WINTER INDUSTRIAL TRAINING REPORT

On

PROGRAMMABLE LOGIC CONTROLLER &

AUTOMATION SYSTEM

Submitted to Guru Gobind Singh Indraprastha University, Delhi (India)

in partial fulfillment of the requirement for the award of the degree of

B. TECH
in

ELECTRONICS AND COMMUNICATIONS

Submitted By

DAKSH TANEJA
Roll. No. 41396302816

DEPTT. OF ELECTRONICS AND COMMUNICATIONS

MAHARAJA SURAJMAL INSTITUTE OF TECHNOLOGY,
NEW DELHI-110058
JANUARY 2019

1
 ACKNOWLEDGEMENT

A research work owes its success from commencement to completion, to the people in
love with researchers at various stages. Let me in this page express my gratitude to all those
who helped us in various stage of this study. First, I would like to express my sincere
gratitude indebtedness to Mr. DILEEP KUMAR DIVEDI(HOD, Department of Electronics
and Communication), Maharaja Surajmal Institute of Technology, New Delhi) for allowing
me to undergo the WINTER training of 14 days at ADVANCE HYDRAU-TECH PVT LTD.
I am grateful to our guide Mr.PANKAJ GUPTA for the help provided in completion
of the project, which was assigned to me. Without his friendly help and guidance, it was
difficult to develop this project.
I am also thankful to Mr. SANJEEV KUMAR for his true help, inspiration and for
helping me to preparation of the final report and presentation.

Submitted By:
DAKSH TANEJA

2
 CANDIDATE’S DECLARATION

I, DAKSH TANEJA Roll No 41396302816 B.Tech (Semester- 6th ) of the Maharaja

Surajmal Institute of Technology, New Delhi hereby declare that the Internship Report
entitled “PROGRAMMABLE LOGIC CONTROLLER & AUTOMATION SYSTEM” is an original work
and data provided in the study is authentic to the best of my knowledge. This report has not
been submitted to any other Institute for the award of any other degree.

DAKSH TANEJA
(41396302816)

Place: ADVANCE HYDRAU-TECH PVT LTD

Date: 03/04/19

3
 COMPANY PROFILE
Advance Hydrau components Pvt. Ltd. is an ISO 9001: 2008 certified company : A leading
distributor & importer of fasteners. We provide advanced fastener solutions to our valued
customers all across the globe. Our product range includes best quality rivets, nut inserts ,
Self drilling screws, self tapping screws, thread forming screws, chipboard screws, drywall
screws, bolts, clinching studs and nuts, riveting tools, Pop Rivets Manufacturers, Clinching
Fasteners Manufacturers, Seld Drilling Screws, Rivet Nut Manufacturers, Blind Rivet
Manufacturers, Flange Nut Manufacturers insert tools, pneumatic tools and all types of
washers. With more than 15 years of Research and Development, Strong quality
Management, fast and comprehensive service we have achieved our Motto of Customer
satisfaction. We believe in establishing strong and long term bond with our clients and
providing premium quality products at competitive prices is our goal.
Advance Hydrau Tech Pvt. Ltd is a forerunner in designing and manufacturing state-of-the-
art and efficient waste management solutions for scraps ranging from scrap metals (ferrous
and non-ferrous) to plastics to paper scrap. Our solutions include both manual and fully
automatic PLC controlled hydraulic scrap baling press machines.
Our range of machines includes metal scrap balers, paper and plastic scrap baling press, metal
shredders, shearing machines, box shear baler and briquetting machines. We have installed
over 8000 scrap processing machines in over 70 countries. Apart from manufacturing and
exporting highly advanced scrap processing systems, the company has also successfully
implemented many turnkey projects in various countries relating to metal melting and
forming. At Advance Hydrau Tech, we strive to be relevant with the current times. As the
time demands, all our machines and processes are labour efficient, production efficient and
power efficient which give higher productions with minimum labour.
Advance Hydrau Tech has won the prestigious STAR Award for quality in Geneva. We
never compromise on quality and our quality products makes us India’s largest manufacturer
of scrap processing machines. The company has been awarded India’s Top 100 SME award
and recognized as India’s Small Giants by India SME Forum. Advance Hydrau-Tech Pvt Ltd.
is an ISO 9001-2015 Certified Company and we feel proud to be associated as a
distinguished member of MRAI.

4
 CONTENTS

1. Introduction to Automation…………………………………………………….….7

1.1 Automation Impacts…………………………………………………………..8

1.2 Advantages of Automation

1.3 Disadvantages of Automation

1.4 Applications

1.5 Limitations to Automation

1.6

2. Introduction
2.1 Programmable Logic Controller (PLCs)…………………………….………….7

2.2 What is PLC…………………………………………………………………….8

2.3 History of PLCs…………………………………………………………………10

3.Functional Descriptions………………………………………………………………....11

3.1 Input System………………………………………….11

3.2 Outputs………………………………………………………………………….13

3.3 Control Process or unit………………………………………………………….14

3.4 Memory unit…………………………………………………………………….15

3.5 Programmable unit………………………………………………………………15

4. General PLCs Architecture …………………………………………………………….16

4.1 Scan Cycle of PLCs…………………………………………………………......17

5. Type of PLCs…………………………………………………………………………….18

5.1 Based on size…………………………………………………………………….18

5.2 Classification according to its output working………………………………….19

6. Sensor……………………………………………………………………………………20

6.1 Need of Senor……………………………………………………………………20

6.2 Actuator………………………………………………………………………….20

6.3 Difference between Actuator and Sensor………………………………………..20

7. Data Types………………………………………………………………………………21
5
8. Memory Types…………………………………………………………………………..22

9.Concept of Relay Functioning………………………………………………………….23

9.1 What is relay? …………………………………………………………………...23

9.2 Why is relay used? ………………………………………………………………23

9.3 Relay Logic…………………………………………………………

10. Sinking and Sourcing……………………………………………………………..

10.1 Output Sinking and Sourcing device………………………………………

10.2 Input Sinking and Sourcing device……………………………………….

10.3 Latching………………………………………………………

6
 INTRODUCTION TO AUTOMATION
Automation is the use of control systems such as computers to control industrial machinery
and process, reducing the need for human intervention. In the scope of industrialization,
automation
is a step beyond mechanization. Whereas mechanization provided human operators with
machinery to assist them with physical requirements of work, automation greatly reduces the
need for human sensory and mental requirements as well. Processes and systems can also be
automated.

1.1 Automation Impacts:

1. It increases productivity and reduce cost.
2. It gives emphasis on flexibility and convertibility of manufacturing process. Hence gives
manufacturers the ability to easily switch from manufacturing products.
3. Automation is now often applied primarily to increase quality in the manufacturing
process, where automation can increase quality substantially.
4. Increase the consistency of output.
5. Replacing humans in tasks done in dangerous environments.

1.2 Advantages of Automation:

1. Replacing human operators in tasks that involve hard physical or monotonous work.
2. Performing tasks that are beyond human capabilities of size, weight, endurance etc.
3. Economy improvement: Automation may improve in economy of enterprises, society or
most of humanity.

1.3 Disadvantages of Automation:

1. Technology limits: Current technology is unable to automate all the desired tasks.
2. Unpredictable development costs: The research and development cost of automating a
process may exceed the cost saved by the automation itself.
3. High initial cost: The automation of a new product or plant requires a huge initial
investment in comparison with the unit cost of the product.
1.4 Applications

1.Automated video surveillance:

Automated video surveillance monitors people and vehicles in real time within a busy
environment. Existing automated surveillance systems are based on the environment they are
primarily designed to observe, i.e., indoor, outdoor or airborne, the amount of sensors that the
automated system can handle and the mobility of sensor, i.e., stationary camera vs. mobile
camera. The purpose of a surveillance system is to record properties and trajectories of
objects in a given area, generate warnings or notify designated authority in case of occurrence
of particular events.

7
2. Automated manufacturing:
Automated manufacturing refers to the application of automation to produce things in the
factory way. Most of the advantages of the automation technology has its influence in the
manufacture processes. The main advantages of automated manufacturing are higher
consistency and quality, reduced lead times, simplified production, reduced handling,
improved work flow, and increased worker morale when a good implementation of the
automation is made.

3. Home automation:
Home automation designates an emerging practice of increased automation of household
appliances and features in residential dwellings, particularly through electronic means that
allow for things impracticable, overly expensive or simply not possible recent past decades.

4. Industrial automation:
Industrial automation deals with the optimization of energy efficient drive systems by precise
measurement and control technologies. Nowadays energy efficiency in industrial processes
are becoming more and more relevant. Semiconductor companies like Infineon Technologies
are
offering 8-bit microcontroller applications for example found in motor controls, general
purpose pumps, fans, and e-bikes to reduce energy consumption and thus increase efficiency.

1.5 Limitations to automation:

Current technology is unable to automate all the desired tasks.

As a process becomes increasingly automated, there is less and less labour to be saved or
quality improvement to be gained. This is an example of both diminishing returns and the
logistic
function.

Similar to the above, as more and more processes become automated, there are fewer
remaining non-automated processes. This is an example of exhaustion of opportunities.

8
 2. Introduction:
2.1 Programmable Logic Controllers (PLCs):
A Programmable Logic Controller (PLC) is a specialized computer like device like device
used to replace banks of electromagnetic relays in industrial process control. The PLC is
also knows as a programmable of controller (PC). The title “PLC” for programmable
controller could be confused in common usage with “PC” used to mean personal computer.
To avoid this confusion we shall refer to the programmable controller as a programmable
logic controller or PLC.

You can think of the programmable logic controller as a heavy-duty computer system
designed for machine control. Like a general-purpose computer, the plc is based on digital
logic and can be field-programmed .The programming language is a bit different because the
purpose of the PLC is to control machine. The PLC is used to time and sequence function
that might be required in to control machines. The PLC is used to time and sequence function
that might be required in assembly lines, robots, and chemical processing. It is designed to
deal with the harsh condition of the industrial environment. Some of the physical
environment problem could include vibration and shock, dirt, and vapors, and temperature
extremes. Some input device includes limit and pressure switches, temperature and optical
sensor, and analog-to-digital converts (ADCs). Some output device values, motors and
cylinders, and Digital-to-Analog convertors (DAC).

Before the advent of solid-state logic circuit systems were designed and build exclusive ly
around electronic mechanical relays. Relays are far from obsolete in modern design, but
have been replaced in many of their former roles as logics-level control device, relegated
most often to those applications demanding high current and or high voltage switching.

System and processes requiring “on/off” control abound in modern commerce and
industry, but such control system are rarely built from either electro mechanical relays or
discrete logics gates. Instead, digital computers fill the need, which may be programmed
to do a variety of logic functions.

In the late 1960’s an American company named Bedford Associate released a computing
device they called the MODICON Digital Controller, and later became the name of a
company division devoted to the design, manufacture, and sale of these special-purpose
control computes. Other engineering firms developed their own version of this device, and
it eventually came to be known in non-proprietary terms as a PLC, or Programmable Logic
Controller. The purpose of a PLC was to directly replace electro mechanical relays as logic
elements, substituting instead a solid–state digital computer with a stored program, able to
emulate the interconnection of many relays to perform certain logical task.

9
A PLC has many “input” terminals, through which it interprets “high” and “low” logical
states from sensor and switches. It also has many output terminals, through which it output
“high” and “low” signal to power light, solenoids, contactors, small motors, and other
devices leading themselves to on/off control. In an effort to make PLC easy to program, their
programming language was designed to resemble ladder logic diagrams. Thus, an industrial
electrician engineer accustomed to reading ladder logic schematics would feel comfortable
programming a PLC to perform the same control functions.

PLC are industrial computers, and as such their input and output signals are typically 120
volts AC, just like the electro mechanical control relays they were designed to replace.
Although some PLC has the ability to input and output low-level DC voltage signal of
the magnitude used in logic gate circuits, this the exception and not the rule.

2.2 What is a PLC?

A Programmable Logic Controller (PLC) is an industrial computer control system that
continuously monitors the state of input device and makes decision based upon a
custom program to control the state of output devices.

Almost any production line, machine function, or process can be greatly enhances using this
type of control system. However, the biggest benefit in using a PLC is the ability to change and
replicate the operation or process while collecting and communication vital information.

10
Another advantage of PLC system is that it is modular. That is, you can mix and match the
type of Input and Output device to best suit your application

According to NEMA (National Electrical Manufacture Association)

”PLC is a digitally operated electronic system, designed specially for the use in industrial environment,
which use programmable memory for internal storage of user oriented instruction for implementing
specific function such as logic, sequencing, timing, counting & arithmetic to control, though digital &
analog input &output for various type of machines & processes.”

Both the PLC & its associated peripherals are designed so that they can be easily integrated
into an industrial control system & easily used in all intended functions.

Need for PLC


 
Hardwired panel were very time consuming to time and debug and change.
 
 The following requirement for computer controller to replace hardware panel.
Solid
 state not mechanical
East to modify input and output device
 Easy programmed and maintained by plant electrician
 Be able to function in an industrial environment

11
2.3 History of Programmable Logic Controller (PLCs):
1968: Design of PLCs developed for General Motors Corporation to eliminate
costly Scrapping or assembly line relays during model changeovers.

1969: First PLCs manufactured for automotive industry as electronic equivalent of relays.

1971: First application of PLCs outside the automotive industry.

1973: Introduction of “smart” PLCs for arithmetic operations, printer control move,
Matrix operations, CRT interface etc.

1974: Introduction of analog PID (Proportional, integral, derivative) control, which

made possible the accessing of thermocouples, pressure sensor etc.

1975: First use of PLCs in hierarchical configuration as part of an integrated

Manufacturing system.

1977: Introduction of very small PLCs based on microprocessor technology.

1978: PLCs gain wide acceptance, sales approach $ 80 million.

1979: Integration of plant operation through a PLC communication system.

1980: Introduction of intelligent input and output module to provide high speed,
accurate control in positioning applicants.

1981: Data highways enable user to interconnect many PLCs up to 15000 feet from Each
other. More 16-bit PLCs become available. Color graphic CRTs are available from
several suppliers.

1982: Larger PLCs with up to 8192 I/O become available.

1983: “Third party” peripherals, including graphic CRTs, operator’s interface, I/O networks,
panel displays, and documentation packages, become available from many sources.

12
3. Functional Description
A programmable controller manufacture by any company has several common function parts.
Figure illustrates a generic PLC architecture.

The diagram shows Power Supply, I/O central processor, memory and programming
and peripheral device subsection. Each is discussed below.

3.1 Input
Input define as real-world signals giving the controller real-time status of process variable.
These signals can be analog or digital, low or high frequency, maintained or momentary.
Typically they are presented to the programmable controller as a varying voltage current or
resistance value. Signal from thermocouples (TCs) and resistance temperature dectors
(RTDs) are common examples of analog signals. Some flow meter and strain gauge
provide variable frequency signals, while pushbuttons, limit switches, or even electro
mechanically relays contacts are familiar example of digital, contact closuer type signals.
One additional type of input signal, the register input, reflect the computer nature of the
programmable controller.

13
Inputs are device that supply a signal/data to a PLC. Typical examples of input are push
buttons, switches, and measurement devices. Basically, an input device tells the PLC,
“Hey, something’s happening out here you need to check this out to see how it affects the
control program.”

A discrete input also referred to as a digital input, is that is either in an ON or OFF condition.
Pushbuttons, toggle switch, limit switches, proximity switches, and contact cloures are
examples of discrete sensor which are connected to the PLC discrete input may be referred
to as logic 1 or logic high. In the OFF condition a discrete input may be referred to as logic 0
or a logic low.

An analog input is a continuous, variable signal. Typically analog inputs may vary from 0 to
20 milliamps, 4 to 20 milliamps, or 0 to 10 volts. In the following example, a level
transmitter monitors the level of liquid in a tank. Depending on the level transmitter, the
signal to the PLC can either increase or decrease as the level increases or decreases.

14
3.2 Output
There are three common categories of outputs: Discrete, Register, and Analog. Discrete
output can be pilot light, solenoid valves, or enunciator Windows (lamp box). Register
output can be drive panel meters or displays; analog outputs can drive signals to variable
speed drive or to I/P converters and thus to control values.

Outputs are device that await a signal/data from the PLC to perform their control function
light, horns, motors, and values are all good examples of output devices. These device stay
put, minding their own business until the PLC says, “You need to turn on now” or “you’d
better open up your value a little more, “etc.

A discrete output is an output that is either in an ON or OFF condition. Solenoids,

contactor coils, and lamps are examples of actuator device connected to discrete outputs.
Discrete outputs may also be referred to as digital outputs. In the following example, a
lamp can be turned on or off by the PLC output it is connected to.

An analog output is a continuous, variable signal. The output may be as simple as a 0-10
VDC level that drives an analog meter. Examples of analog meter output are speed, weight,
and temperature. The output signal may also be used on more complex application such as
a current-to-pneumatic transducer that controls an air-operated flow-control value.

13

15
The PLC program is executes as part of a repetitive process referred to as scan. A PLC scan
starts with the CPU reading the status of inputs. The application program is executed using
the status of the inputs. Once the program is completed, the CPU performs internal
diagnostics and communication tasks. The scan cycle ends by updating the outputs, and
then stars over. The cycle time depends on the size of the program, the number of I/Os, and
the amount of communication required.

3.3 Control Processor Unit (Real Time):

The central processor unit (CPU), or central control unit (CCU), perform the tasks necessary
to fulfill the PLC function. Amount these are scanning, I/O bus traffic control, program
execution device communication, special function or data handling execution
(enhancement), and self-diagnostics.

One common way of rating how a PLC perform these task is it scan time> Scan time is
roughly defined as the time it takes for the programmable controller to interrogate the input
device, execute the application program, and provide updated signals to the output devices.
Scan time can vary from 0.1 millisecond 1K (1024) word of logic to more than 50
millisecond per 1K of logic. Therefore, when selecting a programmable controller other
performance factor must be considered. The user should take into account the application as
well as the speed of the controller.

16
3.4 Memory unit:
The memory unit of the PLC serves several functions. It is the library where the application
program is store. It is also where the PLC’s executive is stored. An executive program
functions as the operating system of the PLC. It is the program that interprets, manages,
and executes the user’s application program. Finally, the memory unit is the part of the
programmable controller where process data from tables. Typically, an image of these data
tables. Typically, images of these data tables are used by the CPU and, when appropriate,
send to the output modules.

Memory can be volatile or non-volatile. Volatile memory is erased if power is removed.

Obviously this undesirable, and most units with volatile memory provide battery back up to
ensure that there will be no loss of power outage. Non-volatile memory does not change
state on loss of power and is used in cases in which extended power outages or long
transportation time to job site (after program entry) are anticipated.

The basic programmable controller memory element is the word. A word is collection of 4, 8,
16, or 32 bits that is used to transfer data about the programmable controller. As word length
increase more information can be stored in a memory location.

3.5 Programmer Units:

The programmer unit provides an interface between the PLC and the user during program
development, start-up, and troubleshooting. The instruction to be performed during each
scan are coded and inserted into memory with the programmer.

Programmers vary from small hand-held units. These units the size of a large calculator to
desktop standalone intelligent CRT-based units. These units come complete with
documentation, reproducing, I/O status, and on-line and off-line programming ability.
Many PLC manufactures now offer controller model that can use a personal computer as
the programming tool.

Under these circumstance, the manufacture will sell a program for the personal computer
that usually allows the computer that module installed in programmable controller.

Programming units are the liaison between what the PLC understands (words) and what the
engineer desired to occur during the control sequence. Some programmers have the ability to
store programs on other media, including cassette tapes and floppy disks. Another desirable
feature is automatic documentation of the existing program. This is accomplished by a
printer attached to the programmer. With off-line programming the user can write a control
program on the programming unit, then take unit to the PLC in the field and load the
memory with new program, all without removing the PLC. Selection of these feature
depends on user requirement and budget. On-line programming allows caution modification
of the program while the PLC is controlling the process or the machine.

17
3. General PLC Architecture:

PLC inputs must convert a variety of logic levels to the 5V dc logic level used on the data
bus. This can be done with circuit similar to those shown below. Basically the circuit
conditions the input to drive an up to coupler. This electrically isolates the external
electrical circuitry from the internal circuitry. Other circuit components are used to guard
against excess or reversed voltage polarity.

PLC output must convert the 5V dc logic levels on the PLC data bus to external voltage
levels. This can be done with circuits similar to those shown below. Basically the circuit
uses an opto coupler to switch external circuitry. This electrically isolated the external
electrical circuitry from the internal circuitry. Other circuit components are used to guard
against excess or reversed voltage polarity.

Advantage of PLC:

  Small size
  Faster response
  Wiring reduced up to 80%
  On-line changes
  Low Maintenance Cost
 Easy for Troubleshooting

Disadvantages of PLC:

  Too much work required in connecting wires

  Difficulty with change or replacement
  Requiring skilful work force finding error
 Fixed program application

16

18
 4.1 Scan Cycle of PLC

Reading the input: The S7-200 copies the state of the physical input to the process-
image input register.

Execution the control logic in the program: The S7-200 executes the instruction of
the program and stored the value in the various memory areas.

Processing any communication request: The S7-20 perform any task required
for communications.

Executing the control logic the program: The S7-200 ensures that the firmware,
the program memory, and any expansion module are working properly.

Writing to the outputs: The values stored in the process-image output register are written to
physical outputs.

19
 5. Types of PLC
Programming logic controller (PLCs) has several types: Based on the size of the module
and it can be classified according to is working.

5.1 Based on Size

 Micro PLC or Small PLC: It is the simplest PLC with the Power Supply module,
CPU, I/O few modules and communication ports in a single chassis. This PLC types
are usually limited to a few I/O discrete and can be expanded. There are various
micro PLCs on the market today. The vast majority offer analog I/O with just about
any micro PLC, or for that matter PLC in general, when the application required the
monitoring of various analog signals, a separate module is required for each signal.
Examples of this type are CP1H Omron, Siemens S7-200, and Fuji Electric SPB.
 Medium PLC or Mini: It is PLC which has CPU module, I/O or communication
ports are separately. Each module is connected by connector or backplane. It has the
capacity more than 2000 I/O. Example of this type are Omron CS1, Siemens S7-300.
 Large PLC or Rack: This kind of PLC is nearly equal to the medium one but it
has large I/O capacity and more able to be connected with the higher control
system. Examples of this type are CVM1 Omron Siemens S7-400.

Medium PLC Micro PLC

Large PLC

20
 5.2 Classified according to its Output working:

  Relay based: This type of PLC are used for general purpose application.
  Transistor based: This type of PLC are used for High speed application.
 SCR based: This type of plc are used for heavy load switching.

Different PLC Manufactures

  Siemens
  Fatek
  Delta
  Allen Bradley
  Mitsubishi
  Omron
  ABB
  Panasonic
  GE Fanuc
 LG

Criteria of Choosing PLC

  Cost
  No. of I/Os
  Memory Capacity
  Processing Speed of CPU
  CPU Capabilities
  No. of Timer, Counters
  Interface Module
 Networking & Communication Facility

21
 6. Sensor (connected to PLC Input)
A sensor is a device that measures a physical quantity and converts it into signal which can
be read by an observer or by an instrument. For example, a mercury- in-glass thermometer
converts the measured temperature into expansion and contraction of liquid which can be
read on a calibrated glass tube. A thermocouple convert temperature converts temperature
to an output voltage which can be read by a voltmeter. For accuracy, most sensor are
calibrated against know standard. Sensors are two types.

 Digital Sensor: Digital sensor have two unique voltage associated them to represent
the two unique voltage associated them to represent the two unique digital states of 0
to 1. These voltages are commonly 0v to 24v but there are many also types.

Ex. IR sensor, Proximity sensor, Hall sensor, PIR sensor

 Analog Sensor: Analog sensor are sensor that vary with respect to

time. Ex. Level sensor, Flow sensor, Temperature sensor, Speed sensor.

6.1 Need for Sensors

Sensors are omnipresent. They embedded in our bodies’ automobiles, airplane, cellular
telephone, radio, chemical plant, industrial plant and counter less other application.

6.2 Actuator (Connected to PLC Output)

An Actuator is a mechanical device for moving or controlling a mechanism or system. It is
operate by a source of energy, usually plant and counter less other application.

6.3 Difference between Actuator and Sensor

A sensor controls the variable for example temperature and pressure and transfer a signal to a
indicator or transmitter. The actuator is a machine which knocks a value or other machine in
accordance with control signal transferred to the transducer. The transducer generally
transforms the control signal to a relative air signal which works the actuator with a great
diaphragm opposite springs.

The mainly common actuator of electron-servo or an actuator can be utilized to pull and
push at a force and fixed length (stroke). This actuator of linear that transfer a piston rod to a
place force and fixed length. The can be utilized to transfer controls through variable
geometry example arcs used in conjunction with cranks and rods.

The actuator of hydraulic has an internal piston to the housing. The present is docked on
one end, which forces the rod to en large it. Reversing the pressure of hydraulic will caused
the rod to know back to origin position. The force that it existing is similar to the pressure
of hydraulic times the piston area.

22
A senor or detector is tool that a measures a physical quantity and transforms it into a
signal which can be interpreted by a separator or by device. Sensors are utilized in every
items for example touch-sensitive buttons of elevator and lamps which brighten or dim by
contacting the base. There are also numerous application for sensor of which mainly
people are not aware. The appliances consist of machine, cars, aerospace, manufacture,
robotics and medicine.

7. Data Type
There are 4 kind of data type supported by most of PLCs, which are as follows:

  Bit (0,1)
  Byte (combinational of 8 bits)
  Word (combinational of 16 bits)=2B
 Double Word (combinational of 32 bits)=2W

23
 8. Memory Type
There are different memory locations, which is represented by memory type abbreviation.

In Siemens the memory types are:

Description International

Input I
Output Q
Variable Memory V
Internal Memory M
Analog Input AL
Analog Output AQ
Counter C
Special Memory SM
Accumulator AC
Timer T

24
9. Concept of Relay

9.1 What is relay?

We know that most of the high end industrial application device have relay for their
effective working. Relay are simple switches which are operated both electrically and
mechanically. Relays consist of an electromagnet and also a set contact. The switching
mechanism is carried out with the help of the electromagnet. There is also other operating
principle for its working. But they are according to their applications. Most of the devices
have the application of relays.

9.2 Why is a relay used?

The main operation of a relay comes in place where only a low-power signal can be used to
control a circuit. It is also used in place where only one signal can be used to control a lot
of circuit. The application of relay started during the invention of telephones. They were
also used in long distance telegraphy. They were used to switch the signal coming from one
source to another destination. After the invention of computer they were used to perform
Boolean and other logical operations. The high end application of relay required high
power to be driven by electric motor and so on. Such relay are called contactors.

9.3 Relay Logic

 There are several kinds of logic that are made with the help of relay.
 These smaller logics are the base of all kind of functioning performed in industries.
 As we get command over this type of logic we can handle even complex functionally
 of plant or process.
 The panel made by the relay is known as relay logic panel.

25
 10. Sinking and Sourcing
One of the most often misunderstood notions in control engineering is the concept of the
sinking and sourcing relationship between I/O devices. This document is meant to give a
solid understanding of these concepts, and clear up the definition issues of Sinking (NPN)
and Sourcing (PNP), from both a technical and terminology perspective. “Sinking” and
“Sourcing” terms are very important in connecting a PLC correctly with external
environment. These terms are applied only for DC modules.

In general, Sinking (NPN) and Sourcing (PNP) are terms that define the control of
direct current flow in a load. They are only pertinent with DC component and should
not be associated with AC control structure. Device like relay output, reed, switches,
etc, are typically not affected since they are not current direction dependent.

10.1 Output Device:

Sinking (NPN) Output: Are output that “Sink” or “Pull” current through the load.

In case the common connection to the load is the 24 VDC (+DC) line.

Sinking output module require the load to be energized by a current, which flows from +24
VDC (+DC), through the load, through the NPN output switch device to the 0 VDC (-DC)
line.

26
Sourcing (PNP) Outputs: Are outputs that “Source” or “Push” current through the load.

This mean that the common connection to the load is the 0 VDC (-DC) line.

Sourcing output module required the load to be energized by a current that flow from +24
VDC (+DC), through the PNP output switch device, through the load to the 0 VDC (-DC)
line.

27
 10.2 Input Device:
Sinking (NPN) Input: Are input that require an external sensor device to “Sink” or
“Pull” current from the circuitry to 0 VDC (-DC). This means that the external sensor
service provide a current path the 0 VDC (-DC) common point. Below is a representation
of the circuit connection.

28
 Sourcing (PNP) Inputs: Are inputs that require an external sensor device to “Source” or
“Push” current from the 24 VDC (+DC) line to the input circuitry. This means that the
external sensor device provide a current path the 24 VDC (+DC) common point to the
input circuitry.

29
Latching: Latching is the process in which once output or coil is energized forever.
Latching is done by contact of output or coil which we want to switch ON Permanently.

I0.1=ON, Q0.1=ON,

I0.1=OFF, Q0.1=ON,

30