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PLC Applications 1716345432
PLC Applications 1716345432
APPLICATIONS
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Presentation Outline
➢ Evolution of Programmable Logic Controllers (PLC)
➢ Introduction to Programmable Logic Controllers
➢ Advantages of PLCs
➢ Functional Components of PLC System
➢ Relay Ladder Logic
➢ Central Processing Unit
➢ Input /Output System
➢ Programming and Peripheral Devices
➢ Programming Concepts
➢ Applications
➢ Manufacturers
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PLC (Programmable Logic Controller)
Origin
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Historical Background
The Hydraumatic Division of the General Motors
Corporation specified the design criteria for the first
programmable controller in 1968
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Historical Background
• The controller had to be designed in modular form, so
that sub-assemblies could be removed easily for
replacement or repair.
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Programmable Controller Development
1968 Programmable concept developed
1969 Hardware CPU controller, with logic
instructions, 1 K of memory and 128 I/O
points
1974 Use of several (multi) processors within a
PLC - timers and counters; arithmetic
operations; 12 K of memory
and 1024 I/O points
1976 Remote input/output systems introduced
1977 Microprocessors - based PLC introduced
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Programmable Controller Development
1980 Intelligent I/O modules developed
Enhanced communications facilities
Enhanced software features
(e.g. documentation)
Use of personal microcomputers as
programming aids
1983 Low - cost small PLC’s introduced
1985 on Networking of all levels of PLC, computer
and machine using SCADA software.
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CONTROLLERS
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WHAT FORM MIGHT A
CONTROLLER HAVE?
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FIG.1. A CONTROL CIRCUIT
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MICROPROCESSOR
CONTROLLED SYSTEM
• INSTEAD OF HARDWIRING EACH CONTROL CIRCUIT FOR EACH CONTROL SITUATION WE
CAN USE THE SAME BASIC SYSTEM FOR ALL SITUATIONS IF WE USE A MICROPROCESSOR
REACT TO EACH INPUT SIGNAL FROM, SAY, SWITCHES AND GIVE THE REQUIRED OUTPUTS
IF SWITCH A CLOSES
IF SWITCH B CLOSES
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PLC(PROGRAMMABLE LOGIC
CONTROLLERS)
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•The term logic is used because programming is primarily concerned with
implementing logic and switching operations, e.g. if A or B occurs switch on C, if
A and B occurs switch on D.
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ADVANTAGES OF PLCs
• The great advantage that the same basic controller can be used with a wide
range of control systems.
• To modify a control system and the rules that are to be used, all that is
necessary is for an operator to key in a different set of instructions. There is no
need to rewire.
• The result is a flexible, cost effective, system which can be used with control
systems which vary quite widely in their nature and complexity.
• Easier and faster to make changes.
• Trouble shooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.
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Functional Components of PLC system
• The processor unit or central processing unit (CPU) is the unit containing the
microprocessor and this interprets the input signals and carries out the control
actions, according to the program stored in its memory, communicating the
decisions as action signals to the outputs.
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• The power supply unit is needed to convert the mains A.C. voltage to the low D.C.
voltage (5 V) necessary for the processor and the circuits in the input and output
interface modules.
• The programming device is used to enter the required program into the memory of
the processor. The program is developed in the device and then transferred to the
memory unit of the PLC.
• The memory unit is where the program is stored that is to be used for the control
actions to be exercised by the microprocessor and data stored from the input for
processing and for the output for outputting.
• The input and output sections are where the processor receives information from
external devices and communicates information to external devices. The inputs
might thus be from switches or other sensors such as photo-electric cells,
temperature sensors, or flow sensors, etc. The outputs might be to motor starter
coils, solenoid valves, etc.
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• Input and output devices can be classified as giving signals which are discrete, digital or
analogue . Devices giving discrete or digital signals are ones where the signals are either
off or on. Thus a switch is a device giving a discrete signal, either no voltage or a voltage.
Digital devices can be considered to be essentially discrete devices which give a
sequence of on−off signals. Analogue devices give signals whose size is proportional to
the size of the variable being monitored. For example, a temperature sensor may give a
voltage proportional to the temperature.
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Internal Structure of PLC
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I/O Module
• The I/O interface section of a PLC connects it to
external field devices.
Current Buffer,
FROM Limiting OPTO-
Filter,
TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits
Rectifier, Buffer,
FROM Resistor OPTO-
Filter,
TO
INPUT Network ISOLATOR Hysteresis
PROCESSOR
DEVICE Circuits
Amplifier
FROM OPTO-
RELAY
TTL TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE
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OUTPUTS
INPUTS MOTOR
CONTACTOR
LAMP
PUSHBUTTONS
PLC
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Allen-Bradley 1746-1A16
L1 L2 I= Input
Module
I:2 slot # in rack
P. B SWITCH 0 Module
Terminal #
Address I:2.0/0
LADDER PROGRAM
INPUT
MODULE
WIRING DIAGRAM
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CONTACTOR
L2 L1 N.
O
MOTOR
L2
C •SOLENOID
L1
•VALVES
FIELD •LAMP
WIRING •BUZZER
OUTPUT MODULE
WIRING
L1 O:4 L2
CONTACTOR 0
LADDER PROGRAM
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Memory Map Organization
•System memory includes an area called the EXECUTIVE,
composed of permanently-stored programs that direct all
system activities, such as execution of the users control
program, communication with peripheral devices, and other
SYSTEM system activities.
•The system memory also contains the routines that
implement the PLC’s instruction set, which is composed of
specific control functions such as logic, sequencing, timing,
counting, and arithmetic.
•System memory is generally built from read-only memory
devices.
APPLICATION
•The application memory is divided into the data table area
•Data Table and user program area.
•The data table stores any data associated with the user’s
•User Program control program, such as system input and output status data,
and any stored constants, variables, or preset values. The
data table is where data is monitored, manipulated, and
changed for control purposes.
•The user program area is where the programmed
instructions entered by the user are stored as an application
control program.
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PLC Communications
Common Uses of PLC Communications Ports
Common Standards
RS 232
9600 baud.
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PLC Communications
Local Area Network (LAN)
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PLC Communications
Programmable Controllers and Networks
Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY
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Examples of PLC Programming Software:
1. Allen-Bradley – Rockwell Software RSLogix500
2. Modicon - Modsoft
3. Omron - Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Texas Instruments – Simatic
6. Telemecanique – Modicon TSX Micro
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Specifications
Several factors are used for evaluating the quality and
performance of programmable controllers when selecting a
unit for a particular application. These are listed below.
NUMBER OF I /O PORTS
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Specifications
OUTPUT-PORT POWER RATINGS
SCAN TIME
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Specifications
MEMORY CAPACITY
•The amount of memory required for a particular
application is related to the length of the program and
the complexity of the control system.
•Simple applications having just a few relays do not
require significant amount of memory. Program length
tend to expand after the system have been used for a
while.
•It is advantageous to a acquire a controller that has
more memory than is presently needed.
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PLC Operation
Basic Function of a Typical PLC
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While the PLC is running, the scanning process
includes the following four phases, which are repeated
continuously as individual cycles of operation:
PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
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PHASE 1 – Input Status scan
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PHASE 4 - Output Status Scan
•An output status scan is then performed, whereby the
stored output values are sent to actuators and other
field output devices. The cycle ends by updating the
outputs.
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As soon as Phase 4 are completed, the entire cycle
begins again with Phase 1 input scan.
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PLC Size
1. SMALL - it covers units with up to 128 I/O’s and
memories up to 2 Kbytes.
- these PLC’s are capable of providing
simple to advance levels or machine
controls.
2. MEDIUM - have up to 2048 I/O’s and memories up
to 32 Kbytes.
3. LARGE - the most sophisticated units of the PLC
family. They have up to 8192 I/O’s and
memories up to 750 Kbytes.
- can control individual production
processes or entire plant.
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Selecting a PLC
Criteria
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A Detailed Design Process
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Tank Used to Mix Two Liquids
MOTOR
A
FS FLOAT SWITCH
SOLENOIDS B
SOLENOID
C
TIMER
1 -MINUTE
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Tank Used to Mix Two Liquids
A tank is used to mix two liquids. The control circuit
operates as follows:
2. When the tank is filled, the float switch trips. This de-
energizes solenoids A and B and starts the motor used
to mix the liquids together.
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Discrete Input
A discrete input also referred as digital input is an input that
is either ON or OFF are connected to the PLC digital input.
In the ON condition it is referred to as logic 1 or a logic high
and in the OFF condition maybe referred to as logic o or
logic low.
Normally Open
Pushbutton
Normally Closed
Pushbutton
Normally Open switch
OFF PLC
Logic 0
Input
Module
24 V dc
IN
ON PLC
Logic 1
Input
Module
24 V dc
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Analog Input
An analog input is an input signal that has a continuous signal. Typical inputs
may vary from 0 to 20mA, 4 to 20mA or 0 to10V. Below, a level transmitter
monitors the level of liquid in the tank. Depending on the level Tx, the signal to
the PLC can either increase or decrease as the level increases or decreases.
Level Transmitter IN
PLC
Analog
Tank Input
Module
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Digital Output
A discrete output is either in an ON or OFF condition. Solenoids, contactors
coils, lamps are example of devices connected to the Discrete or digital outputs.
Below, the lamp can be turned ON or OFF by the PLC output it is connected to.
OUT
PLC
Lamp
Digital
Output
Module
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Analog Output
An analog output is an output signal that has a continuous signal. Typical outputs
may vary from 0 to 20mA, 4 to 20mA or 0 to10V.
OUT
E Supply air
PLC 0 to 10V P
Analog
Output Pneumatic control valve
Module
53
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PROGRAMMING
Power flows through these contacts when they are closed. The
normally open (NO) is true when the input or output status bit
controlling the contact is 1. The normally closed (NC) is true
when the input or output status bit controlling the contact is 0.
54
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Coils
55
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Boxes
56
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AND OPERATION
A B C
Rung
57
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OR OPERATION
A C
Rung
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NOT OPERATION
A C
Rung
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As an example, consider a system where there has to be no output when any one of
four sensors gives an output, otherwise there is to be an output. One way we could
write a program for this is for each sensor to have contacts that are normally closed
so there is an output. When there is an input to the sensor the contacts open and the
output stops. We have an AND logic situation. Figure 9 shows the ladder diagram of
a system that might be used.
Input Input Input Input Output
X400 X401 X402 Y430
X403
1 2 3 4
Sensors
END
Figure 9. Output switched off by any one of four sensors being activated
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Areas of Application
Manufacturing / Machining
Food / Beverage
Metals
Power
Mining
Petrochemical / Chemical
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Manufacturers (Leading Brands) Of PLC
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D
EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
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Leading Brands Of PLC
JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi
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