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EJ501
PROGRAMMABLE
LOGIC
CONTROLLER (PLC)
AND AUTOMATION
2
UNIT 3
INTRODUCTION TO PLC SYSTEM
Objective :
UNIT 3
INTRODUCTION TO PLC SYSTEM
Introduction PLC (Programmable Logic Control)
A digital device (microprocessor based controller) that uses a programmable memory
to store instructions and to implement functions such as logic, sequencing, timing,
counting and arithmetic in order to control machines and processes and has been
specifically designed to make programming easy.
PLCs are similar to computers but have certain features which are specific to their use
as controllers:
UNIT 3
INTRODUCTION TO PLC SYSTEM
Definition PLC
A digitally operated electronic apparatus which uses a
programmable memory for the internal storage of
instructions for implementing specific functions such as
logic, sequencing, timing, counting, and arithmetic to
control, through digital or analog input/output modules,
various types of machines or processes.
UNIT 3
INTRODUCTION TO PLC SYSTEM
Definition PLC
An electronic system working digitally for the use in industrial environment
with a programmable memory for the internal storage of user-orientated control
instructions for the implementation of specific functions, like, for example
logic operation control, process control, timer, counting-and arithmetic
functions, in order to control various machines and processes through digital or
analog input- , and output variables.
- International Standard
IEC 61131-1
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INTRODUCTION TO PLC SYSTEM
PLC Background
The first Programmable Logic Controller (PLC) was developed by a group
of engineers at General Motors in 1968
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INTRODUCTION TO PLC SYSTEM
PLC Functions
PLC performs the functions of conventional relays, timers,
counters.
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INTRODUCTION TO PLC SYSTEM
Type of PLC - compact
TECOMAT
TC600
Omron
Mitsubishi
Zelio
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INTRODUCTION TO PLC SYSTEM
Type of PLC - modular
Omron
Mitsubishi
Eaton
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INTRODUCTION TO PLC SYSTEM
Type of PLC – plug in card
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INTRODUCTION TO PLC SYSTEM
Advantages and Disadvantages of PLC
Advantages Disadvantages
Many inputs and outputs, excellent for Do not use the full capabilities of the
controlling and monitoring many microprocessor
processes
Designed for industrial environments, Ladder logic programming style is
robust and reliable cumbersome and prone to mistakes
Reprogrammable Only good for yes/no decisions
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INTRODUCTION TO PLC SYSTEM
Initial Specifications
• The new control system had to be price competitive with the use of relay
systems.
• The system had to be capable of sustaining an industrial environment.
• The input and output interfaces had to be easily replaceable.
• The controller had to be designed in modular form, so that
subassemblies could be removed easily for replacement or repair.
• The control system needed the capability to pass data collection to a
central system.
• The system had to be reusable.
• The method used to program the controller had to be simple, so that it
could be easily understood by plant personnel.
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INTRODUCTION TO PLC SYSTEM
Recent PLCs
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INTRODUCTION TO PLC SYSTEM
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INTRODUCTION TO PLC SYSTEM
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INTRODUCTION TO PLC SYSTEM
Basic PLC Structure
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INTRODUCTION TO PLC SYSTEM
Hardware of the PLC
Hardware of the PLC are only
consist of several components;
such as Power Supply Unit,
CPU Unit, Memory Unit and
I/O Unit.
UNIT 3
INTRODUCTION TO PLC SYSTEM
Power Supply
The Power Supply is used to give power to all the parts. The most PLC works with power
24 VDC or 220 VAC. The big PLC has the separate power supply and the small PLC has
power supply which is one. The Power Supply is also provided by the battery back up,
when happened the failure of power, automatically battery will replace the power supply to
supply the CPU, so that the program of memory user do not lose.
Memory Unit
The Memory Unit has function to save the data and program will be used by PLC. This
Memory is divisible into two type that is ROM and RAM. ROM contains the data like
facility of the logic program, facility to edit the program, facility to monitor the program,
facility for the communications, etc. The Data will be save permanently and will not lose
though the power supply is off. While RAM contains the data of user program, like ladder
diagram, memory data, I/O status, etc. The Data can be writed and read. RAM has the
character is not permanent, if the power suplply is off the data will lose. To avoid the
mentioned, so the power supply is provided by the battery back up to supply if the especial
power supply is off.
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INTRODUCTION TO PLC SYSTEM
CPU Unit (Central Processing Unit)
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INTRODUCTION TO PLC SYSTEM
I/O Unit
The I/O Unit is the interface unit has function to convert the input signal and output
signal so that the CPU can communicate with the external apparatus like the switch,
stepping motor, solenoid, sensor, etc. The I/O Unit has two type; Discrete I/O and
Analog I/O.
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INTRODUCTION TO PLC SYSTEM
Omron PLC
LG PLC
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INTRODUCTION TO PLC SYSTEM
Input Devices
PLCs can receive input from either automated or manual devices. The PLC
could receive data from the user via a pushbutton switch, keyboard, or similar
device. Automated input could come from a variety of devices: microswitches,
timers, encoders, photosensors, and so on. Some devices, like the Limit Switch
shown below, turn ON or OFF when the equipment actually makes contact
with it. Other devices, like the Photoelectric Switch and Proximity Switch
shown below, use other means, such as light or inductance, in order to get
information about the equipment being monitored.
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INTRODUCTION TO PLC SYSTEM
Output Devices
A PLC can output to a myriad of devices for use in automated control. Almost
anything that you can think of could be controlled (perhaps indirectly) by a PLC.
Some of the most common devices are motors, Solenoids, Servomotors, Stepping
Motors, valves, switches, indicator lights, buzzers, and alarms. Some of these output
devices; such as the motors, Solenoids, Servomotors, Stepping Motors, and valves;
affect the controlled system directly. Others; such as the indicator lights, buzzers,
and alarms; provide output to notify personnel.
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INTRODUCTION TO PLC SYSTEM