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Lecture-12-Programmable Logic Controllers

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4 views38 pages

Lecture-12-Programmable Logic Controllers

Uploaded by

shubhisachan843
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© © All Rights Reserved
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Programmable Logic

Controllers (PLC)
Automation and Robotics
Purpose of Programmable
Logic Controllers (PLCs)
● Initially designed to
replace relay logic boards
○ Sequence device
actuation
○ Coordinate activities
● Accepts input from a
series of switches
● Sends output to devices
or relays
Features of PLC
● PLCs have several key features that make them well-suited for
use in industrial environments. These include:
○ Input/Output (I/O) capabilities: PLCs have a variety of
input and output ports that allow them to interface with
sensors and actuators, such as temperature sensors,
pressure sensors, and motor starters.
○ Programming capabilities: PLCs can be programmed
using a variety of languages, such as ladder logic, which is a
graphical programming language that is well-suited for use
in industrial environments. This allows PLCs to be easily
adapted to changing process requirements.
Features of PLC
○ Real-time control: PLCs are able to control processes in
real-time, which is essential for many industrial processes.
○ Communication capabilities: PLCs can communicate with
other devices and systems, such as supervisory control and
data acquisition (SCADA) systems and other PLCs, via a
variety of communication protocols, such as Ethernet and
Modbus
PLC
What devices does a PLC interact with?

● 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.
What devices does a PLC interact with?

● INTERNAL UTILITY RELAYS-(contacts)


○ 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
What devices does a PLC interact with?
● COUNTERS
○ They 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
○ Most times these counters can count up, down or up and
down
What devices does a PLC interact with?

● TIMERS
○ They 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 1ms through 1s
Terminology for Switches
Throw - number of states

Pole - number of connecting moving parts (number of individual circuits)


Switches
Relays
Counter

Digital counters output in the form of a relay contact


when a pre-assigned count value is reached
Timer
A timer consists of an internal clock, a count value register,
and an accumulator. It is used for some timing purpose.
Ladder Diagram
A ladder diagram (also called contact symbology) is a means of
graphically representing the logic required in a relay logic system
Ladder Representation
PLC Wiring Diagram
SCAN
A PLC resolves the logic of a ladder
diagram (program) rung by rung, from
the top to the bottom. Usually, all the
outputs are updated based on the
status of the internal registers. Then
the input states are checked and the
corresponding input registers are
updated. Only after the I/Os have been
resolved, is the program then
executed. This process is run in an
endless cycle. The time it takes to
finish one cycle is called the scan time
PLC Instructions
1) Relay,

2) Timer and counter,

3) Program control,

4) Arithmetic,

5) Data manipulation,

6) Data transfer, and

7) Others, such as sequencers.


Logic States

ON : TRUE, contact closure, energize, etc.

OFF: FALSE, contact open , de-energize, etc.

● Do not confuse the internal relay and program with


the external switch and relay
○ Internal symbols are used for programming
○ External devices provide actual interface
AND and OR Logic
Combined AND & OR
RELAY

A Relay consists of two parts, the coil and the contact(s).

Contacts: Coil:
a. Normally open -| |-
a. Energize Coil -( )-
b. Normally closed -|/|-
b. De-energize -(/)-
c. Off-on transitional -|↑|-
c. Latch -(L)-
d. On-off transitional -|↓|-
d. Unlatch -(U)-
Timers and Counters
Sequencer

Sequencers are used with machines or processes


involving repeating operating cycles which can be
segmented into steps
An Example of Relay Logic

For process control, it is desired to have the process


start (by turning on a motor) five seconds after a part
touches a limit switch. The process is terminated
automatically when the finished part touches a second
limit switch. An emergency switch will stop the process
any time when it is pushed.
An Example of Relay Logic ...
An Example of Relay Logic ...
Programming a PLC

Oil is consumed randomly.


The tank needs to be
refilled by turning on a
pump. Two hydrostatic
switches are used to detect
a high and low level.
Ladder Logic Solution ...
Ladder Logic for Tank

Input relays 0000 and


0001 will be closed when
the corresponding
sensors attached are not
immersed in oil
Ladder Logic Solution
Ladder Logic Solution
Ladder Logic Solution
Ladder Logic Solution
Ladder Logic Solution
Ladder Logic Solution
Ladder Logic Solution

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