PLC TRAINING

Title of presentation BASIC

CONCEPTS

| 2/18/2011 | | Drives & Control | | © Bosch Rexroth AG 2011. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as
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 Basics Concepts of PLC

What is a PLC ?

• Programmable Logic Controller

• It is an industrial digital computer.
• It is capable of storing instructions to implement control
functions such as sequencing, timing, counting,
arithmetic, data manipulation and communication.
• The PLC has I/O interfaces that provide the connection
between the PLC and the information providers (inputs
like pushbuttons, sensors,…) and the controllable
devices (outputs like valves, relays, lamps,…).
Basics Concepts of PLC

History of PLC

• PLC was born in an automotive industry in USA.

• Before PLC, the controlling, sequencing, and safety
interlock logic in automobile manufacturing industries
was accomplished using hundreds or thousands of
relays, cam timers, drum sequencers and dedicated
closed- loop controllers.
• The process for updating such facilities was very time
consuming and expensive, as electricians needed to
individually rewire each and every relay.
Basics Concepts of PLC

Where is the PLC

used ?

• The PLC controls industrial machines in a

manufacturing unit.
• They are used in assembly line, robotic devices,
and any activity that requires high reliability
control and ease of programming and process
fault diagnosis.
• materials handling, packaging, palletizing, milling,
boring, grinding, filling, sorting, weighing are
the different industries using PLC.
Basics Concepts of PLC
Machine Automation Over View
Command Signals Status Signals
Push Buttons, Limit Switch, Proximity, Machine
Controller Selector Switches Reed Switch etc.,

Inputs

Outputs

Relays, Solenoids, Power contactors

Actuators: Motors, Cylinders, Heaters, Lamps etc.,

HMI
 Basics Concepts of PLC
Inputs – Sample Pictures

Push Button Selector Switch

 Basics Concepts of PLC

Outputs - Switch Gear Products Over View

Power Contactor Aux. Contactor Relay Boards

Over Load Relay Relays

Basics Concepts of PLC
Outputs - Actuators

Cylinders Solenoid Coils Servo Motor

Manifold Block
 Basics Concepts of PLC

Cylinders Over View

Short stroke Compact cylinders Clean profile cylinders

cylinders

Standard ISO cylinders Accessories

Basics Concepts of PLC

Pneumatic Components Over View

Compact valve blocks Pressure switch

Position sensors (Cylinder mounting)

 Basics Concepts of PLC

How does PLC work ?

In the past the movements of industrial machines

were controlled by relay circuits. These relay-controlled
systems were replaced by PLC.
The primary function of the PLC was to perform the
sequential operations that were previously implemented
with relays.
Before we can talk about the working method of an
PLC, we must understand the function of relay circuits.
Basics Concepts of PLC

What is a Relay ?

A relay is an electro-magnetic switch.

It contains:

a coil a switch
and a iron bar
a iron core connected to
the switch
Basics Concepts of PLC

How does a Relay work ?

When a current goes through the coil...

I
 Basics Concepts of PLC

How does a Relay work ?

… a magnetic field is produced in the coil and the iron core

in the coil becomes magnetic.
I
Basics Concepts of PLC

How does a Relay work ?

The electromagnetic force pulls in the switch and...

I
Basics Concepts of PLC

How does a Relay work ?

…a current can go through the switch.

I I
Basics Concepts of PLC

How does the PLC replace Relay in an electric circuit ?

The answer to this question shall be shown with the

following example circuits, A, B, C, and D.
A).
24V technical symbol
of a reinlatyernal
switch

S1
electro magn.
connection

coil

K1
K1 L1

0V
 Basics Concepts of PLC

How does the PLC replace Relay in an electric circuit ?

The answer of this question shall be shown with a little

example circuit.
B).
24V Function of the electrical circuit:

S1
When the user presses button S1, the relay
K1 pulls in its internal switch and the lamp
L1 turns on.

K1 L1

0V
Basics Concepts of PLC

How does the PLC replace Relay in an electric circuit ?

The answer of this question shall be shown with a little

example circuit.
C).
24V 24V

S1
S1
Input Power

PLC
Power Output

K1 L1 L1
0V 0V
Basics Concepts of PLC

How does the PLC replace Relay in an electric circuit ?

The answer of this question shall be shown with a little

example circuit.
D).
24V 24V

S1 PLC logic
S1

K1 L1
L1
0V 0V
 Basics Concepts of PLC

What is PLC logic ?

• The PLC logic is not a mechanical part of the controller.

• The PLC logic is a software program, which runs on the
processor in the PLC.
• This program has to be created with a special
programming tool on a PC. ex: Indralogic or Codesys
24V

S1 SPS logic • After downloading the program

into the PLC, the control
automatically starts the program

L1
0V
Basics Concepts of PLC
RELAY LOGIC
Ph. 220V AC SUPPLY N

START PB STOP PB TMR1 PC

PC

TMR1

LADDER PROGRAM
M1
I1 I2
Q1

Q1
TMR1
M1
En Q

Q1 Trig

T#5s Time
 Basics Concepts of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Machine
 Basics Concepts of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Central
processing unit Machine
 Basics Concepts of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Working- and
Machine
program memory
 Basics Concepts of PLC

How a PLC works: internal

PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Program editor
Machine
and monitoring
 Basics Concepts of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Sensor signal
Machine
input
 Basics Concepts of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Actuator
Machine
command output
 Basics Concepts of PLC

How a PLC works: internal PLC

network Communication
RAM E-EPROM
module

Programming
tool CPU

power cord Input Output

Power supply
modules modules

Control
Machine
communication
Basics Concepts of PLC

How PLC works: processing cycle

Start PLC from E-EPROM

Read user program & Copy to RAM

Read input signals, store in table

Determine new output state of output module

processing cycle

Write output commands in table

Set output values on output module

 Basics Concepts of PLC
PLC & PC In Comparison
Computer PLC

CPU/Memory CPU/ RAM/ Hard disk CPU/ RAM/ Flash Card

Power Supply 220V AC, 1 Ph. 220V AC / 24V DC

Key board, Mouse, Push Button, Selector, Limit

Inputs
Remote station (LAN) Switch, PxS, Bus Interface

Outputs Monitor, Printer, Solenoids, Relays, Lamps,

Projector Etc., Motors, HMI

OS: Windows XP / OS: Firmware / SW:

Software SW: MS Office Machine Logic

Internal Calculator etc., Markers, Timers,

Counters, FBs
Basics Concepts of PLC
Pick & Place Unit

swivel
 Schematic: device
shuttle up/down
pick cylinder suction cylinder
pad place

 Starting position: vac. off, slide right, up; swivel not used (front position)
 Sequence of movements:
1) slide left 5) move down
2) move down & switch on vacuum 6) switch off vacuum
3) move up 7) move up
4) slide right
Basics Concepts of PLC

 Animation:

 Sequence of movements:
slide left
move down & vacuum on
move up
slide right
move down
vacuum off
move up
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