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Origin of PLC
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ORIGIN OF PLC
Developed
Now
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
4
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PNEUMATIC CONTROL
Drawbacks
Hardwired Logic
Control
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The
Disadvantages
Bulky panels
Complex wiring
Longer project time
Difficult maintenance and
troubleshooting
Electronic control
by using Logic
Gates
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In
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
8
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).
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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
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PLC HARDWARE
CPU
Memory
I/O Modules
External Power
Supply
Software
12
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Software
1. Application Software (Logic)
2. Basic Software
Communication Accessories
1. Communication Adapter
I/O Modules
13
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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
Micro Switches
Toggle Switches
Digital Outputs
Relays
Contactors
Indication Lamps
Valves
Examples for
Digital I/O
Modules
15
15
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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.
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Representation of
sensors and
actuators
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ANALOG INPUTS/OUTPUTS
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Elements of Analog
Inputs and Outputs
20
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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
21
Example for
Analog
22
Automation Solutions
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Program memory
24
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
25
CPU
Power Supply
Memory
Input Blocks
Output Blocks
Communications
Expansion
Connections
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Selection Of PLC
26
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
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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
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Programming Languages in 28
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Languages
Examples
29
Programming Languages
Examples
Ladder
Instruction List
Structured Text
Function Block
Sequential Flow Chart
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INSTRUCTION LIST
30
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
31
ADDRESSING EXAMPLE
BINARY SYSTEM
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32
BINARY SYSTEM
7 6
8 BIT= 1 BYTE
MSB
LSB
BYTE
BYTE
16 BIT WORD
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NUMERICAL VALUES
33
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