Appendix D

PLC in Welding Process

In manufacturing of discrete parts, welding is a major part of the system.

Figure 10-8 illustrates a typical welding operation that has been automated.
In this application the programmable controller can control the length of the
weld and the power required producing the correct weld. The programmable
controller is programmed to allow the weld to occur only if all inputs and
conditions are correct. This includes determining:

1. if the parts are present and in the correct position;

2. the correct weld cycle speed and power setting;
3. the correct rate of speed on the line for the given application; and
4. if all interlocks and safety features are functioning.
In addition, the programmable controller can be used to determine if parts
are running low and be set to automatically turn on and off the line as
required. Documentation of production efficiency can be generated for quality
control and inventory requirements.

Figure 10-10: Programmable controllers can be used to control and

automate industrial welding processes.
Although this application illustrates only one welding station the
programmable controller can be used to control and interlock many welders.
Welders at one station may require more power than is available if all the
welders are on simultaneously. In this case, a large power draw can cause
poor quality welds. The requirements in a system using many welders are to
limit the amount of power being consumed at any one point in time. This is
accomplished by time sharing the power feed to each welder.
The programmable controller can be programmed for a maximum power
draw. When a welder requires power, the controller can determine if power is
available. If the correct power level is available, the weld will take place. If
not, the controller will remember the request and when power is available, it
will permit the welder to proceed with the weld cycle. The programmable
controller can also be programmed to determine which welder has priority.

PLC in Machine Control

When machines are linked together to form an automated system, controls
must be synchronised. Figure 10-11 Programmable controllers can be used to
control linear and rotary actuators in an industrial fluid power circuit.
 Figure 10-11. Programmable Controllers are used
to Control Fluid Power Applications
Control of Industrial Drives
Typically, motors have been connected directly to the power lines and
operated at a set speed. As systems have become more automated, there
are many applications that require a variable motor speed. Adjustable speed
controls are available to control the speed of standard AC and DC motors.
These controls are usually manually set for the desired speed, but many
allow for automatic control of the set speed. Figure 10-12 shows a
programmable controller used to control AC drives, which control a given
application. The drives can accept frequency and direction commands in a
BCD for-mat that the programmable controller can provide with a BCD output
module.

Programmable Controllers Are Used To Control Industrial Drives

Figure 10-12 Programmable controllers can be used to control and

synchronise the speed of conveyors on the assembly line. One programmable
controller can control all drives or individual drives.
PLC in Paper Industries

Figure 10-13 illustrates a typical paper mill operation. This type of operation
covers a large area. The control of this type of operation is ideal for a
programmable controller since most of the control logic is of the start/stop,
time delay, count sequential and interlock type functions. The programmable
controller allows for required I/O, which when multiplexed, can transmit
multiple signals over a single pair of wires.
The basic operation of a paper mill is to receive raw material such as logs,
pulp wood or chips, and process, size, store and deliver the material. This
includes a large conveyor system that has diverter gates, over travel
switches, speed control and interlocking. A break in any part of the system
can shut down the entire system. Since the system covers a large area,
finding a fault can be time-consuming. To solve this problem a programmable
controller with fault diagnostics can be used to analyse the system and give
an alarm and printout of where the problem exists with suggested solutions.

Programmable Controllers Are Used In Process Control Applications Such As

Paper Operation

Figure 10-13. In a paper mill, the programmable controller can be used to

control each operation and diagnose a problem in the system.
PLC in Batch Process Control System

Batch processing blends sequential, step-by-step functions with continuous

closed-loop control. Process control is systems control, and systems are
made up r' many parts. This means that individual programmable controllers
can be used to control each part and step of the process with additional
programmable controllers and computers supervising the total operation.
Figure 10-14 illustrates the major components in a programmable controlled
batch process control system. Note that as part of the system an operator
interface is added.

Figure 10-14 in a batch process control system, the operator

interface is used for instrumentation or other monitoring functions.

This may be in the form of instrumentation and process control station, a CRT
terminal, or any other type of interface. To add in interfacing and monitoring
a programmable based system, an access panel can be connected as re-
quired.

Figure 10-15 illustrates a data access panel that will give message
displays.
Figure 10-15: The data access panel is used to monitor the system by
providing message displays.
 Figure 10-19: A two-wire multiplexing system can be used for a
building security system.

The programmable controller's controlling functions on the multiplexing

system can be expanded as necessary. For example, if a security guard is to
patrol a building, the controller can be programmed to monitor the guard as
well as the building. As the guard moves through the building, the controller
would monitor the movement by recording when a door is open and/or when
the guard activates an assigned switch. The controller would know how long
it should take the guard to move from station to station. If something
happens to the guard, the controller would detect this and take corrective
action, such as alarming a central control station.

Conveyor System

Conveyor systems are commonly used in industry for movement of materials.

As industrial systems become more automated, additional control is required.
Additional control means additional wires to be connected from machine to
machine.

Again, multiplexing can be used to reduce the total wires required. As in any
assembly line application, a fault or breakdown at one station requires that
all upstream machines be turned off to prevent a jam-up. Because this
system may cover miles in many applications, multiplexing could be used to
link the system together. Figure 10-20 shows a number of machines
connected together by conveyors.

As illustrated, a sensor could be used to detect a fault at one location and

send a signal over the two-wire system to stop all upstream machines and
conveyors. This system could also be connected for total control of all
functions using the multiplexing system and a programmable controller.
Figure 10-20: An assembly line using several conveyors can be controlled by
a two-wire multiplexing system.
QUESTIONS:

1. What are five major advantages of using programmable controllers in an

industrial application?
2. What are two major market areas that programmable controllers are used
in?
3. What are the four basic parts of a programmable controller?
4. What is the function of the power supply section?
5. What is the function of the input/output section?
6. What is the function of the processor section?
7. What is the function of the programming section?
8. What is an example of a discrete* input?
9. What is an example of a discrete output?
10. What is an example of data input?
11. What is an example of a data output?
12. What are five typical functions performed by the central processor?
13. What is the most popular language used with programmable controllers?
14. What are the steps that must first take place before entering a program
into
the programmable controller?
15. What are two methods of storing a program once it has been developed?
16. What is one of the main advantages of using a multiplexing system?
17. How many wires are required to transmit and receive signals over a
multiplexing system?
PLC Drawings
 AND Gate Logic Symbol and Truth Table

OR Gate Logic Symbol and Truth Table

NOT Function Logic Symbol and Truth Table

Diode Logic AND Circuit

Three-input NAND Logic

NAND/NOR Equality
Combining Logic Circuits

Exclusive OR Gate

R-S Flip-Flop
 J-K Flip-Flop

Functional Logic System

 Brick Style PLC.

Typical Rack Style

Typical PLC expansion Rack

PLC Memory Allocation

PLC Input Module Circuit

PLC Output Module

Individually Isolated Output Module

Individually Isolated Input Module

Single-ended A/D Converter

Current loop Input

Analogue Output Connections

PLC Scan Cycle

.
Effects of Scan Time on Response Speed.

Logical Model of Closed Control

 Remote I/O Rack

Logical Model Closed Loop Control with Integral and Derivative of

Error Term (PID).
Simple Message Display Controlled by PLC Outputs

Operator Interface Panel

Simple Local Area Network (LAN)

Comparison of the three common program representations.

Typical hand-held terminal

PC used as a programming terminal

Typical Electrical Ladder Diagram

Ladder Logic Program
 Typical Discrete Input Module

Typical Discrete Output Module Connection Diagram