Task 1 plc

1- Programable Logic Devices (PLCs) compromises various parts, the

first point required in your report is to illustrate the main parts of
PLC, your illustration should at least include the following:
1- Schematic for the PLC internal architecture.
2- Main parts of the PLC and their role.
3- Key specifications for each part.

1- Central Processing Unit (CPU): The CPU is the brain of the PLC. It performs all
the processing tasks, including executing program instructions, reading
inputs, and controlling outputs. The CPU also manages communication
with other devices and performs various housekeeping functions.
• Key Specifications:
➢ Processing Speed: Typically measured in nanoseconds or microseconds, indicating the CPU's
ability to execute instructions quickly.
➢ Memory Capacity: Indicates the amount of program memory and data memory available for
storing instructions and data values.
➢ Communication Ports: Number and type of ports available for connecting with other devices
or networks.
➢ Programming Language Support: Specifies the programming languages supported by the
CPU, such as ladder logic, structured text, function block diagram, etc.

2- Memory: PLC have different types of memory to store program instructions, data values, and system
parameters. The main types of memory in a PLC are:
• Program Memory: It stores the user-programmed instructions that define the control logic.
• Data Memory: It holds data values used during program execution, such as input and output values,
intermediate calculations, and temporary storage.
• Key Specifications:
➢ Program Memory Capacity: Indicates the maximum size of the program that can be stored in
the PLC.
➢ Data Memory Capacity: Specifies the amount of memory available for storing data values during
program execution.
➢ Retention: Indicates whether the memory retains the program and data when power is lost or
during system shutdown.
3- Input Modules:

These modules interface with the external world by receiving signals from sensors, switches, or other
devices. They convert these signals into digital or analog values that the PLC can process.

• Types of Inputs:
➢ - Digital Inputs: Handle discrete signals (on/off, high/low). –
➢ Analog Inputs: Deal with continuous signals and provide a range of values.
• Key Specifications:
➢ Number of Inputs: Specifies the total number of input channels available for connecting
sensors or switches.
➢ Input Types: Indicates the supported input signal types, such as digital (on/off) or analog
(continuous) signals.
➢ Input Voltage Range: Specifies the acceptable voltage range for digital inputs or the
input range for analog signals.

4- Output Modules:
These modules interface with external devices such as motors, valves, and indicators. They receive
control signals from the PLC and convert them into appropriate output signals to operate the
connected devices.

• Types of Outputs:
➢ Digital Outputs: Control discrete devices (e.g., turning a motor on/off).
➢ Analog Outputs: Provide a continuous range of output values for devices like variable
speed drives
• Key Specifications:
➢ Number of Outputs: Specifies the total number of output channels available for
controlling external devices.
➢ Output Types: Indicates the supported output signal types, such as digital (on/off) or
analog (continuous) signals.
➢ Output Voltage/Current Ratings: Specifies the maximum voltage or current that can be
sourced or sunk by the output module.

5- Power Supply: The power supply unit provides the necessary electrical power to the PLC system.
It converts the incoming power supply into suitable voltage levels required for the PLC's operation.
• Types of power supply
➢ DC Power Supply:
➢ AC Power Supply:
• Key Specifications:
➢ Voltage Input Range: Specifies the acceptable voltage range for the power
supply unit.
➢ Power Output: Indicates the maximum power output provided by the power
supply to the PLC system.
6- Communication Ports:
PLCs often have built-in communication ports for connecting with other
devices or systems. These ports enable data exchange with supervisory
systems, human-machine interfaces (HMIs), or other PLCs for monitoring,
programming, or coordinating control tasks.

• Key Specifications:
➢ Port Types: Indicates the supported communication protocols or standards, such as
Ethernet, RS-232, RS-485, etc.
➢ Data Transfer Rate: Specifies the maximum data transfer rate supported by the
communication port.
➢ Protocol Support: Indicates the specific protocols or networks that can be utilized for data
exchange.

7- Programming Device:
To create, modify, or debug the PLC program, a programming device is used.
It can be a computer running specialized software or a handheld
programming device specifically designed for the PLC model. The
programming device allows users to write and edit the control logic,
configure system parameters, and transfer the program to the PLC.

• Key Specifications:
➢ Programming Software Compatibility: Specifies the compatible programming software
versions and features.
➢ Interface: Indicates the type of interface supported by the programming device, such as
USB, Ethernet, or serial connection.
➢ Display and Controls: Describes the features of the programming device, such as screen size,
keypad, touch functionality, etc.

8- Rack/Chassis:
In modular PLC systems, the rack or chassis provides a physical framework to mount
the CPU, input/output modules, power supply, and other components. It ensures
proper electrical connections and allows for expansion or replacement of modules
as needed.

• Key Specifications:
➢ Rack Size: Specifies the physical dimensions of the rack or chassis.
➢ Expansion Slots: Indicates the number of available slots for adding or removing
modules.
➢ Backplane: Describes the type of backplane used for electrical connections between
modules.
 Ask 2 Compare between PLC and computer

Plc:

1- Practical:
➢ PLC are specifically designed for industrial automation applications. They are rugged,
reliable, and capable of operating in harsh environments with high resistance to
temperature, vibration, and electrical noise. PLCs provide real-time control and have built-in
features for interfacing with various industrial devices, such as sensors, actuators, and motor
drives.
2- Building:
➢ PLC are typically built in a compact and modular form. They have a rugged construction with
built-in features like DIN rail mounting, removable terminal blocks, and front-facing
diagnostic LEDs. PLCs are designed for easy installation and maintenance in industrial control
panels or equipment.
3- Programming:
➢ PLC programming is typically done using specialized software that supports ladder logic,
function block diagrams, structured text, or other industrial programming languages. PLC
programming languages are specifically designed for programming control logic and are well-
suited for tasks such as sequential control, motion control, and process automation.
4- User interface:
➢ - Interfaces with industrial devices, sensors and actuators. - Specialized communication units
are used to connect to industrial networks. - It may have an HMI (human-machine interface)
interface for local control and monitoring.
5- Applications:
➢ PLC are widely used in
• industrial automation applications
• manufacturing
• process control
• robotics
and building automation. They excel in real-time control tasks that require fast response
times, deterministic behavior, and reliable operation. PLCs are commonly found in factories,
power plants, transport action systems, and other industrial environments.
Computer:
1- Practical:
➢ Computers are versatile devices used in a wide range of applications,
including office work, entertainment, and general-purpose computing.
They are not specifically designed for real-time control or industrial
automation. Computers may require additional hardware and software
components to interface with industrial devices, which can make them
less practical for certain industrial control applications.

2- Building:
➢ Computers come in various form factors, such as desktops, laptops, and servers. They are not
specifically designed for easy integration into industrial control panels. Computers may require
additional hardware, such as I/O cards or adapters, for interfacing with industrial devices. They are
generally built for general-purpose use and may not have the same level of durability and ruggedness
as PLC.

3- Programming:
➢ Computers are programmed using general-purpose programming languages such as C++, Python,
Java, etc. These languages are more suitable for developing software applications, data analysis, or
system automation tasks. While it is possible to develop control logic using general-purpose languages
on a computer, it may require additional software frameworks or libraries.

4- User interface:
➢ - Interfaces with a wide range of peripheral devices, including
keyboards, mice, displays, printers, etc. Connects to networks using
standard protocols such as Ethernet, Wi-Fi, etc.

5- Applications:
➢ Computers have a broad range of applications, including office
productivity,
• multimedia
• gaming,
• scientific simulations,
• data analysis
• internet browsing

They are well-suited for tasks that require complex computation, user interaction, and software
development. Computers are commonly found in offices, homes, educational institutions, and various
industries for non-real-time applications.
3- For your selected application, justify the choice of PLC control showing the advantage gained from
introducing PLC control on the system performance, your justification should clearly show how PLC
control the features that PLC control can enhance and all the problems/ emergencies it can solve.

My application selected:

Two direction conveyor is controlled by start pushbutton and stop pushbutton, there are two sensors,
the first one at the start of the conveyor and the second one at the end. Press start pushbutton to start
the conveyor in forward direction but the cart must be sensed by the first sensor S1, then when it arrives
at the end S2 stops the conveyor, then by pressing start for the next time the conveyors moves
backwards until it arrives at the sensor S1 to stop.

In this case
PLC is more recommended than classic control because it can be easily programmed to control the
direction of motion and interact with sensors automatically. PLC provides greater flexibility in
adjusting and controlling the process, and is characterized by reliability and precision in performance.
Additionally, PLC can be connected to other devices to achieve centralized control and coordination in
control tasks.

Classic control, on the other hand, may require more manual intervention and adjustments to ensure
proper control of the conveyor. It may also be less efficient in detecting and responding to changes in
the process, compared to PLC which can be programmed to respond quickly and accurately to sensor
inputs.

Overall, PLC offers more advanced and efficient control capabilities compared to classic control in this
case, making it a more suitable option for controlling the two-direction conveyor.
 Advantages and disadvantages of both plc and classic control

1- Advantages of PLC (Programmable Logic Controller):

✓ Flexibility: PLCs are highly flexible and can be easily reprogrammed or reconfigured to
accommodate changes in control logic or system requirements. This flexibility allows for easier
modifications and upgrades compared to traditional control systems.

✓ Real-time Control: PLCs are designed to provide real-time control, allowing for precise and
timely execution of control logic. They can process inputs, make decisions, and control outputs
with low latency, making them suitable for time-critical applications.

✓ Robustness: PLCs are built to withstand harsh industrial environments. They are resistant to
temperature variations, electrical noise, and vibrations, ensuring reliable operation in
demanding conditions.

✓ Modularity and Scalability: PLC systems are modular, allowing for easy expansion and
modification. Additional input/output modules can be added to accommodate new devices or
system changes without requiring a complete overhaul of the control system.

✓ Diagnostic and Troubleshooting Capabilities: PLCs provide built-in diagnostic features and
monitoring tools that facilitate troubleshooting and maintenance. They can log and display
system errors, monitor input/output status, and perform self-checks to aid in fault detection and
troubleshooting.

2- Disadvantages of PLC:

 Cost: PLC systems can be more expensive compared to traditional control systems, especially for
small-scale applications. The initial cost includes the hardware, programming software, and any
additional modules or accessories required.

 Complexity: Programming a PLC requires specialized knowledge of industrial automation and

programming languages specific to PLCs. The learning curve for programming can be steep for
individuals without prior experience or training.

 Limited Computing Power: PLCs are designed for control applications and have limited
computing power compared to general-purpose computers. Complex computations or data
analysis tasks may be better suited for computers or specialized computing platforms.
3- Advantages of Classic Control (Analog or Relay Control):

✓ Simplicity: Classic control systems are often simpler in terms of hardware and
programming. They involve basic electrical or electronic components, such as relays,
analog sensors, and actuators, making them easier to understand and implement.

✓ Cost-Effectiveness: Classic control systems can be more cost-effective for small-scale

or simple control applications. The components used in classic control are generally
less expensive compared to PLCs, and the programming requirements are minimal.

✓ Wide Availability: Classic control components, such as relays and analog sensors, are
widely available and can be easily sourced. This makes them accessible for
maintenance and replacement in various industries.

4- Disadvantages of Classic Control:

 Limited Flexibility: Classic control systems lack the flexibility of PLCs. Once a classic
control system is designed and implemented, making changes to the control logic or
system configuration can be difficult and time-consuming.

 Lack of Diagnostic Features: Classic control systems often lack built-in diagnostic
capabilities. Troubleshooting and fault detection can be more challenging, requiring
manual inspection and testing of individual components.

 Limited Integration: Classic control systems may have limitations when it comes to
integration with other systems or devices. They may not have the built-in
communication capabilities required for seamless integration with modern industrial
networks or supervisory systems.