PROGRAMMABLE LOGIC CONTROLLERS AND LADDER LOGIC

SUBMITTED BY : ABHISHEK PRANIT N.S.E.C DEPT -AEIE UNIV ROLL NO-09109005004 UNIV REGN NO-091090110323

3RD YR, 6TH SEM

CONTENTS
#.INDEX #. ACKNOWLEDEMENT #. Automation #. PLC 1. INTRODUCTION 2. HISTORY 3. ADVANTAGES 4. HARDWARE OF PLC 5. PLC OPERATION 6. LADDER LOGIC 7. COUNTERS 8. FUTURE OF PLC #. BIBILIOGRAPHY

ACKNOWLEDGEMENT
I am thankful to the institute "IETE" for providing necessary facility to carry out my training successfully. It is my duty to record my sincere thanks and gratitude towards the institute staff who helped me in bringing this project to its present form. The valuable guidance and interest taken by them has been a motivator and source of inspiration for me to carry out the necessary proceedings for the project to be completed successfully. Also, I am highly obliged to the head of our training and placement cell who provided me such a great opportunity to do my WINTER training in a reputed institute like

IETE
AT LAST BUT NOT THE LEAST HELP OF MY FRIENDS.

AUTOMATION
Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provides human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Automation plays an increasingly important role in the world economy and in daily experience.

The main advantages of automation are:

Replacing human operators in tasks that involve hard physical or monotonous work. Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, underwater, etc.) Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc. Economy improvement: Automation may improve in economy of enterprises, society or most of humanity. For example, when an enterprise invests in automation, technology recovers its investment; or when a state or country increases its income due to automation like Germany or Japan in the 20th Century. Reduces operation time and work handling time significantly. Frees up workers to take on other roles.

Programmable Logic Controller (PLC)

INTRODUCTION A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a limited time, otherwise unintended operation will result.

HISTORY In 1968 GM Hydramatic (the automatic transmission division of General Motors) issued a request for proposal for an electronic replacement for hard-wired relay systems. The winning proposal came from Bedford Associates of Bedford, Massachusetts.

ADVANTAGES #.PLCs are very good for controlling outputs (based on inputs). #.They are amazingly robust, and able to stand all sorts of difficult conditions, such as extreme temperatures or dust in the air. #.They last from 5 to 10 years, depending on various circumstances.

#.They do not have contacts that wear out, like relays do. #.They also can switch fairly quickly without heating up much, in direct contrast to relays.

HARDWARE The Central Processing Unit (CPU), contains an internal program that tells the PLC how to perform the following functions: Execute the Control Instructions contained in the User's Programs. This program is stored in "nonvolatile" memory, meaning that the program will not be lost if power is removed Communicate with other devices, which can include I/O Devices, Programming Devices, Networks, and even other PLCs. .Perform Housekeeping activities such as Communications, Internal Diagnostics, etc.

THE CPU The microprocessor or processor module is the brain of a PLC system. It consists of the microprocessor, memory integrated circuits, and circuits necessary to store and retrieve information from memory. It also includes communications ports to other peripherals, other PLC's or programming terminals. Today's processors vary widely in their capabilities to control real world devices. Some

control as few as 6 inputs and outputs (I/O) and others 40,000 or more. RAM RAM or Random Access Memory is a volatile memory that would lose its information if power were removed. This is why some processor units incorporate a battery back-up. The type of RAM normally used is CMOS or Complementary Metal Oxide Semiconductor. CMOS RAM is used for storage of the user's program (ladder logic diagrams) and storage memory.

ROM
ROM or Read Only Memory is a non-volatile type of memory. This means you don't need an external power source to keep information. In this type of memory, information can be read, but not changed. For this reason the manufacture sometimes calls this firmware. It is placed there for the internal use and operation of processor units. INPUT RELAYS (CONTACTS) These are connected to the outside world. They physically exist and receive signals from switches, sensors, etc. Typically they are not relays but rather they are transistors.

OUTPUT UTILITY RELAY

These do not receive signals from the outside world nor do they physically exist. They are simulated relays and are what enables a PLC to eliminate external relays. There are also some special relays that are dedicated to performing only one task. Some are always on while some are always off. Some are on only once during power-on and are typically used for initializing data that was stored.

COUNTERS
These are simulated counters and they can be programmed to count pulses. Typically these counters can count up, down or both up and down. Since they are simulated they are limited in their counting speed. Some manufacturers also include high-speed counters that are hardware based. We can think of these as physically existing.

TIMERS These come in many varieties and increments. The most common type is an on-delay type. Others include off-delay and both retentive and non-retentive types. Increments vary from 1 millisecond through 1 second.

PLC OPERATION
A PLC works by continually scanning a program. We can think of this scan cyclen as consisting of 3 important steps. There are typically more than 3 but we can focus on the important parts and not worry about the others. Typically the others are checking the system and updating the current internal counter and timer values. The first type of scanning, as shown in the diagram below, is not as common as the type that will be discussed second.

PLC Scan Diagram

The first step is to check the input status. This step is therefore generally referred to as the Check Input Status stage. First the PLC takes a look at each input to determine if it is on or off. In other words, is the sensor connected to the first input on? How about the second input? How about the third? This goes on and on through the entire program. It

records this data into its memory to be used during the next step.

PROGRAMMING
PLC programs are typically written in a special application on a personal computer, then downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the PLC either in battery-backed-up RAM or some other nonvolatile flash memory. Often, a single PLC can be programmed to replace thousands of relays. LADDER LOGIC Ladder logic is one form of drawing electrical logic schematics, and is a graphical language very popular for programming Programmable Logic Controllers. Ladder logic was originally invented to describe logic made from relays. The name is based on the observation that programs in this language resemble ladders, with two vertical "rails" and a series of horizontal "rungs" between them. Figure below is a very basic example of ladder logic used in a programmable logic controls program

Basic ladder logic circuit

If Input1 is ON (or true) - power (logic) completes the circuit from the left rail to the right rail - and Output1 turns ON (or true). If Output1 is OFF (or false) - then the circuit is not completed and logic does not flow to the right - and Output 1 is OFF. There are many logic symbols available in Ladder Logic including Timers, Counters, Math, and Data Moves such that any logical condition or control loop can be represented in Ladder Logic. With just a handful of basic symbols - a Normally Open Contact, Normally Closed Contact, Normally Open Coil, Normally Closed Coil, Timer, Counter - most logical conditions can be represented

SWITCHES

Normally Open Contact

This can be used to represent any input to the control logic such as a switch or sensor, a contact from an output, or an internal output. When solved the referenced input is examined for a true (logical 1) condition. If it is true, the contact will close and allow logic to flow from left to

right. If the status is FALSE (logical 0), the contact is open and logic will NOT flow from left to right..

Normally Open Coil

This can be used to represent any discrete output from the control logic. When "solved" if the logic to the left of the coil is TRUE, the referenced output is TRUE (logical 1)..

Normally Closed Contact

When solved the referenced input is examined for an OFF condition. If the status is OFF (logical 0) power (logic) will flow from left to right. If the status is ON, power will not flow.

Normally Closed Coil

When "solved" if the coil is a logical 0, power will be turned on to the device. If the device is logical 1, power will be OFF.

Basic AND Gates

The AND is a basic fundamental logic condition that is easy to directly represent in Ladder Logic. Figure 12 shows a simplified AND gate on a ladder rung.

Simplified AND gate

In order for Light1 to turn TRUE, Switch1 must be TRUE, AND Switch2 must be TRUE. If Switch1 is FALSE, logic (not power) flows from the left rail, but stops at Switch1. Light1 will be TRUE regardless of the state of Switch2. If Switch1 is TRUE, logic makes it to Switch2. If Switch2 is TRUE, power cannot flow any further to the right, and Light1 is FALSE. If Switch1 is TRUE, AND Switch2 is TRUE - logic flows to Light1 solving its state to TRUE.

BASIC OR GATES
The OR is a logical condition that is easy to represent in Ladder Logic..

A simple OR gate

If Switch1 is TRUE, logic flows to Light1 turning it to TRUE. If Switch2 is TRUE, logic flows through the Switch2 contact, and up the rail to Light1 turning it to TRUE. If Switch1 AND Switch 2 are TRUE Light1 is TRUE. The only way Light1 is FALSE is if Switch1 AND Switch2 are FALSE. In other words, Light1 is TRUE if Switch1 OR Switch2 is TRUE

TIMERS AND COUNTERS

Many times we will want to take action in a control program based on more than the states of discrete inputs and outputs. Sometimes, we

will want to turn something on after a delay, or count the number of times a switch is hit. To do these simple tasks, we will need Timers & Counters.

SIMPL E TIMER
A timer is simply a control block that takes an input and changes an output based on time. There are two basic timer types we will deal with initially (there are other advanced timers, but we will start with the basics first) - On-Delay Timer and the Off-Delay Timer. On-Delay Timer - this timer takes an input, waits a specific amount of time, then turns ON an output (or allows logic to flow after the delay). Off-Delay Timer - this timer takes turns ON an output (or allows logic to flow) and keeps that output ON until the set amount of time has passed, then turns it OFF (hence off-delay)

SIMPLE COUNT ER
A counter simply counts the number of events that occur on an input. There are two basic types of counters - Up counter and a Down counter.

Up Counter - as its

name implies, whenever a triggering event

occurs, an up counter increments the counter.

Down Counter - whenever a triggering event occurs, a down counter decrements the counter

MOTOR STARTER EXAMPLE

This motor control application can also be accomplished with a PLC. In the following example, a normally open Start pushbutton is wired to the first input (I0.0), a normally closed Stop pushbutton is wired to the second input (I0.1),

and normally closed overload relay contacts (part of the motor starter) are connected to the third input (I0.2). These inputs are used to control normally open contacts in a line of ladder logic programmed into the PLC.

Initially, I0.1 status bit is a logic 1 because the normally closed (NC) Stop Pushbutton is closed. I0.2 status bit is a logic 1 because the normally closed (NC) overload relay (OL) contacts are closed. I0.0 status bit is a logic 0, however, because the normally open Start pushbutton has not been pressed. Normally open output Q0.0 contact is also programmed on Network 1 as a sealing contact. With this simple network,

energizing output coil Q0.0 is required to turn on the motor

the operation
When the Start pushbutton is pressed, the CPU receives a logic 1 from input I0.0. This causes the I0.0 contact to close. All three inputs are now a logic 1. The CPU sends a logic 1 to output Q0.0. The motor starter is energized and the motor starts.

The output status bit for Q0.0 is now a 1. On the next scan, when normally open contact Q0.0 is solved, the contact will close & output Q0.0 will stay on even if the Start pushbutton is released

When the Stop pushbutton is pressed, input I0.1 turns off, the I0.1 contact opens, output coil Q0.0 de- energizes, and the motor turns off

FUTURE OF PLCs

The PLC offers a compromise between advance control techniques and present day technology. It is extremely difficult to forecast the rate and form of progress of PLCs, but there is strong evidence that development is both rapid and cumulative. Though a PLC is not designed to replace a computer, it is useful and cost effective for medium sized control systems. With the capability of functioning as local controllers in distributed control systems. PLCs will retain their application in large process plants. A further development of PLCs leads to the development of programmable function controller (PFC) is compatible to PCs and directly controls the desired functions. In India every process industry is replacing relay control systems by PLCs and will go for PFCs in near future. In the near future every flats and offices may possess PFCs to control room temperature, as elevator controller, maintain water tank levels, as small telephone exchange etc.

BIBLIOGRAPHY
1. WWW.GOOGLE.COM 2. WWW.WIKIPEDIA.COM 3. WWW.PACONTROL.COM 4. PROCESS CONTROL- SUREKHA BHANOT