EMC 311/3 Mechatronics

Programmable Logic Controller Operation

Lecture 2

Assoc. Prof. Dr Elmi Abu Bakar

Tel.: 04-5995954
Fax: 04-5996911
Email: meelmidr@gmail.com
http://elearning.usm.my/
 Introduction

• Explain how programmable logic controller (PLC)

operates
• Students will learn
• Programmable logic controller (PLC)
• Input/output Unit (Chapter 21.2.1 pg 441-444)
• Input/output processing (Chapter 21.3 pg 444-
445)
• Knowledge and experience on computer help
understanding.
 Input/output Unit (signal conditioning)

• Provide interface between system and external device

• Provide function of signal conditioning & isolation so
that sensor & actuator can be connected directly
without additional circuit
• Larger PLC gives choices of input/output for
voltage/current
1. Input voltage normally 5 V & 24 V
2. Output voltage normally 24 V & 240 V
Input/output Unit (signal conditioning)
Input/output Unit (signal conditioning)
• Output types
• Relay
• Signal from PLC output
is used for operating
relay
• Can switch current few
Omron, 24V dc Coil Non-
ampere in external circuit
Latching Relay DPDT, 10A
Switching Current Plug • Isolate PLC from external
In, 2 Pole
circuit operates slow
Input/output Unit (signal conditioning)
• Transistor
• Using transistor to switch current in
external circuit
• Can switch current few milli-ampere in
external circuit
• Operates fast
• Optical isolator is used to isolate PLC from
external circuit
Input/output Unit (signal conditioning)
• Triac
• Used to control external
load that is connected to
A.C. power supply
• Optical isolator is used to
isolate PLC from external
circuit
 Input/output Unit (user interface)
• Program is loaded into
input/output unit from a panel
• Key pad with liquid crystal
display
• Screen displays program in
ladder diagram format
• Program is constructed using
symbolic keys on key pad
• Connection to personal computer
that is loaded with appropriate
software
• Increase readability of the
program by providing graphical
screen & text comment
• Omron CPM1A-10CDR Example of PLC
Structure of Memory Area in PLC Omron CPM1A
Structure of Memory Area in PLC Omron CPM1A
 Method of processing input/output
• Continuous updating
1. CPU scan input channels as they occur in program instruction
2. Each input is examined & its effect on program is determined
3. There is a built-in delay (3 ms) when each input is examined so that only
valid input signal is read by the microcontroller (not repeating the same
input especially if contact bounce)
4. Within the period many inputs can be scanned before the program has
the instruction for a logic operation to be executed & an output to occur
5. The outputs are latched so that they retain their status until the next
updating
 Method of processing input/output
• Mass input /output copying
1. Avoid delay reading input occurs like continuous updating
2. To execute program rapidly, a specific area of RAM is used as buffer
store between the control logic & the input/output unit
3. Each input/output has address in memory
4. In the beginning of each program cycle, CPU scans all inputs & copy its
status in input/output address in RAM
5. While executing program, stored input data is read from RAM & its
logic operation is executed
6. The resulting output signals are stored in the reserved input/output
section of RAM
7. At the end of each program cycle, all outputs are transferred from RAM
to output channels
8. The outputs are latched so that they retain their status until the next
updating
 Input/output processing
• The sequence that is followed by a PLC
when execute a program can be
simplified as follow
1. Scan all inputs and copy to RAM
2. Fetch, decode and execute all
program instructions in sequence,
copying output instruction to RAM
3. Update all outputs
4. Repeat the sequence

The cycle or scanning time for a PLC, i.e. its

response speed, is determined by:
1.The CPU used.
2.The size of the program to be scanned.
3.The number of inputs/outputs to be read.
4.The system functions that are in use; the
greater the number, the slower the scanning
time.
 Summary
• Students have learned
1. Input/output unit of PLC provides function of signal
conditioning & isolation so that sensor & actuator
can be connected directly without additional circuit
2. 3 types of PLC output are relay, transistor and triac
3. Program is loaded into input/output unit from a
panel
4. Omron CPM1A-10CDR is an example of a PLC
5. PLC processes input/output using either continuous
updating or mass input/output copying
6. PLC follows 4 sequences when execute a program
• Foundation for using PLC
 References
1. Webb, John W., “Programmable logic controllers”
2. Swainston, Fred, “A systems approach to programmable controllers”
3. Parr, E. A. & E. Andrew, “Programmable controllers: an engineer's
guide”
4. Warnock, Ian G., “Programmable controllers: operation and application”
5. Den, Otter J., “Programmable logic controllers”
6. Bolton, Martin, “Digital systems design with programmable logic”
7. Kissell, Thomas E., “Understanding and using programmable
controllers”
8. Treseler, Michael, “Designing state machine controllers using
programmable logic”
9. Stenerson, Jon, “Fundamentals of programmable logic controllers,
sensors, and communications”
10. Knapp, William, “Introduction to programmable logic controllers
(videorecording)”