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PROGRAMMABLE LOGIC

CONTROLLERS

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Now a days PLCs are the most widely used


control hardware in control applications.
The applications ranges from standalone
system to complicated networked systems
for more critical applications

Origin of PLC

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ORIGIN OF PLC
Developed
Now

to replace relays in the late 1960s

used in many industrial designs

APPLICATIONS OF PLC
Machine controls, packaging, palletizing, material
handling, similar sequential task as well as
process control

History of
Automation

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HISTORY OF
AUTOMATION
Programmable Logic Controller
Electronic control using Logic Gates
Relay logic Control
Pneumatic Control
Manual
Control

Manual
Control

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MANUAL CONTROL
All the actions related to process control are
taken by the operators
Drawbacks
Human errors and its effect on quality of final product
The production, safety, energy consumption and usage
of raw material are all subject to the correctness and
accuracy of human action.

Pneumatic Control
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PNEUMATIC CONTROL

Industrial automation, with its machine and process control,


had its origin in the 1920s with the advent of "Pneumatic
Controllers".
Actions were controlled by a simple manipulation of
pneumatic valves, which in turn were controlled by relays
and switches

Drawbacks

Bulky and Complex System


Involves lot of rework to implement control logic
Longer project time

Hardwired Logic
Control

HARD WIRED LOGIC


CONTROL

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The

contactor and Relays together with hardware timers an


counters were used in achieving the desired level of automat

Disadvantages

Bulky panels
Complex wiring
Longer project time
Difficult maintenance and
troubleshooting
Electronic control
by using Logic
Gates

ELECTRONIC CONTROL USING


LOGIC GATES

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In

1960s with the advent of electronics, the logic gates


started replacing the relays and auxiliary contactors in the
Control circuits.
The hardware timers & counters were replaced by electronic
Timers

Advantages
Reduced

space requirements
Energy saving
Less maintenance & greater reliability
Drawbacks
Changes in control logic not possible
More project time

Advantages of plc 7

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ADVANTAGES OF PLCS
Reduced

space
Ease of maintenance
Economical
Greater life & reliability
Tremendous flexibility
Shorter project time
Easier storage, archiving and documentation

DISADVANTAGES OF PLCS
PLC were Designed for Relay Logic Ladder and have
Difficulty with some Smart Devices.
To maximize PLC performance and Flexibility, a
number of Optional Modules must be added
What is a PLC
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What is a PLC

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Programmable
Logic
Controller
A PLC works by looking at its inputs and depending
upon their state, turning on/off its outputs. The user
enters a program, usually via software, that gives the
desired results.
A PLC can be thought of as Industrial Computer with
specially designed architecture in both their central
units (the PLC itself) and their interfacing circuitry to
field devices (input / output connections to the real
world).

What Constitutes A PLC


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?

WHAT CONSTITUTES A PLC ?

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The PLC is programmed interface between the Input


field elements & output field elements

PLC consist of
Hardware
Input Module
CPU (Central Process Unit)
Program memory
Output module
Power Supply

PLC HARDWARE

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PLC HARDWARE
Status LEDs of
the inputs and
outputs
CPU status
LED s

Analog
potentiomet
er

Module
receptacle for
battery,
EEPROM

Communicatio
ns interface

Fixing holes for


wall
mounting

Removable connectionLocking clip for


DIN rail mounting
terminals
(on 224, 226)
PLC HARDWARE
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PLC HARDWARE

CPU
Memory
I/O Modules
External Power
Supply

Software
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Software
1. Application Software (Logic)
2. Basic Software
Communication Accessories
1. Communication Adapter

I/O Modules
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I/O MODULES
A host of input and output modules are connected to the PLC bus
to exchange data with the processor unit. These can be broadly
categorized into Digital Input Modules, Digital Output Modules
Analog Input Modules, Analog Output Modules and Special purpose
Modules.
Digital Input Modules
The Digital Input Modules convert the External Binary signals from
the process to the internal digital signal level of programmable
Controllers.
Digital Output Modules
The Digital output Modules convert the internal signal levels of the
programmable controllers into the binary signal levels required
externally by the process.
Elements f Digital
Inputs and
Outputs

Elements of Digital Inputs and Outputs


Digital Inputs
push button
limit switches
Sensors
Proximity Sensors
Photo Sensors

Micro Switches

Toggle Switches
Digital Outputs

Relays
Contactors
Indication Lamps
Valves
Examples for
Digital I/O
Modules
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Discrete Inputs and Outputs

Sensors and Actuators


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SENSORS AND ACTUATORS

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Input and Output (i/o) Modules connect the plc to sensors


and Actuators.
Provide isolation for the low-voltage, low-current signals

Sensors
Sensors are devices that convert a physical condition into an
electrical signal for use by a controller, such as a PLC. Sensors
are connected to the input of a PLC. A pushbutton is one
example of a sensor that is often connected to a PLC input. An
electrical signal indicating the condition (open or closed) of
the pushbutton is sent from the pushbutton to the PLC.

Sensors and Actuators


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SENSORS AND ACTUATORS


Actuators

Actuators are devices that convert an electrical signal from


a controller, such as a PLC, into a physical condition.
Actuators are connected to the PLC output. A motor starter
is one example of an actuator that is often connected to a
PLC output. Depending on the status of the PLC output, the
motor starter either provides power to the motor or
prevents power from flowing to the motor.

Representation of
sensors and
actuators

REPRESENTATION OF SENSOR AND


ACTUATOR

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Analog Inputs and


Outputs

ANALOG INPUTS/OUTPUTS

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Analogue input cards convert continuous signals via a A/D


converter into discrete values for the PLC

Analogue output cards convert digital values in then PLC


to continuous signals via a D/A converter.

Resolution can be important in choosing an applicable


card

Example, for a temperature input of 0 to 100 degrees C

For 8 bit resolution the value in the PLC is 0 to 255

For 12 bit resolution the value in the PLC is 0 to 4095

For 15 bit resolution the value in the PLC is 0 to 32767

Elements of Analog
Inputs and Outputs

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ELEMENTS OF ANALOG INPUTS AND


OUTPUTS

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Analog Inputs
Pressure Transmitters
Flow Transmitter
Level Transmitter
Thermo Couples
Load Cell
Analog Outputs
Flow Control Valves
Pressure Control Valves
Drive Inputs

Special purpose
modules

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EXAMPLE FOR ANALOG INPUTS AND OUTPUTS

Analog inputs and outputs are continuous, variable signals.


Typical analog signals vary from 0 to 20 milliamps, 4 to
20 milliamps, or 0 to 10 volts.
In the following example, a level transmitter monitors the
level of liquid in a storage tank and sends an analog signal
to a PLC input. An analog output from the PLC sends an
analog signal to a panel meter calibrated to show the level
of liquid in the tank. Two other analog outputs, not shown
here, are connected to current-to-pneumatic transducers
that control air-operated flow control valves. This allows the
PLC to automatically control the flow of liquid into and out
of the storage tank.

Example for
Analog

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EXAMPLE FOR ANALOG I/O


MODULES

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Special purpose Modules


These may include special units for
High speed counting
High accuracy positioning
On-line self optimizing control
Multi axis synchronization, Interpolation
These modules contain additional processors, and are used to
relieve the main CPU from the high computational loads
involved in the corresponding tasks.

Program memory
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Program Memory
System

memory
Load Memory
Work Memory
System Memory Consists of all Hardware configuration details.
Load Memory Consists of Program logic
Work Memory is the working area of the PLC consisting of
data regarding the status of Inputs & Outputs, mathematic
calculations, timer & counter values etc.,

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Basic PLC
Architecture

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Basic PLC Architecture

CPU
Power Supply
Memory
Input Blocks
Output Blocks
Communications
Expansion
Connections

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Selection Of PLC

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Selection Of PLC
Selection of PLC Based on
1. No. of Inputs & Outputs
2. Input Voltage
3. Memory
4. Scan Time
5. Special I/O modules
6. Expansion Capabilities
7. Stand alone or Networked
8. Communication Capabilities

HOW PLC WORKS


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HOW PLC WORKS


A PLC works by continuously scanning a
program. The complete cycle of one scan has
the following steps
Step

1-CHECKING INPUT STATUSa)


PLC Scans each input
b)Records the data in work memory.
)Step

2-EXECUTE PROGRAM
a)
PLC goes through the program logic step
by step
b)PLC executes the program depending on
input status.
c)Write the output image in work memory
)Step

3-UPDATE OUTPUT STATUS


a)
Changes the statues of the output on/off.
b)Again starts the cycle from step one

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Programming Languages in 28

Programming Languages in PLC

IL (Instruction List) mnemonic programming


LD (Ladder Diagram) Relay logic
ST (Structured Text) A C like programming
language
FDB (Functional Block Diagram) Graphical
dataflow
programming language
SFC (Sequential Flow Chart) Graphical method
for
structured programs

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Languages
Examples

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Programming Languages
Examples

Ladder

Instruction List

Structured Text

Function Block
Sequential Flow Chart
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INSTRUCTION LIST

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INSTRUCTION LIST

Logic
Timer and Counters
Comparison
Range Comparison
Data Movement
Data Shift
Jump
Serial Communications
Increment/Decrement
Math

Conversion
ASCII
Number Systems
Floating Point Math
Scaling
PID
PID with Auto tune
Clock / Date
Block Processing
IF,THEN,ELSE,LOOP
Table Processing
ADDRESSING
LIFO, FIFO EXAMPLE

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ADDRESSING EXAMPLE

BINARY SYSTEM
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BINARY SYSTEM

BIT Each digit of a binary number


BYTE Group of 8 bit
WORD Group of two bytes
DOUBLE WORD- Group of two Words

7 6

8 BIT= 1 BYTE
MSB

LSB
BYTE

BYTE
16 BIT WORD
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NUMERICAL VALUES

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EXPRESSION OF NUMERICAL VALUES


a)
b)
c)
d)
e)
f)

All Digital Signals are expressed in bits


All Analog signals are group of digital signals are
expressed in Bytes and words
Digital Signal or bit can only express a value of 0 or 1
In case a value of more than one has to be expressed in
Bytes or Word only
A Byte can express a value of 0-255
A Word Can Express A value of 0-32767

HUMAN MACHINE INTERFACE


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