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‫پی ال سی چیست و توسط چه کسی اختراع شد‬

‫ریچارد دیک مورلی ( ‪ (Richard Dick Morley‬به عنوان پدر صنعت ‪ PLC‬در دنیا‬
‫شناخته میشود که در اول دسامبر سال ‪ 1932‬در ماساچوست امریکا به دنیا آمد و در‬
‫هفدهم اکتبر سال ‪ 2017‬در ایالت نیوهمپشر امریکا در ‪ 85‬سالگی دار فانی را وداع‬
‫گفت‪.‬او تحصیالت خود را در انستیتو فنی ماساچوست گذراند ‪.‬‬
 What is PLC and by whom was it invented?

Richard Dick Morley is known as the father of the PLC industry

in the world. He was born on December 1, 1932 in
Massachusetts, USA, and passed away on October 17, 2017 in
New Hampshire, USA at the age of 85. He studied. He spent his
time at the Massachusetts Institute of Technology.

Prior to the invention of the PLC, mechanical relays were used

to create logic systems. Due to the noise generated, as well as
the high volume of breakdowns and depreciation, the need for
an intermediate logic system was strongly felt. Morley as a
mechanical engineer for the first time Modicon PLC, which itself
is a combination of the three words Modular digital Controller,
was later acquired by Schneider.
Morley launched his company's first PLCs at General Motors.
Morley's invention revolutionized the world industry, and later,
after Schneider, companies such as Alan Bradley and Siemens
developed the equipment, and the current PLCs, which happens
to be abbreviated. The three words Programmable Logic
Controller are the result of their services.

What is PLC?
PLC stands for Programmable Logic Controller, which means
programmable logic controller.

What does programmable logic controller mean ?!

Word by word, this sentence has an important meaning in its

heart, which we will examine in the following

controller

From this word we learn that we are dealing with a device that
can do all the control work for us, which is why PLC is also called
automation, because an automation is a completely control
system and of course pragmatic Be.

Logical
This may not seem like a big deal, but basically all the
advantages of PLC can be summed up in this word, when it is a
logical device, we can expect it from a rational person, to put it
simply; If we understand his language, we can easily talk to him.

So far we have a logic controller that can be very interesting to

us, but a miracle happens when a third word is added to it…
 Programmable

Yes, exactly, if the above two are possible but we can not provide
commands for it in some way, this device is practically useless,
the programming of a PLC can be done in various ways. In the
distant years, we have witnessed a lot of tastes in PLC
programming languages, which fortunately, with the presence of
the IEC standard, all these tastes were directed to a specific
point, and today, learning and choosing a programming
language to start or learn PLC is a very simple thing.

PLC is a programming controller that belongs to the computer

family; This controller is mainly used for industrial purposes. It
receives the input of various digital or analog signals from the
field and then converts them to the binary system logic signals
for the cpu, and the cpu executes the commands according to
the programs in which it is stored and outputs the output as logic
signals. These signals can be sent in analog or digital form to
equipment or operators.

Before PLC

The function of PLC in the past was the responsibility of relay

control circuits, the use of which is obsolete today in industrial
environments. It will follow the process. Electronic steering
circuits were built to fix these problems, but many changes to the
control system hardware needed to be made when there was a
change in the process or operation of the machine.

With PLC, minor changes in the process or operation of the

machine are easy, because it is no longer necessary to change
the wiring and hardware of the control system, and it is enough
to make changes in the program and send it to the PLC to
achieve the intended purpose. The idea is realized.

PLC is a controller like an electric steering circuit.

PLC is logical unlike electric steering circuit.

The above advantages along with the smaller dimensions of the

control system, faster troubleshooting, less downtime, the ability
to run more complex programs, the ability to exchange
information with other systems, etc., made relay circuits quickly
field for the presence of PLCs. To empty. PLCs were built instead
of traditional control panels whose operation depended on logic
electromagnetic relays based on timers for industrial control
systems. The PLC is able to continuously monitor the inputs from
the sensors and decide on the outputs.

Contactor relay

Contactor relays have always caused dissatisfaction among

engineers. Circuits that not only do not have logic but can not be
programmed in any way, let me explain the depth of the disaster
with an example!
Imagine we have a metropolis with 100 cities around it, all of
which are located 900 km from our metropolis. We have to travel
to one of these cities once a month and send them a letter. .

In the relay model, it was like we had to build roads for all 100
cities, which in general required (900 * 100km) ninety million
kilometers of roads, but this is only one part of the story, that you
have to keep these roads every year. The second challenge is
the same. But with the PLC method, it was enough to use the
Internet in the city of origin and destination! It may not be
believable, but there was so much difference between a relay
system and a PLC-style automation system.

The problem of relays in industrial automation

To modern factories f
Using PLC reduces the volume of control panels. -1

Using PLC saves a lot of money. - 2

PLC does not have mechanical depreciation, so in addition to -3
longer life, it does not need periodic service and repairs.

PLC power consumption is much less than relay circuits. -4

PLC does not cause noise and electrical noise. - 5

Troubleshooting control circuits with PLC is quick and easy - 6

and usually the PLC itself has a troubleshooting program.

PLC building block diagram

A PLC with the ability to store programs has a structure similar

to computers, except that the PLC is used as part of the
processing and control of an industrial process.

As shown in the figure below, the inputs transmit the necessary

information to the PLC and the PLC controls the outputs
according to the needs of the control system and based on the
program written in it.
PLCs basically consist of a power supply, input signal receiving
unit, central processing unit with microprocessor, program
In PLC, ‫در‬storage memory, output signal transmission unit, etc.
how to control the process as a program is stored in its memory.
In the figure below, you can see the different units of a PLC,
which we will describe in the following.

It should be noted that PLCs available in the industry are

available in compact, modular, network and also as industrial
PCs. For PLCs with a small number of inputs and outputs, ie with
a maximum About 100 DI / DO (digital inputs and outputs)
compact or micro models are used as model PLCs (S7 200) and
for PLCs with more than 100 inputs and outputs (DI / DO) from
Modular model PLCs are used.

Principles of operation and different parts of a PLC

PLCs receive the inputs and, after reading the program written
inside it, give the necessary command to the outputs.

In general, PLC consists of the following three main parts.

CPU -

Input section -
 Output section -

The following figure describes the performance of each section

Input section

As mentioned, a series of inputs are connected to the PLC and

give the necessary information to the PLC. These inputs may be
sensors, switches, laminate switches, etc. In general, these
inputs can be divided into two categories of analog that The
same signal is continuous and digitally split.

In the figure below you can see the types of inputs that are
connected to the PLC.

In this section, the ability to read and process values and

variables should include:

Limit values of switches

Analog variables (such as values of heat and pressure sensors)

Have positions in position finder systems, etc.

 Output section

In the PLC output section, various industrial devices such as

motors, valves, displays, hydraulic valves, etc. can be
connected. The output section can also be divided into two
general modes, digital and analog.
The following figure shows the types of outputs that are
connected to the PLC.

This section should also enable special devices, including:

Electric motors

Pneumatic or hydraulic cylinders

Magnetic relays and coils

Have analog outputs, etc.

CPU

The CPU is the mastermind of the PLC and is in fact responsible

for all control processes. All the information collected from the
inputs is processed in the CPU according to the written control
program, then the outputs are controlled. It is worth mentioning
that the CPU includes components such as Memory and
microprocessor.
After getting acquainted with the three important parts of a PLC
and for a better understanding of the subject, an example is
given in the figure below to see the performance of all three
parts. In this example, pushbuttons are connected to the PLC
inputs and the motor to the output by the driver The PLC is
connected, turned on and off according to the written program.
This program can be left-right or a simple self-holding circuit. The
push key can also be assumed as a sensor that senses hand
pressure.

Basic concepts in the operation of a PLC system

In this section, we will introduce the topics that are the basis of
PLC work, and in fact, we will introduce the process of working
and reading the program by the CPU.

Image Inputs Process Image Input))

Before execution, the CPU checks the status of all inputs and
stores them in a part of the memory called PII. Except in
exceptional cases and only in some types of PLCs, the CPU
often does not refer to the inputs during the execution of the
program. Information about the status of each input refers to the
cell in PII. In some cases, this part of the memory (IITInput Image
Table) is also called.

Output Image (PIQ)

Whenever an output value is obtained during program execution,
it is stored in this part of the memory. Except in exceptional cases
and only in some types of PLCs, often the CPU does not refer to
the outputs during program execution, but to record the latest
status. Each output refers to the desired cell in the PIQ, and at
the end of the program, the last state of the output from the PIQ
is transferred to the physical output. In some cases, this part of
the memory is called the PITPut Image Table.

Scan cycle
In a hardware circuit implemented by the PLC as shown below,
which is programmed in the LADDER programming language,
the input modes change the output state.

In a PLC, the output of the output to the input states is not fast,
but a PLC performs a three-step process to perform operations
related to the designed process. This three-step process is
called a CPU scan cycle.

The following figure shows the three steps involved in performing

a scan cycle.

These three steps can be introduced as follows:

Step 1: Determine the status of the input equipment

The stage
Power supply (AC power supply) is responsible for the AC -1
voltage in the system from the system power supply, which
causes safety against noise and fluctuations of the input voltage
in industrial environments.

CPU The microprocessor executes the program stored in the .2

PLC, taking into account the status of the inputs. And accordingly
instructs the output to activate the desired output.

Memory is used to store programs and information. -3

The programmer relation is used by the user to write the -4

program and transfer it to the PLC memory and they are divided
into two categories in terms of appearance:

A small keyboard with a screen -1

Using personal computers and installing software required for -2

special programming.

I / O unit that connects the PLC to the outside world. -5

Types of PLCs

In the PLC industry, there are more than one hundred factories
with a great variety in designing and manufacturing different
types of PLCs. PLCs can be categorized in terms of size,
memory, number of inputs / outputs, scope of operation (local or
large) and.. It should be noted that to evaluate the capability of a
PLC, other features such as processor, runtime, simplicity of
programming language, scalability, etc.

PLCs with local application

Application: Control of systems with small volume (limited

number of inputs and outputs) and for simultaneous control of a
smaller number of processes or control of separate industrial
devices (due to more limited capabilities), most manufacturers
offer this type of PLCs along with other PLCs, but Some
manufacturers offer it under the name of micro PLC. Among
these types of PLCs, the following examples can be mentioned:

ZEN Made by Omron Japan

LOGO made by SIEMENS Germany

Zelio Made by Telemecanique France

Moeller Germany

LG Korea

Wide application PLCs

Application: Factory site control.

In large industries, PLCs are usually present in different parts of
the factory site and exercise local control over the parts they
cover. The required information is then transferred to the central
control room using various data transfer methods, where the
information is converted to graphic form and displayed on the
monitor screen using various industrial monitoring methods.
However, the operator can control the system only by knowing
how to work with the computer and without the need for
specialized information.
Among the most famous PLCs of this family that can be named
are:

S7 and SIMATIC S5 of the German company SIEMENS

OMRON Japan Company

French Telemecanique Company

Mitsubishi Japan

LG Korea

Allen-Bradley USA

ABB Switzerland-Sweden

Having a complete view of the variety of PLCs is the most

important issue in choosing and buying a suitable PLC;
Therefore, when buying, you should pay attention to the
following points:

Number of entries

Number of outputs

Number of flags

Number of counters

Number of timers

Types of flags and timers

 Memory size

SCAN TIME program execution speed

Classification of types of plc brands

In general, plc brands are divided into four different categories,

which we will introduce in the following

mini plc

Compact plc

Modular plc

Rack plc

Mini PLC

Mini plc .1
Mini PLCs are among the small types of PLC. Less output and
input restrictions are among the features of this type of PLC. Due
to the benefit of this type of PLC with less output and input (up
to 40 output inputs), mini PLCs are often used for small projects.

Compact PLC

Compact plc
Other types of plc include compact or integrated PLC. In this type
of plc, all parts such as outputs and inputs, processor and power
supply are designed in one box. Having more outputs and inputs
(up to 300 output inputs), has made it possible to use integrated
plc in medium projects.
This type of PLC is commonly used for smart and factory
automation projects.

Modular PLC

In this type of plc, the main parts such as inputs, outputs,

processor and power supply modules are separated from each
other, but it is possible to put these parts next to each other in
order to form a plc. Enables a large number of outputs and inputs
commensurate with the power of the CPU (it is possible to add
up to 2,000 output inputs to this PLC).

Note that to work with this type of PLC, the frame at the end must
be closed and the PLC completed.

RAC plc

PLC rack is another example of a type of plc that is very similar

to modular PLC. In this plc, all inputs and outputs are connected
to the central module that is located behind it. So the LC rack is
installed vertically and due to having a lot of outputs and inputs
(you can get 5000 output inputs with this PLC), this type of plc is
considered one of the best options for large projects, such as
refinery and petrochemical projects.
 Application of PLC

Today, the use of PLC in industries in various industrial

processes is abundant.

Automotive industry: -1

Automatic drilling operations, connecting parts, as well as testing

car parts and equipment, spray systems and shaping the body
by automatic presses, etc.

Plastic manufacturing industries: -2

Injection molding and molding machines, air blowers, plastic

production and analysis systems.

Heavy industries: -3

Industrial furnaces, automatic temperature control systems,

appliances, etc.
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