Programmable logic control

1. INTRODUCTION

A PLC is user friendly, microprocessor-based specialized computer that carries out

control functions of many types and levels of complexity. Its purpose is to monitor crucial
process parameters and adjust process operations accordingly. A programmable logic
controller (PLC) is a solid state device designed to perform logic functions previously
accomplished by electromechanical relays. The design of a PLC is similar to that of a
computer. The PLC is an assembly of solid state digital logic elements designed to make
logical decisions and provide outputs. Programmable logic controllers are used for the control
and operation of manufacturing process equipment and machinery. They are capable of
storing instructions, such as sequencing, timing, counting, arithmetic, data manipulation, and
communication, to control industrial machines and processes.

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1.1 PLC PRODUCT APPLICATION RANGES

Figure graphically illustrates programmable controller product ranges. This chart is not
definitive, but for practical purposes, it is valid. The PLC market can be segmented into five
groups:
1. Micro PLCs
2. Small PLCs
3. Medium PLCs
4. Large PLCs
5. Very large PLCs

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Fig: PLC

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2. BASIC BLOCK DIAGRAM OF PLC

Here the overall look inside the plc is given with the block diagram. It contains Input
module, CPU, Microprocessor, Memory, Output module, Programmer/Monitor, Power
Supply and Rack & Chassis. Below the following modules are explained.

2.1 CENTRAL PROCESSING UNIT

The brain of the system which is having three parts

1. Microprocessor: the computer center that carries out mathematics and logical
operations
2. Memory: The area of the CPU in which the data and information are stored and
retrieved. Holds the system software and user program.
3. Power supply: The electrical supply that converts AC to various operational DC
voltages. In the process the power supply filters and regulates the DC voltages to
ensure proper computer operations.

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2.2 PROGRAMMER/ MONITOR (PM)

 Used to communicate with circuit of plc

 Can be handheld terminals, Industrial terminals and personal computer

2.3 INPUT MODULE

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 Input modules have terminals into which outside process electrical signals generated
by senses or transducer are entered.
 The output module has terminals to which o/p signals are sent to actuate relays,
solenoids, various solid state switching devices, motors and displays. An electronic
system for connecting I/O modules to remote locations can be added.
 The actual operating process under plc control can be thousands of feet from c p u and
its I/O modules.

2.4 PLC OUTPUT MODULE

The output module operates in the opposite manner from the input module. A dc
signal from the CPU is converted through each module section to a usable output voltage
either AC or DC. The CPU signal goes through an isolation stage. Any erratic voltage surge
from output devise does not get back to CPU and cause damage. The isolator out is then
transmitted to switching accomplished by turning on a triac.The output of a module section
may be through a relay or a dc or ac output.

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2.5 POWER SUPPLY MODULE

 Power supply module provides power to the CPU and often provides power to drive
sensors and low power actuators connected to I/O modules. It converts line voltage
(230 V ac/115V ac) into 24v dc which provide power.

Fig. Power supply Unit

2.6 RACK AND CHASIS

The racks on which plc parts are mounted and the enclosures on which the CPU, PM
and modules are manual.

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3. PRINCIPLES OF OPERATION

A programmable controller, as illustrated in Figure, consists of two basic sections:

 The central processing unit
 The input/output interface system

The central processing unit (CPU) governs all PLC activities. The following three
components, shown in Figure, form the CPU:

 The processor
 The memory system
 The system power supply

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The operation of a programmable controller is relatively simple. The input/ output

(I/O) system is physically connected to the field devices that are encountered in the machine
or that are used in the control of a process. These field devices may be discrete or analog
input/output devices, such as limit switches, pressure transducers, push buttons, motor
starters, solenoids, etc. The I/O interfaces provide the connection between the CPU and the
information providers (inputs) and controllable devices (outputs). During its operation, the
CPU completes three processes:
(1) it reads, or accepts, the input data from the field devices via the input interfaces,
(2) it executes, or performs, the control program stored in the memory system, and
(3) it writes, or updates, the output devices via the output interfaces.

This process of sequentially reading the inputs, executing the program in memory, and
updating the outputs is known as scanning. Figure illustrates a graphic representation of a
scan.

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3.1 STANDARD PLC SCAN CYCLE

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Each PLC operational cycle is made up of three separate parts:

 Input scan at which input terminals are read and the input status table is updated,
 Program scan at which data in the input status table is applied to the user program,the
program isexecuted and the output status table is executed
 Output scan at which data associated with the output status table is transferred to
output terminals.

The input/output system forms the interface by which field devices are connected to
the controller. The main purpose of the interface is to condition the various signals received
from or sent to external field devices. Incoming signals from sensors (e.g., push buttons, limit
switches, analog sensors, selector switches, and thumbwheel switches) are wired to terminals
on the input interfaces. Devices that will be controlled, like motor starters, solenoid valves,
pilot lights, and position valves, are connected to the terminals of the output interfaces. The
system power supply provides all the voltages required for the proper operation of the
various central processing unit sections.

Although not generally considered a part of the controller, the programming device,
usually a personal computer or a manufacturer’s mini programmer unit is required to enter
the control program into memory. The programming device must be connected to the
controller when entering or monitoring the control program

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4. PROGRAMMING

The first PLCs were programmed with a technique that was based on relay logic
wiring schematics.This eliminated the need to teach the electricians, technicians and
engineers how to program a computer but, this method has stuck and it is the most common
technique for programming PLCs today. An example of ladder logic can be seen in Figure 6.
To interpret this diagram imagine that the power is on the vertical line on the left
hand side, we call this the hot rail. On the right hand side i s the neutral rail. In the
figure there are two rungs, and on each rung there are combinations of inputs(two vertical
lines) and outputs (circles). If the inputs are opened or closed in the right combination the
power can flow from the hot rail, through the inputs, to power the outputs, and
finally to the neutral rail. An input can come from a sensor, switch, or any other type of
sensor. An output will be some device outside the PLC that is switched on or off, such as
lights or motors. In the top rung the contacts are normally open and normally closed. This
means if input A is on and input B is off, then power will flow through the output and
activate it. Any other combination of input values will result i n t h e o u t p u t X b e i n g
o f f . T h e r e a r e o t h e r m e t h o d s f o r p r o g r a m m i n g P L C s . One of the earliest
t e c h n i q u e s involved mnemonic instructions. These instructions can be derived
directly from the ladder logic diagrams and entered into the PLC through a simple
programming terminal. Sequential Function Charts (SFCs) have been developed
to accommodate the programming of more advanced systems. These are similar to
flowcharts, but much more powerful.

4.1 LADDER LOGIC

Ladder logic is the main programming method used for PLCs. As mentioned before,
ladder logic has been developed to mimic relay logic. The decision to use the relay logic
diagrams was strategic one. By selecting ladder logic as the main programming method, the
amount of retraining needed for engineers and tradespeople was greatly reduced. Modern
control systems still include relays, but these are rarely used for logic. A relay is a simple

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device that uses a magnetic field to control a switch, as pictured in Figure 2. When a voltage
is applied to the input coil, the resulting current creates a magnetic field. The magnetic field
pulls a metal switch (or reed) towards it and the contacts touch, closing the switch. The
contact that closes when the coil is energized is c a l l e d normally open. The normally closed
contacts touch when the input coil is not energized. Relays are normally drawn in schematic
form using a circle to represent the input coil. The output contacts are shown with two
parallel lines. Normally open contacts are shown as two lines, and will be open (non-
conducting) when the input is not energized. Normally closed contacts are shown with two
lines witha diagonal line through them. When the input coil is not energized the normally
closed contacts will be closed (conducting).Relays are used to let one power source close a
switch for another (often high current) power source, while keeping them isolated. An
example of a relay in a simple control application is shown in Figure. In this system the first
relay on the left is used as normally closed, and will allow current to flow until a voltage
is applied to the input A. The second relay is normally open and will not allow current to
flow until a voltage is applied to the input B. If current is flowing through the first two relays
then current will flow through the coil in the third relay, and close the switch for output
C.This circuit would normally be drawn in the ladder logic form. This can be read logically
as C will be on if A is off and B is on. The example in Figure 3 does not show the entire
control system, but only the logic. When we consider a PLC there are inputs, outputs, and the
logic.

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4.1.1 PLC INPUT INSTRUCTIONS

The various types of inputs includes

1. NORMALLY OPEN CONTACT

When this contact closes the functions carries out some kind of actions.

2. NORMALLY CLOSED CONTACT

When this contact opens the functions carries out some kind of actions.

3. LATCH OR UNLATCH SYSTEM

Actuating the latch input turns the function on or closes it to change the state. The
function then stays on even if latch input is turned off. To turn the function off,
another input, unlatch, is turned on, which turns the function off. If unlatch is the
turned off, the function remains off.

4. DIFFERENTIATING UP, OR RISING-EDGE ACTUATION

This involves turning the function on for one scan time at the leading edge of an input
pattern.

5. DIFFERENTIATION DOWN, OR FALLING-EDGE ACTUATION

This involves turning the function on for one scan time at the trailing edge of a signal
pattern.

4.1.2 OUTPUTS: COILS, INDUCTORS, AND OTHERS

Coils in an internal PLC program are related to output signals that are sent to external
devices. An output is energized through the output module when its corresponding coil
number is turned on in the PLC ladder diagram. Note that not all coils in the program have a
corresponding output. Many coils are used for internal logic only. The output devices voltage
and current requirements must be matched for the output module values.
In ladder logic there are multiple types of outputs, but these are not consistently
available on all PLCs. Some of the outputs will be externally connected to devices
outside the PLC, but it is also possible to use internal memory locations in the PLC. Six

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types of outputs are shown in Figure . The first is a normal output, when energized the
output will turn on, and energize an output. The circle with a diagonal line
through is a normally on output. When energized the output will turn off.
Thistype of output is not available on all PLC types. When initially energized the OSR (One
Shot Relay)instruction will turn on for one scan, but then be off for all scans
after, until it is turned off. The L(latch) and U (unlatch) instructions can be used to lock
outputs on. When an L output is energized the output will turn on indefinitely, even
when the output coil is de-energized. The output can only be t u r n e d o f f u s i n g
a U output. The last instruction is the IOT (Immediate Outpu t) that
w i l l a l l o w out puts to be updated without having to wait for the ladder logic scan to be
completed. When power is applied (on) the output x is activated for the left output, but turned
off for the output on the right.

4.2 EXAMPLE PROGRAM

4.2.1 AND Gate

The function of an AND gate is simulated in the electric circuit
displayed in Figure. Notice that the lamp will be on only when both
switches are closed. Figure displays a two-input AND logic gate symbol,
its Boolean expression, and its truth table. In the truth table, you can see
that there is only one set of inputs that produces a logic high output.
Figure displays a ladder logic diagram that performs the function of a two-
input AND gate. When normally open inputs I:0/0 and I:0/1 are closed,
output O:0/0 is energized.

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6. COMPARISON

6.1 PC Vs PLC

 PLCs are constructed for a specific purpose with a smaller program, whereas PCs
perform general tasks.
 PLCs are sequential-type controllers which can process individual steps in a program
in order
 PLCs do majority of the control jobs whereas PCs handle most of the data and math
functions.
 PLCs can be programmed, controlled and operated by a person unskilled in operating
computers.
 Dedicated application to a specific function using a relatively small control program.
 Rapid simultaneous execution of the individual steps in the program.
 The PLC can operate any system that has input/output devices that go on and off ass
well as any system with variable input/outputs.

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7. ADVANTAGES & DISADVANTAGES OF PLCS

7.1 ADVANTAGES

 Increase in flexibility,
 Faster implementation of changes and correction,
 Lower cost,
 Easy visualization of process running,
 Increased visual observations,
 Increased operation speed,
 Increased reliability and maintainability,
 Increased security,
 Reprogramming capability,
 Elimination of wiring.

7.2 DISADVANTAGES

 Too much work required in connecting wires.

 Difficulty with changes or replacements.
 Difficulty in finding errors; requiring skillful work force.
 Fixed program applications,
 High initial investment cost.

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8. USE OF THE PLC

 PLC is used -:

1. To control different functions done by the machine

2. To provide protection to the people working manually on the machine and to the
machine in case of some power failure or some cases of short circuit also.

3. To operate the machine automatically.

Various production equipment that can be connected to PLCs include :

 Thermocouple
 Strain gauge
 Position encoder
 Servo valves
 Electrical motors
 Linear motors
 Stepping motors

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9. REFERENCES

1.Er. Surendra Jingar (production department), Videocon Industries Limited, Shahjahanpur

2.www.toodoc.com/search/plc/plc.pdf
3.Wedd Reis, “programmable logic controller”, Pearson education, 2nd edition
4.http://en.wikipedia.org/wiki/programmable logic controller

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