MECHANICAL ENGINEERING DEPARTMENT

Introduction to Mechatronics (MEng 5271)

2015 EC

Chapter Five
Fundamentals of PLC

Compiled by Genaye M.
WHAT IS INDUSTRIAL 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.
Making products under the control of computers and programmable
controller is known as Industrial Automation.
Automation is a delegation of human control functions of technical
equipment for increasing productivity, better quality, increasing safety
in working conditions reducing manpower and cost.
HOW DO YOU DO ?

Simplification through applying ideas of appropriate branch of

engineering
ELECTRICAL
ELECTRONICS
MECHANICAL
INSTRUMENTATION
MECHATRONICS
OPTICAL
COMPUTERS,
IF WE
Consider, MAN : with MACHINE
HISTORY OF AUTOMATION ?
MANUAL CONTROL

All the actions related to process control are taken by the operators
Drawbacks
Likely human errors and consequently its effect on quality of final
product

The production, safety, energy consumption and usage of raw

material are all subject to the correctness and accuracy of human
action.
PNEUMATIC CONTROL

Industrial automation, with its machine and process control, had its origin
in the 1920s with the advent of "Pneumatic Controllers".

Actions were controlled by a simple manipulation of pneumatic valves,

which in turn were controlled by relays and switches.
Drawbacks
Bulky and Complex System
Involves lot of rework to implement control logic
Longer project time
HARD WIRED LOGIC CONTROL

The contactor and Relays together with hardware timers and counters
were used in achieving the desired level of automation
Drawbacks
Bulky panels
Complex wiring
Longer project time
Difficult for maintenance and troubleshooting
ELECTRONIC CONTROL USING LOGIC GATES
In 1960s with the advent of electronics, the logic gates started replacing the relays
and auxiliary contactors in the control circuits.

The hardware timers & counters were replaced by electronic timers

Advantages
Reduced space requirements
Energy saving
Less maintenance & greater reliability

Drawbacks
Changes in control logic not possible
More project time
PROGRAMMABLE LOGIC CONTROLLERS
In 1970s with the coming of microprocessors and associated peripheral
chips, the whole process of control and automation underwent a radical
change.

Instead of achieving the desired control or automation through physical

wiring of control devices, in PLC it is achieved through a program or say
software.

The programmable controllers have in recent years experienced an

unprecedented growth as universal element in Industrial Automation.

It can be effectively used in applications ranging from simple control like

replacing small number of relays to complex automation problems
AUTOMATION ADVANTAGES

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 DISADVANTAGES

Unemployment rate increases due to machines replacing humans and

putting those humans out of their jobs.
Technical Limitation
Security Threats/Vulnerability
Unpredictable development costs
High initial cost
AREAS OF APPLICATIONS
Any application in any industry that requires
electrical control
Packaging
Industry
bottling & Canning
Cement
Material Handling
Automobile
Machining
Chemicals
Power Generation
HVAC/ Building Automation Plastics

Security Systems Metals Paper

Automated Assembly
Paint Lines
Water treatment
WHAT IS PLC?

A PLC is a solid state / industrial computer that performs discrete or

sequential logic in a factory environment.
It was originally developed to replace mechanical relays, timers,
counters.

A sequence of instructions is programmed by the user to the PLC

memory. Its purpose is to monitor crucial process parameters and
adjust process operations accordingly.
PLC
FUNCTIONS OF PLC
On/Off
Timing
Control
Sequencing
Data Handling
Counting
Arithmetic
 ADVANTAGES
PLC Saves By
Material cost Reduced wiring & associated errors
Installation cost Less space
Troubleshooting No moving parts - rugged
Labor cost Possibility of reprogramming

Value added benefits

Reliability
Flexibility
Advanced Function
Communication
Speed
Diagnostics
 DISADVANTAGES
Too much work required in connecting wires.
Difficulty with changes or replacements.
Difficulty in finding errors; requiring skillful work force.
BASIC COMPONENTS OF A PLC SYSTEM
Network Interface
Most PLCs have the ability to communicate with other devices.
The PLC will communicate to the other devices through a
network interface.
VARIOUS BRANDS IN PLC
Allen Bradley USA
Siemens Germany
Modicon France
Mitshubishi Japan
GE Fanuc USA
Omron Japan
PLC’S COME IN A VARIETY OF SIZES...
Pico
Typically less than 20 I/O
Micro
Typically less than 32 I/O
Small
Typically less than 128 I/O
Medium
Typically less than 1024 I/O
Large
Typically greater than 1024 I/O
PLC HARDWARE SYSTEM
A PLC system has five basic components

 The processor unit

 Memory

 The power supply unit

 Input / output interface

 Programming device
PLC ARCHITECTURE

The Structure of PLC is based on the same principles as those

employed in computer architecture.
ARCHITECTURE
INPUTS
PLC system consists of Inputs

1) Inputs - Discrete - On/Off type

o Pushbuttons

o Switches

o Limit Switches

o Selector Switches

o Proximity sensors

o Photo - electric sensors

2) Inputs devices - Analog

o Resistance Temp. Detectors
o Thermo - couple
 INPUT MODULES
The input module performs tasks electronically as:
o Determines the presence or absence of input
o Converts input single to a DC level use able PLC
o Provides Electronic isolation B/w input signal & PLC
INPUT MODULES
OUTPUTS
PLC system consists of Outputs
Solenoids
Relays - AC or DC powered
Contactors
Motor Starters
Indication Lights
Valves
Alarms
 INPUT / OUTPUT SECTION
Consists of input module and output module
The I/O system forms the interface by which field
devices are connected to the controller.
Field devices are actual external devices which must
be physically wired into the system.
The PLC employs an optical isolator which uses light to
electrically isolate the internal components from the
input /output terminals.
OUTPUT MODULES
 INPUT/ OUTPUT INTERFACE
Input interface module accept signal
from the machine or process devices
and convert them into signals that can
be used by the controller.
Output interface module convert
controller signals into external signals
that can be used to control the
machine or process.
 OUTPUT MODULES
The output module operates in opposite manner from input module
 PROCESSOR UNIT
Consists of a microprocessor for implementing the logic
and controlling the communication among the modules.
The processor accepts input data from various sensing
devices, executes the stored user program and sends
appropriate output command to the control devices.
It is designed to enter desired circuit in relay ladder
logic form
PROGRAMMING DEVICE

A programming terminal device is needed to enter, modify, and troubleshoot the

PLC program. PLC manufacturers use various types of programming devices.
This proprietary programming device has a connecting cable so that it can be
plugged into a PLC’s programming port. Certain controllers use a plug-in panel
rather than a hand-held device
Hand-held programmers are compact, inexpensive, and easy to use. These units
contain multifunction keys and a liquid-crystal display (LCD) or light-emitting diode
(LED) window.
There are usually keys for instruction entering and editing, and navigation keys for
moving around the program. Hand-held programmers have limited display
capabilities.
Some units will display only the last instruction that has been programmed,
whereas other units will display from two to four rungs of ladder logic.
CONTINUED…

The most popular method of PLC programming is to use a personal

computer (PC) in conjunction with the manufacturer’s programming
software.
Typical capabilities of the programming software include online and
offline program editing, online program monitoring, program
documentation, diagnosing malfunctions in the PLC, and
troubleshooting the controlled system.
Hard-copy reports generated in the software can be printed on the
computer’s printer. Most software packages will not allow you to
develop programs on another manufacturer’s PLC.
 CONTINUED…
A personal computer is the most commonly used programming device.
The software allows user to create, edit, document, store and troubleshoot
programs.
Removing the programming unit will not affect the operation of user program.
 POWER SUPPLY
It supplies DC power to other modules
plugged in to the rack.
In small PLC systems it is also used to supply to
the field devices. But in large PLC systems is
not normally used to power field devices.
 PROGRAMMING A PLC
In order to create or change a program, the
following items are needed:
 PLC
Programming Device
Programming Software
Connector Cable
•Memory unit: is where the
program is stored that is to be
used for control actions.

•Programming device: is used to

entered the required program into
the memory of the processor.
 MEMORY
The processor consists of memory locations known as words
Each word can store binary data
The number of bits that a word can store depends on the system of PLC
The 16-bit word is more common

It is divided into two parts :

1)The user memory is for storage of user program
i.e. ladder logic
2)The storage memory is used to store information such as input/ output status
timers, or counters
 EXPANSION MODULES
The S7-200 PLCs are expandable. Expansion modules contain additional
inputs and outputs. These are connected to the base unit using a ribbon
connector.
WORKING OF CONTROLLER

For any execution of program processor has to scan the entire

program
Scan cycle consist of:-

 Input Scan

 Program Scan

 Output Scan
 PLC OPERATION
The PLC program is executed as part of a repetitive
process referred to as a scan. A PLC scan starts with
the CPU reading the status of inputs.

The application program is executed using the status

of the inputs. Once the program is completed, the
CPU performs internal diagnostics and
communication tasks.

The scan cycle ends by updating the outputs, then

starts over. The cycle time depends on the size of the
program, the number of I/Os, and the amount of
communication required.
FACTS ABOUT SCAN CYCLE

Scan Cycle Depends upon No of I/Os

More I/Os More scan time
Application Decides the Scan time of a PLC
Scan time in normal applications is 1 ms to 2 ms & in bigger
applications 100 ms to 200 ms
PROGRAMMING LANGUAGES
Ladder Diagram (LD)
Functional block Diagram (FBD)
Structured Text (ST)
Instruction List (IL)
Sequential Functional Chart (SFC)
CONTINUED..

1.Ladder Diagram (LD) —a graphical representation of a process with rungs

of logic, similar to the relay ladder logic schemes that were replaced by PLCs. It
is the primary programming language for PLCs
2.Function Block Diagram (FBD) —a graphical representation of process flow
using simple and complex interconnecting blocks.
3.Sequential Function Chart (SFC) —a graphical representation of
interconnecting steps, actions, and transitions.
4.Instruction List (IL) —a low-level, text-based language that uses mnemonic
instructions.
5.Structured Text (ST) —a high-level, text-based language such as BASIC, C,
or PASCAL specifically developed for industrial control applications.
…CONT.
Example – 1: Figure below shows a ladder-logic diagram for the three
instructions normally open (NO), normally closed (NC), and output coil
(OC). It implements the four combinational logics AND, OR, XOR, and
XNOR. This diagram assumes two input switches (SW1 and SW2) and
four output coils (AND_LOGIC, OR_LOGIC, XOR_LOGIC, and
XNOR_LOGIC).
 EXAMPLE
AND Logic Operation
•The AND logic operation ANDs 2 bytes, words, or double words at the value
IN1 and IN2 inputs bit by bit and outputs the result in the OUT output.
•Figure below shows the AND instruction.
…CONT.
OR Logic Operation
•The OR logic operation ORs 2 bytes, words, or double words at the
value IN1 and IN2 inputs bit by bit and outputs the result at the OUT
output. Figure shows the OR instruction.
…CONT.
…CONT.
Write the Boolean equations for the following logic diagrams:
…CONT.
List the conditions required to turn ON motor M for the line diagram in
Fig. below
…CONT.
Convert the following logic diagrams into a ladder-logic program.
 TIMER EXAMPLE
Figure below shows a ladder-logic diagram for the TOF timer instruction. This
diagram assumes a normally open START push button (PB), a normally closed
STOP push button, a timer preset (PT) value of 10 seconds, output MOTOR1
(Q0.0), and output MOTOR2 (Q0.1). The ladder diagram consists of two
networks.
…CONT.
COUNTER EXAMPLE
Figure below shows a ladder-logic diagram example for the CTD counter
instruction. This logic diagram assumes a normally open START push
button, a normally closed STOP push button, a photoelectric cell (PE),
Motor 1 running input ( MOTOR1_RUN), a counter preset value (PV) of
10, output Motor 1 (Q0.0), and output Pilot light 1 (Q0.4).

The system uses a motor to derive a conveyor system. The system requires
that the conveyor system shuts down once a preset value for rejected
parts is reached. Part rejection is initiated through a photoelectric
inspection cell.

This example and the preceding one assume that the motor running input
signal is realized immediately after the motor is commanded to start and
before the next scan. Typically, this indication is delayed for several scan
times.
…CONT.
 WRITE LD FOR THIS TASK
Ladder Diagrams diagram for a batch
process: filling a container with a liquid,
mixing the liquid, and draining the container.
•The sequence of events is as follows: 1. fill
valve opens and lets the liquid into the
container until it is full. 2. liquid in the
container is mixed for 3 minutes. 3. a drain
valve opens and drains the tank.
PLC EXAMPLE
-END-