Programmable Logic Controller

PLC
 It is an electronic device used for automation
of industrial processes where output results
must be produced in response to input
conditions within the the bounded time,
otherwise miscontrol will result.
 Thus a PLC is used to control, time and
regulate the sequence of operations.

“ It is a digital device that uses a programmable

memory to store instructions and to implement
functions in order to control machines and
processes”.
 PLC is important since all production
processes go through a fixed repetitive
sequence of operations that involve logical
steps and decisions.
 Unlike general purpose computers, the PLC
is designed for extended temperature ranges,
dirty or dusty conditions, immunity to
electrical noise, and resistance to vibration
and impact.
 drivers for
industrial process sensors
the status of switches,
past values of data
and other working data
are stored. Data Input
Memory Process
devices
Sensors
Control
Unit

Program Output
Memory Process
devices
Actuators
(motors)
the instructions for the
logical control sequence
are stored.
PC drivers for industrial process
actuators, such as solenoid
switches, motors and valves
through which the logical sequence
that the PLC will execute is built and edited.
 V1

PLC L1
Tank
1

Wait for 10s L2

Wait for 20s
V2

L3
Tank
2
ON
OFF L4

V3
Reservoir
R1 P Reservoir
R2
 Programming
 PLC programming is based on the use of Ladder
Diagrams. Using these, writing a program is
equivalent to drawing a switching circuit.
 The basic components in a ladder logic program
are:

Input Input
Normally open contact Normally closed contact Output device

Inputs in series
Logic AND Inputs in parallel Special Instruction
Logic OR
 Y 430
X400
• Each rung must start with an
input or a series of inputs
and end with an output. X401 X402
Y 431

• Inputs and outputs are

Y 432
numbered, the notation used X403 X404
depends on the PLC
manufacturer

X406

End
 A normally open start switch. When the
switch is closed, the coil is energized

 In case of a normally closed switch the coil is

energized provided that the switch does NOT
change.
Logic Functions

The coil is not energized unless two A B C

normally open switches are both closed
(both changes their state), thus gives
AND logic situation.
C=A.B A B

Inputs Output
C
A B
0 0 0
0 1 0
1 0 0
1 1 1
The coil is not energized until either one
of 2 normally open switches is closed C
which thus gives an OR logic situation. A
C=A+B

B
Inputs Output
C A
A B
0 0 0
0 1 1 B
1 0 1
1 1 1
For the coil to be energized we require A
to be closed and either B or C to be
closed
A.(B+C) A B D

Inputs Output
A B C
C
0 0 0 0
0 0 1 0 B
A
0 1 0 0
0 1 1 0
1 0 0 0 C
1 0 1 1
1 1 0 1
1 1 1 1
A B C

NOR
C=

A C

B NAND
A C
B

A B
EOR
Entering the program

 Each horizontal line i.e. rung on the ladder

represents a line in the program and the
entire ladder can be translated into a program
using a keyboard with the graphic symbols
for the ladder elements and then the program
panel translates these symbols into machine
language that is then stored in the PLC
memory.
Develop a program that will cause output D to go true
when switch A and switch B are closed or when switch C
is closed.

Solution:
D = A  B + C

A B
D

C
•Develop a program that will cause output D to be on
when push button A is on, or either B or C are on.

Solution:
D = A + B  C

A
D

B C

B C
•Develop a Ladder Logic for a car door/seat belt safety system.
When the car door is open, and the seatbelt is not done up, the ignition power
must not be applied.
If all is safe then the key will start the engine.

Solution:

Door Open Seat Belt Key

Ignition
•Design a motor controller that has a forward and reverse button. The
motor forward and reverse outputs will only be on when one of the buttons
is pushed. When both buttons are pushed the motor will not work.

Solution:
F = BF  BR where,
F = motor forward
R = BF  BR R = motor reverse
BF = forward button
BR = reverse button

BF BR
F

BF BR
R
 A robot is used to unload processed parts of a machine into
AGV, pick up a new part for processing from AGV and load it
onto the machine. The AGV is to be dispatched after
completion of the cycle. Construct a ladder logic diagram for
the task.
20
01 04 03

01 AGV has arrived

21
02 AGV is carrying 20 02

a new part to be processed.

03 AGV has space to store 01 04
a processed part.
04 Machine has a finished part 21 22
to be unloaded
20 Unload old part from machine
20 02
onto AGV
21 Pick new part from AGV
and load onto machine 01 04

22 Dispatch the AGV

 20
01 04 03

01 AGV has arrived

21
02 AGV is carrying 20 02

a new part to be processed.

03 AGV has space to store 01 04
a processed part.
04 Machine has a finished part 21 22
to be unloaded
20 Unload old part from machine
20 02
onto AGV
21 Pick new part from AGV
and load onto machine 01 04

22 Dispatch the AGV

 20
01 04 03

01 AGV has arrived

21
02 AGV is not carrying 20 02

a new part to be processed.

03 AGV has space to store 01 04
a processed part.
04 Machine has a finished part 21 22
to be unloaded
20 Unload old part from machine
20 02
onto AGV
22 Dispatch the AGV
01 04
Timers and Counters
 Timers: It counts time units. It is represented TIM
by the symbol below where the number
indicated means that the following task will be 09
performed after timer counts that number of #
time units (usually seconds).

 Counter: They are used when there is a need

to count a specified number of contact
operations e.g. where items pass along a CT
conveyer into boxes, and when the specified 47
number of items has passed into a box, the #
next item is diverted into another box. It is
represented by the symbol below with the
number indicting that the following step will be
performed after the counter counts that
number of times.
 During the powder metallurgy process, a punch
is used to press blended metal powder into a die. 30
01 02
A pushbutton is used to start the process. When
the start button is pressed, the die is filled with
powder. The punch is then advanced and it
applies pressure to the powder for a duration of 33
10 seconds, after which it is retracted. The
pressed compact is then ejected from the die and 31
then the cycle repeats. The cycle can be 30
interrupted by pressing a stop button. If the stop
button is pressed, the punch is required to retract
(if it had been advanced) before the process is 31 TI
stopped. It is required to construct a ladder logic #10
diagram for this task
TI 32

01 Start button
02 Stop button 02

TI Timer (with a limit of 10 s)

33
30 Fill die 32
31 Advance punch
32 Retract punch 02
33 Eject part (i.e compact) 34
02
34 Stop cycle
Question

 Why a stop button must be normally closed

(NC) and a start button must be (NO) ?????

If a NC stop button is damaged, the machine

will act as if the stop button was pushed and
shut down safely. If a NO start button is
damaged the machine will not be able to start