through
limit switches and carried on the card through P2 ).4 to opto isolators %C)7. #ts
output is connected to port pins of &)44 via 6*+pin 72R8 connector. otal no. of
digital inputs are $*.
4. DIGITAL OUTPUT CARD
#ts bloc! diagram is shown in fig.).he digital outputs are ta!en from
&)44 ports. hese are used to ma!e on and off the relevant $' ;5 solenoid valve
through proper signal conditioning circuit. hese outputs are also used to change the
armature voltage of ). ;/C motor (Lens rotation motor) in the step of ). ; and $4 ;
through proper signal conditioning. otal no. of digital outputs are $*.
3
Programmable Logic Controller
CLOSED LOOP PI CONTROLLER CARD :-
#ts bloc! diagram is shown in fig.). Characteristics of the /C motor are shown in
fig.(.
Power developed by motor < a=)=P#=9 watt ($)
where, a <5rmature torque in 9m.
9 < %otor speed in rps.
P# < (.$.
:rom this it is clear that the motor rotates at constant torque till rated speed and it
enters in the constant power mode above rated speed.
he bac! 7%: 7b is given by,
7b < ; > la=Ra ())
and also 9 < 3= (7b?field flu,) (()
herefore speed of motor is directly proportional to @ac! 7%: and inversely
proportional to :ield flu,.
"peed of the /C motor can be sensed by different methods such as.
acho meter "troboscopic method, @ac! 7%: sensing method etc. @ac! 7%: sensing
method is suitable in noisy industrial environment and therefore it is selected to sense
the speed of /C motor.
;, #a, Ra are sensed and given through proper signal conditioning
circuit as input to the 5/C '&'& (& channel successive appro,imation 5/C).
8verload current is also sensed through proper signal conditioning and given as input
to 5/C. Control signals of 5/C. Control signals of 5/C are connected to port $ of
4
Programmable Logic Controller
&'($ and controlled through software. he /5C input is connected to the port of
&)44 and its output is connected to 5/C input through P# controller circuit.
SELECTION OF CONTROLLER :-
P# controller has following properties 1 $) #t contains properties of P
and # elements. )) #t can be used to compensate one time constant of the system. () #t
has the sluggish response. /ue to motor inertia the sluggish operation is desired to
control the speed of motor. 0ere P# controller is selected as against P,P#,P#/.
OPERATING ODES :-
he system wor!s in si, different modes of the operation. hese modes
can be selected through the !eyboard . hese modes are 1
i) Configure mode,
ii) Report mode,
iii) Programming mode,
iv) 7,ecution mode,
v) /evelopment mode and
vi) "elf test mode.
hese modes are e,plained in the following paragraphs. #n the
Configure mode, the set points for the analog inputs, the loo!+up tables are loaded
into the memory. 5lso the initialiAation of the 0igh "peed #?8 section is done in this
mode. #n the Report mode, the recorded data is sent to the computer or the %8/7%
5
Programmable Logic Controller
over the serial communication lin!. Programming mode enables the user to load the
program (set of the instructions) into the program memory of the PC. his mode is
further e,plained in the following section. #n the 7,ecution mode , programs loaded
in the above mode are e,ecuted. :or the e,ecution program number and the starting
step number is required.
he /evelopment mode is useful for moving a bloc! of memory from
one place to another communicating with a computer(down+ loading and up+loading
of the program or the data) and modifying the memory contents.
he "elf+test mode carries out the #?8 chec!ing for any malfunctioning
of the channels or discontinuity of the channel and indicates the fault on the display.
AFTER THE POWER ON :-
5fter the power on of the system (or after the power+on reset) the
following procedures are carried out1
$ CP2 test,
). %emory test,
(. Register initialiAation,
.. Peripheral /evice #nitialiAation,
4. he #?8 #nitialiAation
#f all the tests and initialiAations are successful, then the system enters
into the Bmode selectionB phase in which it accepts only the mode selection !eys,
otherwise, it displays the error message and halts. /uring the mode selection, it waits
6
Programmable Logic Controller
for a mode selection !ey to be pressed. hese !eys are C89:#C, R7P8R, PR8C.
7D7C, /7;P and 7" !eys. 5fter selecting the mode, the mode name is displayed
on the display of the program terminal and then further functions within that mode
can be selected through the B9DB (9e,t) and BCRB (Carriage Return) !eys. his will
be clear from the following e,ample.
Power+on /isplay 1 %#9# PLC
3ey pressed 1 /isplay
CR 1 C7 %8/7
C89:#C 1 C89:#C2R7
9D 1 L/ "7P
9D 1 #9# 0"8
7"C 1 C7 %8/7
( L/ "7P 1 Loads the set points for the analog input channels
L/@L" 1 Loads the loo!+up tables etc.)
hus the modes and the subfunctions within the modes are displayed on
the L7/ displays. 5nd to select the subfunction , CR !ey is used.
7
Programmable Logic Controller
HOW TO PROGRA !
he PC is programmed using the statement list programming. he
instructions for the PC cover the arithmetic, Logic, transfer and #?8 type of the
operations. #n all there are fifty instructions. he direct logical 59/ing?8ring
operations of the digital inputs is also provided which simplifies the programming for
the ladders. /elay instructions gives the time delays in micro+ or milli+seconds which
are useful in the ladder solutions. hese instructions are placed into the program
memory at certain step numbers. Ehile loading the instructions, the display shows the
step number (first two digits). hen the instruction and its operand ( if necessary). he
program mode shows the previously loaded instructions and also enables to change
these instructions. 5n instruction to be loaded is selected by an instruction !ey
(e.g.R/, ER, L/, " etc.) and then the actual instruction is obtained by pressing the
F9DG !ey till the display shows the desired instruction, the instruction field, e.g. he
actual instructions for BR/B are R/5# (read analog input) and R//# (read the digital
input. he desired instruction is confirmed by pressing the BCRB !ey. o cancel the
selection B7"CB !ey is used.
8
Programmable Logic Controller
-: APPLICATION OF PLC :-
LS C"#$%"&&'%
:ig. "hows how the control action is achieved #?P devices (e.g.
mechanical switches, pro,imity sensors) and 8?P devices (e.g. motors, solenoids) to
be controlled are connected to the L"% #$' interface card. 5 user has to write a
program to operate the #?P and 8?P devices. he L%" Controller continuously
monitors the status of the #?P and control the 8?PGs according to user program.
he programmable motion controller is an intelligent module designed
to control position, velocity, acceleration and Her! of high speed servomotors. he
transition from analog electric to digital is an swing in modern industry and the digital
intelligent controllers are having many advantages li!e.
$) Peruse control is possible.
)) 5daptive control techniques can be used to compensate problems li!e noise, temp,
drift.
() :eatures previously implemented using mechanisms, can how be implemented in
electronics such as
7lectronic gearing
#nde,ing
Cut+to+ length application.
Programmability leads to fle,ibility.
Report generation and built in diagnostics are possible.
9
Programmable Logic Controller
L"% servo motion controller card is used to control /C "ervo motor.
#t is build up of digital signal processor (/"P). hese processor are very fast which
can perform tens of millions of operation per second. L"% "ervo motion controller is
used to control /C "ervo motors. #t is a Pc based system, where the Pentium
processor is the host computer. he actual complications (P#/ control, velocity
profile) is done by a digital signal processor (/"P) and application specific integrated
circuity (5"#C).
#n addition to very sophisticated control capabilities, it can also has
e,tensive communication capabilities. "o in turn it can provide and interface between
controllers to control several motors of at high speeds for simultaneous movement of
multiple areas.
LSM Servo Cards
he L"% "ervo Cards is the heart of the system, that can control four
/C "ervo motors simultaneously. #t provides closed loop digital servo control bar
large variety of servomotors. #t uses optical incremental encoders feedbac! and a
/5C or PE% compatible 8?P drive.
5ccording to the reference command given by the user it generates the
reference voltage (/5C ;oltage). Reference voltage will be directly proportional to
the defined velocity. hese voltage can range between I?+ $'v. #t also generates drive
enable voltage to enable the desired drive.
4 Quadra! DC Servo Dr"ve.
he reference voltage and drive enable voltage of L"% "ervo Card are
fed to the /C "ervo drive through the L"% servo interface card. /c "ervo drive
10
Programmable Logic Controller
amplifies the reference voltage I?+$'v to I?+ ).v /C "ervo drive gets the velocity
feedbac! from the tachogenerator and compares the defined velocity to maintain the
desirable velocity.
DC Servo Mo!or#$
he amplified voltage from the drive is fed to the /C servomotor
through the L"% motor. acho generator interface card motor can be coupled to any
mechanical device.
E%oder #$
8ptical incremental encoder gives the position f?@ to the L"% "ervo
Card. he signal from the encoder tell the controller whether the motion has properly
occurred.
Ta%&o'eera!or #$
achogenerator generates the velocity feedbac! to the /C "ervo drive.
hese gives out the voltage proportional to the speed of the dc servo motors shaft.
11
Programmable Logic Controller
CONCLUSION :-
he desired PLC is useful in areas li!e special purpose machines lab
instruments, process control and motion?position control systems. he powerful
instruction set enables the user to program the PC in many different configurations
and control methods to suit various applications. he ability to communicate with
other controllers or the main computer facilitates its roll in the large automation
systems using discrete, small siAe controllers. he effort has been made to !eep the
product cost to a minimum. he product is based on a compact, modular and
e,pandable structure, with the facility of modifying the systemBs programs to enhance
its capability and the number of the #?8s to three to four times its current capacity.
12
Programmable Logic Controller
REFERENCE :-
$. Robert Eilhem Hr., Programmable Controller 0andboo!, 0ayoen @oo! Company,
$6&..
). /ouglas Considine, Process #nstruments and Control 0andboo!, (
rd
edition, %c+
Craw0ill.
(. $*+bit 7mbedded Controller 0andboo!, #ntel Corp., 2"5.
.. 7mbedded Control 5pplications 0andboo!, #ntel Corp., 2"5.
13