A 

programmable logic controller (PLC) or programmable controller is an industrial digital

computer that has been ruggedized and adapted for the control of manufacturing processes,
such as assembly lines, robotic devices, or any activity that requires high reliability, ease of
programming, and process fault diagnosis.
PLCs can range from small modular devices with tens of inputs and outputs (I/O), in a housing
integral with the processor, to large rack-mounted modular devices with thousands of I/O, and
which are often networked to other PLC and SCADA systems.
They can be designed for many arrangements of digital and analog I/O, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control
machine operation are typically stored in battery-backed-up or non-volatile memory.
PLCs were first developed in the automobile manufacturing industry to provide flexible, rugged
and easily programmable controllers to replace hard-wired relay logic systems. Since then, they
have been widely adopted as high-reliability automation controllers suitable for harsh
environments.
A PLC is an example of a "hard" real-time system since output results must be produced in
response to input conditions within a limited time, otherwise unintended operation will result.

Contents

 1Invention and early development

o 1.1Modicon
o 1.2Allen-Bradley
o 1.3Early methods of programming
 2Architecture
o 2.1Mechanical design
o 2.2Discrete and analog signals
o 2.3Redundancy
 3Programming
o 3.1Programming device
o 3.2Simulation
 4Functionality
o 4.1Basic functions
o 4.2Communication
o 4.3User interface
 5Process of a scan cycle
 6Security
 7Safety PLCs
 8PLC compared with other control systems
o 8.1PLC Chip / Embedded Controller
o 8.2Cam timers
o 8.3Microcontrollers
o 8.4Single-board computers
o 8.5PID Controllers
o 8.6Programmable logic relays (PLR)
 9PLC manufacturers
 10See also
 11References
o 11.1Bibliography
 12Further reading
Invention and early development[edit]
PLC originated in the late 1960s in the automotive industry in the US and were designed to
replace relay logic systems.[1] Before, control logic for manufacturing was mainly composed
of relays, cam timers, drum sequencers, and dedicated closed-loop controllers.[citation needed]
The hard-wired nature made it difficult for design engineers to alter the process. Changes would
require rewiring and careful updating of the documentation. If even one wire were out of place, or
one relay failed, the whole system would become faulty. Often technicians would spend hours
troubleshooting by examining the schematics and comparing them to existing wiring.[2] When
general-purpose computers became available, they were soon applied to control logic in
industrial processes. These early computers were unreliable[3] and required specialist
programmers and strict control of working conditions, such as temperature, cleanliness, and
power quality.[4]
The PLC provided several advantages over earlier automation systems. It tolerated the industrial
environment better than computers and was more reliable, compact and required less
maintenance than relay systems. It was easily extensible with additional I/O modules, while relay
systems required complicated hardware changes in case of reconfiguration. This allowed for
easier iteration over manufacturing process design. With simple programming language focused
on logic and switching operations, it was more user-friendly than computers using general-
purpose programming languages. It also permitted for its operation to be monitored.[5][6] Early
PLCs were programmed in ladder logic, which strongly resembled a schematic diagram of relay
logic. This program notation was chosen to reduce training demands for the existing technicians.
Other PLCs used a form of instruction list programming, based on a stack-based logic solver.[7]

Modicon[edit]
In 1968, GM Hydramatic (the automatic transmission division of General Motors) issued a
request for proposals for an electronic replacement for hard-wired relay systems based on a
white paper written by engineer Edward R. Clark. The winning proposal came from Bedford
Associates from Bedford, Massachusetts. The result was the first PLC—built in 1969–designated
the 084, because it was Bedford Associates' eighty-fourth project.[8][9]
Bedford Associates started a company dedicated to developing, manufacturing, selling, and
servicing this new product, which they named Modicon (standing for modular digital controller).
One of the people who worked on that project was Dick Morley, who is considered to be the
"father" of the PLC.[10] The Modicon brand was sold in 1977 to Gould Electronics and later
to Schneider Electric, the current owner.[9]
One of the first 084 models built is now on display at Schneider Electric's facility in North
Andover, Massachusetts. It was presented to Modicon by GM, when the unit was retired after
nearly twenty years of uninterrupted service. Modicon used the 84 moniker at the end of its
product range until the 984 made its appearance.[citation needed]

Allen-Bradley[edit]
In a parallel development Odo Josef Struger is sometimes known as the "father of the
programmable logic controller" as well.[10] He was involved in the invention of
the Allen-Bradley programmable logic controller during 1958 to 1960[11][12][13] and is credited with
inventing the PLC acronym.[10][11] Allen-Bradley (now a brand owned by Rockwell Automation)
became a major PLC manufacturer in the United States during his tenure.[14] Struger played a
leadership role in developing IEC 61131-3 PLC programming language standards.[10]

Early methods of programming[edit]

Many early PLCs were not capable of graphical representation of the logic, and so it was instead
represented as a series of logic expressions in some kind of Boolean format, similar to Boolean
algebra. As programming terminals evolved, it became more common for ladder logic to be used,
because it was a familiar format used for electro-mechanical control panels. Newer formats, such
as state logic and Function Block (which is similar to the way logic is depicted when using digital
integrated logic circuits) exist, but they are still[when?] not as popular as ladder logic. A primary
reason for this is that PLCs solve the logic in a predictable and repeating sequence, and ladder
logic allows the person writing the logic to see any issues with the timing of the logic sequence
more easily than would be possible in other formats.[15]
Up to the mid-1990s, PLCs were programmed using proprietary programming panels or special-
purpose programming terminals, which often had dedicated function keys representing the
various logical elements of PLC programs.[8] Some proprietary programming terminals displayed
the elements of PLC programs as graphic symbols, but plain ASCII character representations of
contacts, coils, and wires were common. Programs were stored on cassette tape cartridges.
Facilities for printing and documentation were minimal due to a lack of memory capacity. The
oldest PLCs used non-volatile magnetic core memory.