Industrial Automation

&
PLC Programming

Dr. Izhar (Associate Professor)

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 Industrial Revolutions

18th Century 19th Century 20th Century Today

Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0
Equipment Mass production Automated Intelligent production
powered by assembly lines production using incorporating with IoT,
steam and water requiring labor electronics & IT cloud technology and big
and electrical data
energy

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Industrial 3.0 vs. Industry 4.0
What has changed?

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Benefits of Industry 4.0/Smart Factories

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The Smart Factory – Automated Systems & Processes

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Automation Levels

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Automation Levels

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Automation Levels

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Automation Levels

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SCADA vs. HMI

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Automation Levels

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Automation Levels

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Automation Levels

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 Programmable Logic Controller

A programmable logic controller (PLC) or programmable controller is an industrial digital computer which has
been 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.

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 Need of PLC

Electrical relays were used prior to PLCs:

• Control systems were hard wired using relays, timers and logical units
• Control systems had to be re-wired for new applications
• Inflexible and time consuming
• Resulted in product delays, high production costs....

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 Advantages of PLCs

• Flexible in nature
• Easy to install and troubleshoot
• Cost effective
• Software-in-loop simulation
• Single programming method
• Ease in maintenance

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PLC Overview

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 Main Parts of PLCs

1. Program Memory: Stores information for logical control

sequence
2. Data Memory: stores status of switches, interlocks, past
and current values of data items
3. Output devices: hardware/software drives for industrial
process actuators (solenoid switches, motors, valves)
4. Input devices: Hardware/software drives for industrial
process sensors (Switch status sensors, proximity
detectors, interlock setting....)
5. CPU: Brain of the PLC

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 PLC Internal Features

Two screw terminals provide

connection to 120VAC for powering
 Inside PLC housing, each input
the PLC internal circuitry i.e. L1, L2
terminal connected with common
Six screw terminal on left had side
terminal (opto isolater device-Light
to provide connection to input
emitting device) to provide electrically
devices and each representing
isolated “high” Logic Signal to the
different input channel and is labelled
computer circuitry. An indicating LED
with “X”
on the front panel of the PLC gives
 Lower left screw terminal is a
visual indication of an energized input
“common” connection and is
generally connected with L2 neutral
of 120VAC power source
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 Types of PLCs

(1) Compact
Monolithic construction
Monoprocessor
Fieldbus connection
Fixed casing
Fixed number of I/O (most of them binary)
No process computer capabilities (no MMC)
Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7-1200

(2) Modular PLC

Modular construction (backplane)
One- or multiprocessor system
Fieldbus and LAN connection

Large variety of input/output boards

Connection to serial bus

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Major PLC Players

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Major PLC Players

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Major PLC Players

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Major PLC Players

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Major PLC Players

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Major PLC Players

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Major PLC Players

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Major PLC Players

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Application of PLCs

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 PLC Programming Languages

IEC: International Electro-technical Commission

Section 61131-3 standard divided into 10 parts:
General Information, Equipment requirements, Programming languages,
User guidelines, Communications, Functional Safety, Fuzzy Control Programming
Guideline for programming and implementation, Digital communication & XML Format
Ladder Diagram

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Sequential Function Charts (SFC)

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Function Block Diagram

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Structured Text (ST)

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Instruction List (IL)

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 Basic Ladder Logic Symbols

The IEC 61131-3 standard describe the complete list of

ladder logic contact and coil symbols
 PLC Ladder Logic Programming
1. Vertical lines represents power
rails between which circuit are
connected
2. Each rung on the ladder
defines one operation in the
control process.
3. Ladder diagram read from left
to right and from top to bottom
4. Procedure of going through all
the rungs of the program is
termed as cycle.
5. End rung might be indicated
by a block with the word END
or RET
6. Scan time depends on number
of rungs in the program –
typically 1 ms per 1000 bytes of
program and so typically
ranging from 10ms to 50 ms
7. Each rung must start with
input/inputs and must end with
at least one output.
 PLC Ladder Logic Programming (Contd.)

1. Power Rails: Pair of

vertical lines
2. Rungs: Horizontal Lines
3. Contacts: A, B, C arranged
on rungs
4. There must be continuous
path thru the contacts to
energize the output
5. Out put appears on
extreme RHS of the rungs
always

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 Logic Functions in Ladder Logic

1. OR Operation

• Control behaviour: The light should be on when

either switch A is ON or switch B is ON, otherwise it
should be OFF
• Task: Implement this behaviour using
1. Relay Circuit
2. PLC Ladder Logic

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Simple Ladder Logic
OR Operation
Possible Combination of 2 switches

OR Truth Table

A B Light
OFF OFF OFF
OFF ON ON
ON OFF ON
ON ON ON

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 Simple Ladder Logic
Relay Circuit

• Switch A and B are connected in parallel to relay coils AR and BR

respectively
• When switch A (or switch B) is closed relay coil AR (or BR) gets
energized
• The normally open (NO) contact AR (or BR) get closed
1. Power is transmitted to coil LR
2. Relay coil LR gets energized
3. The NO contact LR gets closed
4. Power is transmitted to the Light Bulb 41
 OR Operation
Relay Ladder Logic Circuit

“Alternative paths provided by

vertical paths from the main
rung of a ladder diagram, that
is, paths in parallel,
represents logical OR
operations”

OR Operation
PLC Ladder Logic
Append above to the leading two
rungs of relay logic diagram
Switch A and B are connected to
discrete input channel
Light is connected to output channel
(actuator) of the PLC
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 Simple Ladder Logic
AND Operation
Control Behaviour: the light should be on when switch A is
on and switch B is on, otherwise it should be off

Task: implement this behaviour using

1. Relay circuit
2. PLC Ladder Logic

Possible Combination of 2 switches

AND Truth Table

A B Light
OFF OFF OFF
OFF ON OFF
ON OFF OFF
ON ON ON 43
 AND Operation
Relay Circuit

• Switch A and B are connected in series to relay coils AR and BR

respectively
• When switch A is closed relay coil AR gets energized
• The normally open (NO) contact AR gets closed
1. Power flows to Normally Open (NO) contact BR where it terminates
until BR is energized
2. Subsequently when BR gets energized, LR is energized, which causes
the NO contact LR to close
3. Power is transmitted to the light bulb

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 AND Operation
PLC Ladder Logic Circuit

“On a ladder diagram, contacts in a horizontal rung,

that is, contacts in series, represent the logical AND
operations”

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 Simple Ladder Logic
NOT Operation
Control Behaviour: the light comes ON only when switch A is
ON and switch B is OFF. Otherwise it should be OFF

Task: implement this behaviour using

1. Relay circuit
2. PLC Ladder Logic

Possible Combination of 2 switches

NOT Truth Table

A B Light
OFF OFF OFF
OFF ON OFF
ON OFF ON
ON ON OFF 46
 NOT Operation
Relay Circuit

• Switch A and B are connected to relay coils AR and BR respectively

• When switch A is closed relay coil AR gets energized
• When switch B is off relay coil BR is not energized

NOT Operation
PLC Ladder Logic

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