SME3-01: MECHATRONIC SYSTEMS Programmable Logic Controller (PLC) see Unit-V renee eine " Sette a eer eee ee eer eet eee See eet een ee Programmable Logic Control PLC - Introduction * PLC implements logic contol functions by means of «program + Definition according to NEMA standard 1CS3-1978 “A digitally operating electronic apparatus See eas internal storage of instructions for Pert eee ere toe logie, sequencing, timing, counting and Coretta Ranta cro een — How does a PLC differ from a computer? *A.computer is optimized for calculation and display tasks +A computer is programmed by specialists * APLC is designed for (logic) control and regulation tasks * APLC is programmed by non-specialists * APLC is well adapted to industrial environmentPLC - Introduction + Developed to replace Costs dropped and became popular by 1980s + Now used in many industrial designs + The Hydrometric Division of the General Motors Corporation specified the design criteria forthe first programmable controller in 1968 + Ther primary goal "To eiminate the high costs associated with inflexible, rela PLC- Introduction + Developed to replace relays in the late 1960s + Costs dropped and became popular by 1980s ‘+ Now used in many industrial designs + The Hydrometric Division of the General Motors Corporation specified the design criteria forthe frst programmable controller in 1968 with primary goal “To eliminate the high costs associated with inflexible, relay-controlled systems PLC - Introduction Leading Brands of PLC The logic control tasks such as interlocking, ~ Aeon “apa sequencing, liming and counting (previously 2 Gold dion LOnven undertaken with relays or pneumatics) 3 fea lnm Se In addition, PLCs can perform a variety of 6 Cut sso calculation, communication and monitoring tasks buenas 2 Klockner & Mouler 2 TeemechasgnePLC Size + Small: + Itcovers units with up to 128 10's and memories up to 2 Kbytes + These PLC's are capable of providing simple to advance levels cor machine controls + Medium: + Have up to 2048 10's and memories up to 32 Kbytes, “Large: * The most sophisticated units ofthe PLC family. * They have up to 8192 VO's and memories up to 750 Kbytes + Can control individual production processes or entire plant. Major Components of a Common PLC Major C ts of a Common PLC * Power Supply +110 Modules + Processor + Programming DevicePLC jon sequence ‘Self test: Testing of ts own handware and software fr faults. 2ylnput sean: If there are no problems, PLC will eopy al the inpts and copy their values ino memory $3)Logicsolvelscan: Using inputs, the ladder iogie program is solved once nd outputs are updated ‘Output scan: While solving loge the output values are updated only in memory when adder sen done, the outputs wil be updated using temporary values in memory Programming Languages of PLC Most common languages encountered in PLC programming are: 1) Ladder Logic 2) Functional Block Diagram 3) Sequential Function Chart 4) Boolean mnemonics Ladder Programming + Adder diagram is a symbolic ‘and sehematie representation of both the process hardware and process coat + ts called a “Ladder’ because all * the devices are connected sctoss ‘the Supply lines making it look Tikes ladder, + Each parallel conection sealed "Rung" itean contain many inputs but only one output Ladder Logic PLC Programming >The ladder logics the oldest programming language for PLC >is wel suited to express Combinational ogc. >The msi ladder Tog symbols represent the elements SE mitecomac pe -O- wetLadder Logics for basic gates Ladder Logics for basic gates Ladder Program Ladder Program 7 Gis Dlagram + Ladder Diagram (CA) = GRSROIBGFIR > Ck ye Pc CF ee ee oeLadder program Example ae {aera Pan er Sap of ter eas x 2 sx [Hie] rn Staring of Motor To Stop the MotorCriteria for selecting a PLC Selecting a PLC * How many control imput to be processed ~ Nos. of Input + How many output devices or controling elements are contolled — [Nos of Output + What memory capacity is needed to store the “user program’? + What speed of processing and operations capabilities desire? + What are the communication requirements? + Ate there any special or specific requitements eluding that of safety, reliability expandability etc + System volage availabe fr auxiliary supply of PLC + On geting this information check forthe specification of th Pus lable ~ Number of logical inputs and outpus * Gontlr There sould be sufficient 1 ports to mex reson: egurements ‘ens pate provide frimnrte te cpus, + Memory ‘The amouat of emery regu for a pura aplication elated othe {engi of the program andthe complet ofthe con system, + Progra length td expand af te system have bee ed fora wie Selecting a PLC Advantages of PLCs + Number of special 10 modules + Sean Time * This the ped at which he onl execs the ely adr loge rogren Tis arses ely speed the san ne er 100 Tog * Communications + Software + Less wiring + Wiring between devices and relay contacts are done in the PLC program + asicr and faster to make changes + Trouble shooting aids make programming easier and reduce dovrntime + Reliable components make these likely to operate for yeas before failure, They are cost-effective ‘They ae exible, reliable and compact + They have significant advantages over traditional control systems based on relay or pneumaticsDisadvantages of PLCs Areas of Application : “PLC devices are proprictary it means that part or software of ‘one manufacturer can't be used in combination with parts of ‘another manufacturer + Limited design and cost option + Fixed Circuit Operations. + PLCs manufacturers offer only closed architectures, } Wherever automation is desired the PLCs are best suited to meet the task. > Manufacturing / Machining > Food / Beverage Metals >Power >Mining > Petrochemical / Chemical