Professional Documents
Culture Documents
(Courtesy of Allen-Bradley)
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Definition of PLC
PLC is a digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by 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.
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Outputs of PLC
Most often is the control signal to motor, valves, etc.
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Types of switches
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A Relay
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A counter
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A timer
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Wiring diagram
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Memory
ROM RAM PROM EPROM etc
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Input/output module
Analog inputs
Flow sensors Humidity sensors Potentiometers Pressure sensors Temperature sensors
Analog outputs
Analog meters Analog valves and actuators DC and AC motor drives
Digital input/output
Bar code, encoder Display
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Power input connections: (a) AC, (b) DC, and (c) TTL
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Power output connections: (a) AC, (b) DC, and (c) TTL
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Peripherals
Operator console Printer Simulator EPROM loader Network communication PC based programming software
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A ladder diagram (also called contact symbology) is a means of graphically representing the logic required in a relay logic system.
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A ladder diagram
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PLC scan
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Functions of PLC
Relay Timer and counter Program control Arithmetic Data manipulation Data transfer Others, such as sequencers
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Basic logic
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And logic
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OR logic
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Example
A robot is used to load/unload parts to a machine from a conveyor. A part comes along the conveyor. When it touches a microswitch, it is scanned by a bar-code reader to identify it. If the part is the desired one, a stopper is activated to stop it. A robot picks up the part and loads it onto the machine if it is idle. Otherwise, the robot waits to unload the machine.
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Cell layout
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Example
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Program
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Wiring diagram
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Rung 1. If a part arrives and no part is stopped, trigger the barcode reader. Rung 2. If it is a right part, activate the stopper. Rung 3. If the stopper is up, the machine is not busy and the robot is not busy; load the part onto the machine. Rung 4. If the task is completed and the robot is not busy, unload the machine.
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Procedure for developing automation system using PLC 1. 2. 3. 4. 5. 6. 7. 8. 9. Define the process to be controlled. Make a sketch of the process operation. Create a written step sequence listing for the process. Add sensors on the sketch as needed to carry out the control sequence. Add manual controls as needed for process setup or operational checking. Consider the safety of the operating personnel and make additions and adjustments as needed. Add master stop switches as required for safe shutdown. Create the ladder logic diagram that will be used as a basis for the PLC program. Consider the "what if's" where the process sequence may go astray.
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2. Process sketch
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4. Add sensors
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6. Consider safety
One basic way to keep hands out of a process is to have two start buttons. Then both hands must be away from the work to depress both buttons (which works until the operator figures out how to use one knee and one hand). Other considerations, which we do not cover in detail here, might be operating a fan to disperse fumes during spraying, or perhaps a photocell proximity-personnel-system-stop device.
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9. Determine what-ifs
All possible situations and emergencies should be listed. In this example, some of them might be:
What if no part is in place when the start buttons are pushed? What if the power fails during the cycle when the part is rising, during painting, or at any other time? What if the sprayer runs out of paint? What if the same part is left in for a double coat? What if the master stop button is pushed? Does the stop button really stop the entire process, or can the mandrel move and create a safety problem after the stop button is depressed (it can)?
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System I/O
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Truth table
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