PROGRAMMABLE LOGIC CONTROL

Programmable Logic Controller (PLC) is an industrial computer control system that

continuously monitors the state of input devices and makes decisions based upon a custom program
to control the state of output devices.

In the late 1960’s an American company named Bedford Associates released a computing device
they called the MODICON (Modular Digital Controller).

 These controllers eliminated the need for rewiring and adding additional hardware for
every new configuration of logic.
 The new system drastically increased the functionality of the controls while reducing the
cabinet space that housed the logic.

Dick Morley – 1969 – invented the first PLC – model 084

Michael Greenberg – 1973 – designed the first commercial successful PLC – the 184

Ladder diagrams – diagrams used to guide electricians in a construction process to incorporate

logic in a system.

Ladder logic diagrams derive their name from the ladder-like graphical symbolism used to depict
PLC logic. The vertical lines, which look like upright ladder support indicate power to an
electrical system. The horizontal lines, which look like the rungs of a ladder, depict the
availability of power to a device of trough a device. “Gates” in the horizontal lines indicate
whether current is actually flowing through a particular device.

Ladder logic diagrams are read from left to right and from top to bottom. Generally, devices are
rearranged in order of decreasing impact. Devices that have a larger impact on the system are
generally shown above devices with relatively minor impact. Contacts, relays, and other devices
are shown in their shelf position.
Consider the diagram on the right. Switch A is considered A X
normally open (NO) because there is no diagonal line
intersecting it. When power is applied to this circuit relay, X
Ladder Diagram (Power On)
remains de-energized because the circuit path is broken by
switch A. However, if there had been a diagonal line, like in B X
the second diagram, the switch would be considered
normally closed (NC). When power is applied to this circuit
Ladder Diagram (Power Off)
relay, X is energized because the closed switch A enables
current to flow in the circuit.

Ladder logic is the main programming method used for Programmable Logic Control (PLC). It
was a method intentionally developed to mimic relay logic. PLCs gained their name from its ability
to program logic into these controls.

To have a view of a ladder diagram, here is an example:

In the figure, the vertical lines on the Hot rail Neutral rail

left and right are the power source “rails”. In A B X

between the left rail and the right rail are
horizontal lines or “rungs”. On these rungs
C D G Y
are a combination of inputs and outputs.
Inputs are entered into the system by sensors
or switches. Outputs exit the system and are E F H
sent to devices such as lights and motors that Inputs Outputs
are outside the PLC. If the inputs on the ladder
diagram are opened or closed in the right combination, the power can flow from the left rail,
through the inputs, to the power outputs, and finally to the right rail.

PLC functionality can be expressed as a three-part process:

1. Scan inputs from switches or transmitters,

2. Execute logic or control within the PLC,
3. Set outputs based upon results or logic.
 Ladder logic functions primarily as a series of “and/or”, “if/then”, or “true/false”
statements and is represented through drawings called ladder diagrams.

Ladder diagrams show the logic of the controls but they are not used to build the system, a
wiring diagram is used for that. But the wiring diagram wouldn’t be used to trouble shoot with or
show functionality, that’s where the ladder is most useful.
L1 START L2
STOP O.L.
M
M
Figure 1: Standard motor control
2 3 circuit
When viewing the pictorial version of the controls as in standard motor control circuit, one
can see that the devices on a rung of the ladder are in series reading horizontally and in parallel
reading vertically. Control voltage is supplied to the vertical rails, L1 being hot and L2 being
common or ground. In Figure 1 we see a normally closed (N.C.) stop button and a normally open
(N.O.) start button and a motor starter. Normally open switch won't conduct electricity until it is
pressed down, and normally closed switch will conduct electricity until it is pressed. The circle
with the M represents the coil of a relay, not the actual motor. The M contact is physically part of
the starter and actuates with the coil. The contact labeled O.L. (over load) is also part of the starter
and is a circuit breaker tripped by over current in the motor legs. The M contact is called the seal
contact. Without it, the motor would run as long as someone held down the start button and would
stop when released. With it, the power is allowed to flow through the start button to energize the
coil, which closes the M contact, maintaining the complete circuit when the start button is released.
To stop the motor, any element in series with the coil can break the circuit, in this case the stop
button.

Another purpose of this is to perform Boolean or digital logic. AND, OR, NOT,
EXCLUSIVE OR, NOR, and NAND circuits are common in ladder logic and parallel designs
found in digital logic circuits. Simple circuits can be combined into larger circuits to perform very
complicated tasks. PLCs use the same type of logic as does digital logic texts. Some common
digital and ladder logic equivalent circuits follow:
 AND
Input A Input B Output X
0 0 0
X
A B
0 1 0
1 0 0
1 1 1
A*B=X
A
X
B

OR
Input A Input B Output X
0 0 0 X
A
0 1 1
1 0 1
1 1 1
B
A A+B=X
X
B

NAND
X
Input A Input B Output X A
0 0 1
0 1 1
B
1 0 1
1 1 0
A*B=X
A
X
B
 NOR
Input A Input B Output X
0 0 1 X
A B
0 1 0
1 0 0
1 1 0
A+B=X
A
X
B

XOR
Input A Input B Output X X
A B
0 0 0
0 1 1
1 0 1 A B
1 1 0
(A*B) + (A*B) = X
A
X
B

Input A Output X
0 1
X
1 0 A

A X A =X
ADVANTAGES OF PROGRAMMABLE LOGIC CONTROL OVER RELAY
1. Reliability - The internal relay systems of a PLC are solid state
2. Ease of Troubleshooting - you can read through the programming and usually figure out
what is and isn’t working.
3. Easy expandability - versatility with the programming and easy expandability.
4. Smaller Size - physical size requirements of a PLC system are far smaller than a relay
system.
DISADVANTAGES OF PROGRAMMABLE LOGIC CONTROL OVER RELAY

1. Difficulty with some Smart Devices

2. Optional Modules loading
3. PLC'S are designed by semiconductors, which are depends on thermal characteristics
4. Debugging the PLC consumes time

APPLICATIONS AND EXAMPLES OF PROGRAMMABLE LOGIC CONTROL

Industrial Applications:
1. Glass industry - to control the material ratio as well as to process flat glasses
2. Paper industry - to control the machines that produce paper products at high speeds. It
also monitors the production of book pages or newspapers in offset web printing.
3. Cement manufacturing - to ensure that the right amount and quality of raw materials.
PLCs are incorporated in controls of ball milling, coal kiln and shaft kiln.
Mechanical Systems

1. Automatic Car Wash - for soap – water mixture concentration and duration of wiper spin
2. Elevator – for the route of the elevator based on pending button calls - direction/floor to
which the lift would go
3. Automatic Doors – for opening of the door by identifying if something is in front of the
door using detectors
4. Conveyer Belts – to start conveying using a switch button, and stop when loaded item
reaches the end
5. Roller Coasters - for forward direction of the cars and prevent from capsizing