Rayat Shikshan Sanstha’s

Karmaveer Bhaurao Patil Polytechnic,Satara

Micro-Project Report

On

‘PROGRAMMABLE LOGIC CONTROLLER’

Presented by

03-Sanket Tanaji Deshmukh.

04-Vedant Sandip Dhanawade.
20-Atharv Govind Salunkhe.

Program : Diploma in Mechanical Engineering

Class : SYME ( Semester - IV )
Course: fundamental of mechatronics

Guide By
Prof. Zore P.V.
( Mechanical Engineering Department)
[2022- 2023]

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 Rayat Shikshan Sanstha’s

Karmaveer Bhaurao Patil Polytechnic, Satara

CERTIFICATE

This is to certify that

Mr. Sanket Tanaji Deshmukh
Mr. Vedant Sandip Dhanawade
Mr. Atharv Govind Salunkhe

Of Second Year ( Semester IV ) have successfully completed the Micro-Project work

entitled “Programmable Logic Controller ” in the Course fundamental of mechatronics of
Program Diploma in Mechanical Engineering of Maharashtra State of Technical Education,
Mumbai, Maharashtra State.

Prof.Zore P.V. Prof.N.B.Devi Dr.Shaikh K.C.

Guide Head of Department Principal

Date: / /
Place:K.B.P Polytechnic satara

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 Undertaking By Students

We will preserve micro-project and the report in our custody till end of completion of our
program. We assure that we will produce the same whenever we or anybody from our
group will be asked to produce it without fail.

Roll No Name of Students Mobile No. Signature

03 Sanket Tanaji Deshmukh 7709492664
04 Vedant Sandip Dhanawade 8975250134
20 Atharv Govind Salunkhe 8788975997

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Title of Micro project – programmable logic controller

1.0 Brief Introduction

A programmable logic controller (PLC) is a small, modular solid state computer
with customized instructions for performing a particular task. PLCs, which are
used in industrial control systems (ICS) for a wide variety of industries, have
largely replaced mechanical relays, drum sequencers and cam timers.

2.0Aim of the Micro-Project

A] To study about programmable logic controller.
B] To obtain information about programmable logic controller.
3.0Action plan

Sr. No. Planned Planned Name of Responsible

Details of Activity Start date Finish Team Members
date
1 Selection of Project 10-02-2023 10-02-2023 All members
2 Searching information 10-02-2023 10-02-2023 All members
3 Collection of data 17-02-2023 27-02-2023 All members
4 Preparation of data 06-03-2023 06-03-2023 All members
5 Final printing 10-03-2023 10-03-2023 All members
6 Submission 10-03-2023 10-03-2023 All members

4.0Resources Requires

Sr.
Name of resource / material Specification Quantity Remarks
No.
1 Laptop Windows 7 03
2 Internet Airtel 01
3 Reference Book 02

INTRODUCTION OF PLC
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 A programmable logic controller (PLC) is a small, modular solid state computer with
customized instructions for performing a particular task. PLCs, which are used in
industrial control systems (ICS) for a wide variety of industries, have largely replaced
mechanical relays, drum sequencers and cam timers.
First commercial & successful Programmable Logic Controllers was designed and
developed by Modicon as a relay replacer for General Motors.Earlier, it was a machine
with thousands of electronic parts.Later,in late 1970's, the microprocessor became
reality & greatly enhanced the role of PLC permitting it to evolve form simply relay to
the sophisticated system as it is today

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

computer which has been ruggedised and adapted for the control of manufacturing
processes, such as assembly lines, or robotic devices, or any activity that requires high
reliability control and ease of programming and process fault diagnosis.  They were first
developed in the automobile industry to provide  flexible, ruggedised and easily
programmable controllers to replace  hard-wired relays, timers and sequencers. Since then
they have been  widely adopted as high-reliability automation controllers suitable for  harsh
environments 

The four basics steps in PLC operation are:

Input Scan - Detects the state of input devices connected to the PLC.
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 Program Scan - Executes program created by user.
Output Scan - Operate all output devices connected to the PLC.
Housekeeping - Communicates with other devices and runs diagnostics.

What are the Functions and Applications of PLCs ?

The functionality of the PLC has evolved over the years to include sequential relay
control, motion control, process control, distributed control systems, and networking.
The data handling, storage, processing power, and communication  capabilities of some
modern PLCs are approximately equivalent to desktop computers.  PLC-like
programming combined with remote I/O hardware, allow a  general-purpose desktop
computer to overlap some PLCs in certain  applications. Desktop computer controllers
have not been generally  accepted in heavy industry because the desktop computers run
on less  stable operating systems than do PLCs, and because the desktop computer
hardware is typically not designed to the same levels of tolerance to  temperature,
humidity, vibration, and longevity as the processors used  in PLCs. Operating systems
such as Windows do not lend themselves to  deterministic logic execution, with the
result that the controller may  not always respond to changes of input status with the
consistency in  timing expected from PLCs. Desktop logic applications find use in less
critical situations, such as laboratory automation and use in small  facilities where the
application is less demanding and critical, because  they are generally much less
expensive than PLCs 

PLC Advantages
Richard and his team focused on ensuring maintenance electricians and plant engineers
could easily understand and use this new programmable controller. Naturally, the
process took much trial and error to get to a controller that solved all the previous pain
points while still being user-friendly. Eventually, they were able to achieve this with the
MODICON 184.

Nowadays, PLCs offer several advantages over the hardwired relays including reliability,
flexibility, cost effectiveness, speed, better communication, and advanced data
processing functions. However, the most unique advantage to PLC systems is the ability
to reprogram them. Therefore, they’re highly adaptable to changes in processes or
monitoring application requirements.

In addition, programmable logic controllers feature several diagnostic tools that

facilitate easy troubleshooting such as:

 Report generation
 Fault Logs
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 Step-by-step program simulation
 Manually run inputs/outputs

PLC Programming

PLCs require programming before they can function and perform their given tasks. These
programs are usually written in a programming device or software. The program is then
downloaded into the memory or RAM of the programmable logic controller. Based on
the written program the CPU can read the information provided by the inputs and
instruct the PLC to execute the desired outputs. There are many programming languages
available to configure your PLC system.
According to IEC 61131, there are 5 standard programming languages available:
 Ladder Diagram or Ladder Logic (LD)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Sequential Function Chart (SFC)
 Instruction List (IL)

Input/Output Unit
The input/output unit provides the interface between the system and the outside world,
allowing for connections to be made through input/output channels to input devices such
as sensors and output devices such as motors and solenoids. It is also through the
input/output unit that programs are entered from a program panel. Every input/output
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point has a unique address that can be used by the CPU. It is like a row of houses along a
road; number 10 might be the “house” used for an input from a particular sensor, whereas
number 45 might be the “house” used for the output to a particular motor. The
input/output channels provide isolation and signal conditioning functions so that sensors
and actuators can often be directly connected to them without the need for other circuitry.
Electrical isolation from the external world is usually by means of opto-isolators (the term
opto-coupler is also often used). Figure shows the principle of an opto-isolator. When a
digital pulse passes through the light-emitting diode, a pulse of infrared radiation is
produced. This pulse is detected by the phototransistor and gives rise to a voltage in that
circuit. The gap between the light-emitting diode and the phototransistor gives electrical
isolation, but the arrangement still allows for a digital pulse in one circuit to give rise to a
digital pulse in another circuit. The digital signal that is generally compatible with the
microprocessor in the PLC is 5 V DC. However, signal conditioning in the input channel, with
isolation, enables a wide range of input signals to be supplied to it. A range of inputs might
be available with a larger PLC, such as 5 V, 24 V, 110 V, and 240 V digital/discrete, that is,
on/ off, signals. A small PLC is likely to have just one form of input, such as 24 V.

2.0 Aim of the Micro-Project

a. To collect information about PLC.
b. To understand PLC.

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3.0 Course Outcome Integrated
a. We learnt about PLC.
b. We learnt different types of inputand output devices .
c. We learnt introduction about PLC.

4.0 Actual Procedure Followed

a. We decide the topic of our micro project with the help of our guide.
b. We collect some information related to the “PLC ”
through various sources like internet and books.
c. We typed the report of the project and submitted it to our guide

5.0 Output of the Micro-Project

a. We learnt about PLC.
b. We learnt different types of inputand output devices .
c. We learnt introduction about PLC.

6.0 Skill developed / Learning out of the Micro-Project

a. In this project We learned about programmable logic controller.
b. we learned different types of input and output devices .
c. we learned about different types of buttons that are used in programmable
logic controller.