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Digital Controllers
• Traditional (Hardwired).
• Digital Logic (Electronic).
• Microcontroller.
• Programmable Logic Controller (PLC).
Traditional Controller
(Hardwired)
Hard-wired Controller
Disadvantages
• Very low reliability.
• Inflexibility (very hard to expand and
modify).
• No communication, data collection, and
data handling capabilities.
• Very hard to troubleshoot.
• Very large size.
Programmable Logic Controller
(PLC)
Definition:
Programmable logic controller (PLC) is a
specialized computer (microprocessor-based
controller) used to control machines and
processes. It uses a programmable memory to
store instructions and execute specific
functions that include: On/off control, timing,
counting, sequencing, arithmetic, signal
processing, and data handling.
PLC and Personal Computer
(PC)
Unlike the PC, the PLC has been
designed to operate in the industrial
environment and is equipped with
special input/output interfaces and
also a special control program
language.
PLC and Traditional
Controller
• Initially, the PLC was used to replace relay
logic (hard-wired controller).
• Many technological advances in the
programmable logic controller industry
continue today. Changes include both
hardware (physical components) and
software (control program) upgrades.
Therefore, PLC can be used in many and
more complex applications.
PLC and Traditional
Controller
• Because the structure of PLC is based on
the same principles as those employed in
computer architecture, PLC is capable not
only to performing relay switching tasks
but also capable to perform other functions
such as counting, arithmetic, data
handling, comparing, analogue signal
processing, and so forth.
PLC Advantages
• Relatively low cost.
• High reliability: The program takes the
place of much of external wiring that would
normally be required for controlling the
process.
• Flexibility/programmability: It is easier to
create and change a program in the PLC
than to wire and rewire a control circuit.
PLC Advantages
• Communication capabilities: PLC can
communicate with other controllers,
computers, and/or equipments to perform
several functions.
• Fast scan and response time.
• Easier to troubleshoot: PLCs have
diagnostics and override functions that
allow users to easily track and correct
software and hardware problems.
PLC Advantages
• Special interfaces have allowed certain
devices to be connected directly to the
controller, such as thermocouples and
strain gauges
• Powerful instructions have been provided
and advanced functional block instructions
have been implemented
PLC Advantages
• Expandability/modular
• Ease of use in an industrial environment
• Ease of installation
• Used less space (small size)
PLC Applications
• Automotive.
• Chemical and Petrochemical.
• Glass Processing.
• Manufacturing and Machining.
• Materials Handling.
• Metals.
• Power.
• Rubber and Plastic.
PLC
• Hardware components.
• Principle of operation/scan cycle.
• Response time.
• Modes of operation.
• Types and classifications.
• Specifications.
• Connections.
• Programming languages.
• Programming Instructions (logic functions, set/reset,
timers, and counters).
• Examples/Applications.
PLC
PLC Programming Languages
• Statement List (Instruction Set)
• Functional Block Diagram (FBD)
• Ladder Diagram (Ladder Logic)
• Structured Text (ST)
• Sequential Function Chart (SFC)
Ladder Diagram
• A very commonly used method to program PLCs.
• Ladder diagram is equivalent to drawing a control
circuit of traditional controller.
• Ladder diagram consists of two vertical lines.
• Circuit elements connected as horizontal lines.
• Each rung on the ladder defines one operation in the
control process.
• A ladder diagram is read from left to right, and from
top to bottom.
• Each rung must start with an input(s) and must end
with at least one output.
Logic Gate Programming
• Basic Logic Operation and Functions
• Basic Rules of Boolean Algebra
Basic Logic Operation and Functions
• Commutative Law.
• Associative Law.
• Distributive Law.
• DeMorgan’s Theorem.
• Basic Rules.
Logic Gate Programming
Example:
Write a PLC program that will turn on a light if one or
other of two switches is closed, and the light will be
turned off when a reset switch is closed. If both
switches are closed simultaneously, the light will be
turned off and an alarm light will operate which can
only by shut off by closing the reset switch.
Inputs Outputs