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IJARSE, Vol. No.2, Issue No. 2, February, 2013 ISSN-2319-8354(E)

INITIAL FACE OF AUTOMATION

“PROGRAMMABLE LOGIC CONTROLLER”
1
Komal Gupta, 2Kirti Mourya
UG, 1,2 Department of Electronics and Communication Engineering,
Raj Kumar Goel institute of technology for Women, UP (India)

ABSTRACT:

This paper presented on Programmable Logic Controller (PLC) is to give insights on hardware of PLC.
Programmable logic controllers are extensively used in industries for controlling sequence of actions of the process.
The sequence of process flow is decided for controlling the parameters like level and temperature. The brain of the
system is PLC .Appropriate hardware for interfacing the process to the controller is developed for controlling the
level ant temperature of the process.

Programmable Logic Controller (PLC) is designed to operate in real time environment. It has been observed
that in many industries distributed control system and PLCs are extensively used. PLC based sequential batch
process control (PLCSBC) is a laboratory type setup. This setup will be useful for demonstrating the use of PLC in
sequential control operations in industry and development of ladder diagram for particular application. The system
under consideration is designed to carry out sequence of events.

I INTRODUCTION

With the development of computer technology, control theory, digital communication technology and
microprocessor technology, PLCs birth and development conformed to modern industry requirements for rapid
changes of market demand. It is only forty years that since the first PLC was made in 1969, but by right of its own
advantages of very high reliability and performance –price ratio, well expansibility and good real –time
performance, maintainability, now PLC is the most important technology in control and automation field and one of
four pillars, which includes PLC, Numerical control Technology, computer aided design technique and robotics
.PLC widely divided applied not only in industry but also in civil application, such as elevator, washing machine,
traffic signal light and so on.
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IJARSE, Vol. No.2, Issue No. 2, February, 2013 ISSN-2319-8354(E)

1.1 AUTOMATION

Automation is the act of implementation of the control system, to control industrial machinery and processes,
reducing the need for human intervention. Control & Automation generally go hand in hand. The advantages offered
by Automation are:-

1) Increase in productivity
2) Reduction in running cost.
3) Precision in control.
4) Early Fault Notification.
5) Safety in operation for both man & Machine.

Figure 1: PLC automation control system

II. PLC

A PLC (i.e. Programmable Logic Controller) is a device that was invented to replace the necessary sequential relay
circuits for machine control. In the late 1960's PLC’s were first introduced. The primary reason for designing such a
device was eliminating the large cost involved in replacing the complicated relay based machine control systems.
Bedford Associates (Bedford, MA) proposed - Modular Digital Controller (MODICON). The MODICON 084
brought the world's first PLC into commercial production PLC is computerized industrial controller that performs
discrete or sequential logic in a factory environment. A PLC is currently defined as digital electronic device that
uses programmable memory to store instructions & to implement specific functions such as timing, counting,
logical, arithmetic operations, to control machine & processes.
A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used
for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement
rides, or light fixtures. The abbreviation "PLC" and the term "Programmable Logic Controller" are registered
trademarks of the Allen-Bradley Company (Rockwell Automation. PLCs are used in many industries and machines.
Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, 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. A PLC is an example of
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IJARSE, Vol. No.2, Issue No. 2, February, 2013 ISSN-2319-8354(E)

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.

(a) (b)
Figures 2: Programmable Logic controller (a) and (b)

2.1 Principle of PLC

The program in CPU of PLC includes operating system and user program. Operating system is used for dealing with
tasks, for example start-stop of PLC, refreshing PLC maps area, calling user program, processing errors, managing
storage area, and communication. User program is made by user, which is used to finish automation control tasks.

Organizational block

Start cycling time monitoring

Write data into output module

Read data from input module

User program working

Other tasks

Fig 3: Principle of PLC

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IJARSE, Vol. No.2, Issue No. 2, February, 2013 ISSN-2319-8354(E)

PLC adopt working mode of cyclic scanning which is also called as scan mode:

1. Operating system starts cyclic time monitoring.

2. CPU writes data from out process map area to output module.
3. Read data from input module and store them into input process map area.
4. CPU deals with data from input module and execute program.
5. At the end of cyclic scan, operating system implements all hang–up task, for example to download and
delete block, receive and send data.
6. Return to1, start new cyclic scan.

2.2 Automation with PLC

Following is the example of small control system required to control the level of the tank. A level sensor (LS)
continuously measures the level of liquid in a tank & sends the signal to the level controller. A controller then
sends the signal to control ON/OFF action of valve. This system works on definite logic. When liquid level
goes below the predetermined level then valve turns ON, & when liquid level goes above the predetermined
level then valve turns OFF.
In this process PLC is the Controller, which decides controlling action. PLC receives number of inputs
from different devices located at different parts of the plants. PLC then decides controlling action on the basis
of status of inputs & logic written in its memory.
According to the controlling action the output device operates. As it uses programming logic to control the
process, called as Programmable Logic Controller. As PLC takes decisions without interference of man, it is
used for automation.

Fig 4: Level control application of PLC

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2.3 Traditional PLC Concept:

 PLC performs relay equivalent  Ladder diagram programming

functions  Designed for industrial
 PLC performs ON/OFF control environment

2.3 History of PLC:

Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles
was mainly composed of relays, cam timers, drum sequencers, and dedicated closed-loop controllers.
Since these could number in the hundreds or even thousands, the process for updating such facilities
for the yearly model change-over was very time consuming and expensive, as electricians needed to
individually rewire relays to change the logic. Digital computers, being general-purpose
programmable devices, were soon applied to control of industrial processes. Early computers
required specialist programmers, and stringent operating environmental control for temperature,
cleanliness, and power quality. Using a general-purpose computer for process control required
protecting the computer from the plant floor conditions. An industrial control computer would have
several attributes: it would tolerate the shop-floor environment, it would support discrete (bit-form)
input and output in an easily extensible manner, it would not require years of training to use, and it
would permit its operation to be monitored. The response time of any computer system must be fast
enough to be useful for control; the required speed varying according to the nature of the process

III. OPERATING CYCLE OF PLC

a) Input scan: The status of external inputs (terminal block voltage) is written to the Input image (“input
file”).
b) Program scan: each ladder rung is scanned using data in the input file. The resulting status (logic being
solved) is written to the output file (“output image”).
c) Output scan: The output image data is transferred to the external output circuits, turning the output device
ON or OFF.
d) Housekeeping: Internal checks on memory, speed and operation. Service any communication requests, etc.
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Fig 5: Operating cycle of PLC

IV. ILLUSTRATE THE SYSTEM OF COMPONENTS OF PLC:

There are five basic components in a PLC system:

 The PLC processor, or controller

 I/O (Input /Output) modules
 Chassis or backplane
 Power supply
 Programming software that runs in a PC

PLC- program

Input module Central control unit Output module

Sensors Actuators

Fig 6: Block diagram of components of PLC

4.1 Processor, controller, or CPU

 Stores the control program and data in its memory
 Reads the status of connected input devices
 Executes the control program
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 Commands connected outputs to change state based on program execution For example: Turn
a light on, start a fan, adjust a speed, or temperature
 Comes in various physical forms.

Fig7 (a): Processor that fits in a chassis Fig7 (b): Stand alone PLC

4.2 I/O modules

 Input modules convert real world voltage and currents to signals the PLC can
understand. Since there are different types of input devices, there is a wide variety of
input modules available, including both digital and analog modules.
 Physically connect to field devices
 Input modules convert electrical signals coming in from input field devices such as
pushbuttons, to electrical signals that the PLC can understand.
 Output modules take information coming from the PLC and convert it to electrical
signals the output field devices can understand, such as a motor starter, or a hydraulic
solenoid valve.
 I/O comes in various forms

Fig8 (a): I/O that fits in a chassis with the PLC Fig8 (b): I/O that remotely located from the PLC
Requires a network connection back to the PLC
4.3 Chassis or backplane
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All PLCs need some method of communicating between the controller, I/O and communications modules.
Here are three ways used to accomplish this communications between the various components that make up
the PLC system.
 Modules are installed in the same chassis as the PLC and communicate over the chassis
backplane
 Modules are designed to “plug” into each other. The interconnecting plugs form a
backplane. There is no chassis
 Modules are built into the PLC. The modules come together in one physical block. The
backplane in this case is transparent to the user.

Backplane
connector

Fig 9: Example of Backplane connector

Above is an example of a backplane in a chassis based system. You can see the backplane in the area where the
modules are not inserted. The modules have connectors that plug into the black connectors on the backplane. All of
the connectors on the backplane are connected together electrically.

4.4 Power Supply:

A power supply is needed to provide power to the PLC and any other modules. Power supplies come
in various forms:
 Power supply modules that fit into one of the slots in a chassis
 External power supplies that mount to the outside of a chassis
 Stand alone power supplies that connect to the PLC or I/O through a power cable
 Embedded power supplies that come as part of the PLC block.
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Power supply that fits in

Power supply a slot of chassis
mounted to the
side of the chassis

(a) Fig10: Power supply diagram (a) & (b) (b)

V PROGRAMMING OF PLC

PLC programs are typically written in a special application on a personal computer, the downloaded by a direct-
connection cable or over a network to the PLC. The program is stored in the PLC either in battery-backed-up RAM
or some other non-volatile flash memory. Often, a single PLC can be programmed to replace thousands of relays.

Under the IEC 61131-3 standard, PLCs can be programmed using standards-based programming languages. A
graphical programming notation called Sequential Function Charts is available on certain programmable controllers.
Initially most PLCs utilized Ladder Logic Diagram Programming, a model which emulated electromechanical
control panel devices (such as the contact and coils of relays) which PLCs replaced. This model remains common
today.

 IEC61131-3 currently defines five programming languages for programmable control

systems: function block diagram (FBD), ladder diagram (LD), structured text (ST; similar to
the Pascal programming language), instruction list (IL; similar to assembly language) and sequential
function chart (SFC).These techniques emphasize logical organization of operations.
 While the fundamental concepts of PLC programming are common to all manufacturers, differences
in I/O addressing, memory organization and instruction sets mean that PLC programs are never
perfectly interchangeable between different makers. Even within the same product line of a single
manufacturer, different models may not be directly compatible.
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Fig11: Example of PLC programming software

5.1 Programming device of PLC:

Programmer performs ladder logic into Programming Device. Processor files are created in the offline mode using
programming device. These files are then downloaded to the processors for on line operations. Most of the
operations perform with the programming device involve the processor file & the two components created with it,
program files & data files. The programming device stores processor files on hard disk (or floppy disk). Monitoring
and editing of processor files is done in the workspace of the computer. After you select a file from disk and edit it,
you then save the file hard to disk, replacing the original disk version with the edited version. The hard disk is the
recommended location for a processor.

5.2 PLC compared with other control system:

PLCs are well adapted to a range of automation tasks. These are typically industrial processes in manufacturing
where the cost of developing and maintaining the automation system is high relative to the total cost of the
automation, and where changes to the system would be expected during its operational life. PLCs contain input and
output devices compatible with industrial pilot devices and controls; little electrical design is required, and the
design problem centers on expressing the desired sequence of operations. PLC applications are typically highly
customized systems, so the cost of a packaged PLC is low compared to the cost of a specific custom-built
controller design. On the other hand, in the case of mass-produced goods, customized control systems are
economical. This is due to the lower cost of the components, which can be optimally chosen instead of a "generic"
solution, and where the non-recurring engineering charges are spread over thousands or millions of units.
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A microcontroller-based design would be appropriate where hundreds or thousands of units will be produced
and so the development cost (design of power supplies, input/output hardware and necessary testing and
certification) can be spread over many sales, and where the end-user would not need to alter the control. Automotive
applications are an example; millions of units are built each year, and very few end-users alter the programming of
these controllers. However, some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls, because the volumes are low and the development cost would be uneconomical .

5.3 PLC Scan time:

A PLC program is generally executed repeatedly as long as the controlled system is running. The status of physical
input points is copied to an area of memory accessible to the processor, sometimes called the "I/O Image Table".
The program is then run from its first instruction rung down to the last rung. It takes some time for the processor of
the PLC to evaluate all the rungs and update the I/O image table with the status of outputs. [6] This scan time may be
a few milliseconds for a small program or on a fast processor, but older PLCs running very large programs could
take much longer (say, up to 100 ms) to execute the program. If the scan time was too long, the response of the PLC
to process conditions would be too slow to be useful.

VI AREAS OF ADVANTAGES AND ITS APPLICATION

6.1 Advantages over relay:

 All the capabilities of the earlier  No special programming skills
systems required by maintenance personnel
 Dramatic performance increase over  Physical size of the PLC system is
the relay logic systems. much smaller than the conventional
 Greater reliability relay based logic
 Little maintenance due to no moving  And most importantly, much lower
parts cost
6.2 Advantages over computer based software:
 Better power failure response  Higher reliability that minimizes
 Cost advantages for simple the expense of shutdown,
machine control troubleshooting, repair, & startup
 Industrially hardened packaging  Maintenance personnel already
 Long availability and support for experienced in PLC
product models without rapid troubleshooting and servicing relay
obsolescence of PCs ladder logic programming, not PC
software
6.3 Applications of PLC:
 Car parking
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 Traffic light control, Process  Doorbell digital clock

control, tank level control  Switching of lights
 Sequential control motors  Washing machine
 Reaction vessel

VIII PLC HARDWARE TYPES:

8.1 Most Basic Of PLC Systems:
In the most basic of PLC systems, a self contained (shoe box) PLC has two terminal blocks, one for inputs
and one for outputs
Today, most PLC in this category is known as Micros. Typically they provide front panel LED status
indication of I/O and processor states.

8.2 Modular chassis- less PLC systems:

Also available from many vendors are “chassis less” but still Modular PLC systems. These systems still
require a Processor, I/O modules, Power supply, but in place of a chassis these components mount directly
onto a panel, din rail, and many use a tongue and grove system to allow easy insertion and removal.

IX CONCLUSION:

This report has discussed the role that PLCs have in the efficient design and control of mechanical processes.
Also discussed the understanding of logger logic and the programming involved in it. Finally, the report has
discussed the relay logic and the evolution that ladder logic made from it. It will help the utilities respond to
the challenges presented by deregulation. Therefore with development of computer technology, control theory,
digital communication technology and microprocessor technology, PLC must ultimately resort to these new
technologies to improve its development and perfect its function, so it can catch up with development trend of
automation.

REFERENCES

[1]. “The father of invention: Dick Morley looks back on the 40th anniversary of the PLCs”.
Manufacturing Automation, 12 September 2008.
[2]. W. Bolton, “Programmable Logic Controllers”, 5th edition Newnes, 2009
[3]. M. A. Laughton, D.J. Warne (ed), Electrical Engineer’s Reference book, 16th edition, Newnes,
2003 Chapter 16 “Programmable Controller”
International Journal Of Advance Research In Science And Engineering http://www.ijarse.com
IJARSE, Vol. No.2, Issue No. 2, February, 2013 ISSN-2319-8354(E)

[4]. Harms, Toni M. & Kinner, Russell H.P.E., Enhancing PLC Performance with Vision Systems.
18yh Annual ESD/HMI “International Programmable Controllers” Conference Proceedings,
1989, p. 387-399