UNIT IV-COntroller and Algorithms PDF

UNIT IV
CONTROLLERS AND ALGORITHMS

Dr. RM. KUPPAN CHETTY., M.Tech., Ph.D
CONTENTS
 MICROPROCESSORS
 MICROCONTROLLERS
 PROGRAMMABLE LOGIC CONTROLLERS
 ARTIFICIAL NEURAL NETWORKS
 FUZZY LOGIC CONTROLLERS
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OUTCOMES
Students are able to
 Describe the basic structure and architecture of the microprocessor and micro
controllers and how they can be applied in mechatronic system design
 Describe the basic structure of the Programmable logic controller (PLC) and
appreciate its uses in mechatronic system design
 Discuss the use of Artificial Neural Networks and Fuzzy logics as control
algorithms in mechatronic systems.
Why do we need to learn
Microprocessors/controllers?
• The microprocessor is the core of computer systems.
• Nowadays many communication, digital entertainment,

portable devices, are controlled by them.
• A designer should know what types of components he

needs, ways to reduce production costs and product
reliable.
INTRODUCTION
DIAGRAM OF A COMPUTER SYSTEM
A computer is a programmable machine that receives input, stores
and manipulates data/information, and provides output in a useful
format.
25-12-2019 Diagram Of AHITS-II-BMS-RMKP

Computer
6 System
Building Blocks of Processor Systems
MEM ORY
INPUT-OUTPUT
CONTROL
DATAPATH
CPU
Processor System Architecture
The typical processor system consists
of:
 CPU (central processing unit)

 ALU (arithmetic-logic unit)
Interconnections between
 Control Logic
these units:
 Registers, etc…
 Address Bus
 Memory
 Data Bus
 Input / Output interfaces  Control Bus
General-purpose microprocessor
• CPU for Computers

• Commonly no RAM, ROM, I/O on CPU chip itself
Many chips on motherboard

Data Bus
CPU
General-
Serial
Purpose RAM ROM I/O Timer COM
Micro- Port
Port
processor
Address Bus
Bus and CPU
Bus: A shared group of wires used for communicating

signals among devices
• Address bus: the device and the location within the
device that is being accessed
• Data bus: the data value being communicated
• Control bus: describes the action on the address and
data buses
CPU: Core of the processor, where instructions are executed

• High-level language: a = b + c
• Assembly language: add r1 r2 r3
• Machine language: 0001001010111010101
Memory and I/O
Memory: Where instructions (programs) and data are stored
• Organized in arrays of locations (addresses), each storing
one byte (8 bits) in general
• A read operation to a particular location always returns the
last value stored in that location
I/O devices: Enable system to interact with the world

 Device interface (a.k.a. controller or adapter) hardware connects
actual device to bus
 The CPU views the I/O device registers just like memory that
can be accessed over the bus. However, I/O registers are connected
to external wires, device control logic, etc.
 Reads may not return last value written
 Writes may have side effects
8085 Microprocessor Architecture
The 8085 Bus Structure
The 8-bit 8085 CPU (or MPU – Micro Processing Unit) communicates with the
other units using a 16-bit address bus, an 8-bit data bus and a control bus.
Address Bus
 Consists of 16 address lines: A0 – A15
 Operates in unidirectional mode: The address

bits are always sent from the MPU to peripheral
devices, not reverse.
 16 address lines are capable of addressing a

total of 216 = 65,536 (64k) memory locations.
 Address locations: 0000 (hex) – FFFF (hex)

Data Bus
 Consists of 8 data lines: D0 – D7
 Operates in bidirectional mode: The data bits are

sent from the MPU to peripheral devices, as well
as from the peripheral devices to the MPU.
 Data range: 00 (hex) – FF (hex)
Control Bus
 Consists of various lines carrying the control
signals such as read / write enable, flag bits.
The 8085: CPU Internal Structure
The internal architecture of the 8085 CPU is

capable of performing the following operations:
 Store 8-bit data (Registers, Accumulator)
 Perform arithmetic and logic operations (ALU)

 Test for conditions (IF / THEN)
 Sequence the execution of instructions
 Store temporary data in RAM during execution

Microcontroller :
• A single-chip computer
• On-chip RAM, ROM, I/O ports...
• Example：Motorola’s 6811, Intel’s 8051, Zilog’s Z8 and PIC 16X
CPU RAM ROM
Serial
I/O Timer COM
Port
Port
17
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Microcontroller
18
Microprocessor vs. Microcontroller
Microprocessor Microcontroller
• CPU is stand-alone, RAM, ROM,
I/O, timer are separate • CPU, RAM, ROM, I/O and timer are
all on a single chip
• designer can decide on the
amount of ROM, RAM and I/O • fixed amount of on-chip ROM,
ports. RAM, I/O ports
• expensive • for applications in which cost,
• versatility power and space are critical
• general-purpose • single-purpose (control-oriented)
• High processing power • Low processing power
• High power consumption • Low power consumption
• Instruction sets focus on • Bit-level operations
processing-intensive operations • Instruction sets focus on control
• Typically 32/64 – bit and bit-level operations
• Typically deep pipeline (5-20 • Typically 8/16 bit
stages) • Typically single-cycle/two-stage
19
pipeline
Intel 8051 Basic Component
• 4K bytes internal ROM
• 128 bytes internal RAM
• Four 8-bit I/O ports (P0 - P3).
• Two 16-bit timers/counters
• One serial interface
CPU RAM ROM
A single chip
I/O Serial Microcontroller
Timer COM
Port
Port
20
Block Diagram of General Microcontroller
External Interrupts
Interrupt 4k 128 bytes Timer 1

Control ROM RAM Timer 2
CPU
OSC Bus
4 I/O Ports Serial
Control
P0 P2 P1 P3 TXD RXD
21
25-12-2019 Addr/Data
HITS-II-BMS-RMKP
Other 8051 features
• only 1 On chip oscillator (external crystal)
• 6 interrupt sources (2 external , 3 internal, Reset)
• 64K external code (program) memory(only read)PSEN
• 64K external data memory(can be read and write) by RD,WR
• Code memory is selectable by EA (internal or external)
• We may have External memory as data and code
22
8051 Internal architecure
23
Selection of Microcontroller
- Factors to be considered
 No of Input / Output Pins. I.e. No. of I/O’s needed for the task
concerned
 Interface required. Ex. PWM is needed for motor control
 Memory requirement – Size of the memory for the task
 No. of Interrupts – based on no. of critical events need to be
serviced
 Processing Speed
24
Simple Temperature Measurement System using
Microcontroller
Temperature as voltage – ADC – Converted into BCD data – storage

register – 7 Segment Display
25
Domestic Washing using Microcontroller
26
Programmable Logic Controllers
(PLC)
Programmable Logic Controllers
• PLC – microprocessor based system used to control
machines and processes
• Stores instructions in a programmable memory
• Implements functions or set of rules
• Logics
• Sequencing
• Timing
• Counting
• Arithmetic etc..
PLC – Basics – Introduction (contd.)
• Defined as miniature industrial computers that contain

hardware and software used to perform control functions
• PLC is a dedicated computer designed to work in an industrial
environment
• Equipped with special Input / Output Interfaces
• Features
• Rugged, withstand industrial environment such as heat,
humidity, shocks and vibrations
• Ease of Programming with dedicated mnemonics
• Capable of implementing both logic and PID control
Control Structure architecture of PLC
PLC – Basic Components
PLC’s consist of a few different

components
• Power supply.
• Input module.
• Output module.
• Processor (CPU)
• Programming device / Teach Pendant
• Monitor / Display
• Rack or mounting assembly.
• Programming unit (software)
PLC – Basic Components (Contd.)
Processor:
• It is the heart of PLC
• He processor processes the signals
from input module and generates
controlling signals for the system
• It also scans and solve the logic of the
user program
• It consists of ALU, microprocessor unit,
memory unit and system power supply
Memory:
• Contains the program stored in it
• Programs were written with control actions to be executed by the microprocessor
for the input given
• RAM is a temporary storage device used to store ladder diagram and for testing
and evaluation
PLC – Basic Components (Contd.)
Power Supply:
• Convert the main A.C voltage into a low - level D.C voltage (5V).
• D.C. voltage is supplied to the processor and the circuits in the input and output
interface modules.
• Should be free from heavy loads, noises and voltage fluctuations.
Input / Output Modules (peripheral devices)

• Input module receives information from extended devices and sends to processor
• Output modules communicates the processed information to the external devices
• Input devices are mechanical switches, photo sensors, temperature sensors, flow
sensors, other type of sensors keypads etc.,
• Output devices may include solenoid valves, Relays, contactors, lights, Horns,
Heating elements, fans, Motor starter, signal Amplifiers. Conveyor belt, lift,
automatic door etc..
PLC Architecture
PLC Architecture
CENTRAL PROCESSING UNIT (CPU)
• It has the following:
• An Arithmetic and Logic Unit (ALU) that is responsible for data manipulation
and carrying out arithmetic operations of addition and subtraction and logic
operations of AND, OR, NOT, and EXCLUSIVE-OR.
• Memory, termed registers, located within the microprocessor and used to
store information involved in program execution.
• A control unit that is used to control the timing of operations.
MEMORY
• System read-only-memory (ROM) gives permanent storage for the operating
system and fixed data used by the CPU.
• Random-access memory (RAM) is used for the user’s program.
• Random-access memory (RAM) is used for data.
PLC Architecture (contd.)
Control Unit / Processor:
• A control unit is used to control the timing of
operations.
• Analyze the data from the sensors through input
modules and make decisions based on the user
defined functions
• The processor functions under a permanent
supervisory operating system that directs the
overall operations from data input and output to
execution of user programs.
• Controller can perform only one operation at a time.
So, it scans each of the inputs sequentially,
evaluates the ladder diagram program, provide each
output(s), and then repeat the whole process.
• Hence, the timing control's necessary for a PLC
system.
Control Unit / Processor:
Arithmetic and Logic Unit (ALU):
• Performs data manipulation and arithmetic and logical operations on input
variable data and determines the proper state of the output variables.
• Arithmetic operation includes addition, subtraction etc., and logic operations
include AND, OR, AND, EXCLUSIVE - OR.
Memory Unit:
• Registers located within the microprocessor and used to store information
involved in a program execution, which contains control actions to be executed by
the microprocessor for the given input.
• There are several memory elements in a PLC system.
• System Read-only Memory (ROM) gives permanent storage for the operating
system and fixed data wed by the CPU.
• RAM for the user to develop program and acts a temporary memory.
• In addition, temporary buffer stores
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for the I/O channels.
HITS-II-BMS-RMKP 38
Memory Unit:
• During entering and editing including Debugging, the program is stored in the
temporary storages called RAM (Random Access memory).
• Once the program is completely finished (free & from errors), It may be 'burned'
into ROM
• When the ROM is plugged into the PLC, the device is ready to be placed into
service in the industrial environment.
• Memory may be either volatile type or Non-volatile type.
Volatile Memory:
• Volatile memory will lose all its programmed contents if operating power is
removed or lost.
Non Volatile Memory: It does not lose its content during power failure.
• Permanent memory or system memory is (used) a system memory that stores
the monitor a booting programs, lookup tables etc.,
• This usually programmed and supplied by the manufacturer and controls the
operation of PLC.
The Different Types of ROMS are
BUSES:
BUSES:
INPUT & OUTPUT UNIT
Selection of PLC - Factors to be considered
To determine the most suitable PLC to be used in the automation
task there are several basic considerations to be made:
• Necessary input/output capacity
• Types of I/O required
• Size of memory required
• Speed and power required of the CPU and instruction set
• Communication protocols
• Power supply
Self Study:
– Role as control algorithm in Mechatronic System design
• Artificial Neural Networks (ANN)
• Fuzzy Logic – Role as Control algorithm in Mechatronic
System design

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UNIT IV

CONTROLLERS AND ALGORITHMS

• Nowadays many communication, digital entertainment,

• A designer should know what types of components he

25-12-2019 Diagram Of AHITS-II-BMS-RMKP

 CPU (central processing unit)

• CPU for Computers

Many chips on motherboard

Bus: A shared group of wires used for communicating

CPU: Core of the processor, where instructions are executed

I/O devices: Enable system to interact with the world

 Operates in unidirectional mode: The address

 16 address lines are capable of addressing a

 Address locations: 0000 (hex) – FFFF (hex)

 Operates in bidirectional mode: The data bits are

 Data range: 00 (hex) – FF (hex)

The internal architecture of the 8085 CPU is

 Store 8-bit data (Registers, Accumulator)

 Perform arithmetic and logic operations (ALU)

 Sequence the execution of instructions

 Store temporary data in RAM during execution

CPU RAM ROM

Interrupt 4k 128 bytes Timer 1

Temperature as voltage – ADC – Converted into BCD data – storage

• Defined as miniature industrial computers that contain

Control Structure architecture of PLC

PLC’s consist of a few different

Input / Output Modules (peripheral devices)

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