PLCcc

PLC(Programmable logic
controller)
• Programmable Logic Controller (PLC) is a
digital computer used for the automation of
various electro-mechanical processes in
industries.
• These controllers are specially designed to
survive in harsh situations and shielded from
heat, cold, dust, and moisture etc.
• PLC consists of a microprocessor which is
programmed using the computer language.
• The program is written on a computer and is
downloaded to the PLC via cable.
• These loaded programs are stored in non –
volatile memory of the PLC.
• During the transition of relay control panels to
PLC, the hard wired relay logic was exchanged for
the program fed by the user.
• A visual programming language known as the
Ladder Logic was created to program the PLC.
• PLC Hardware
• The hardware components of a PLC system
are CPU, Memory, Input/Output, Power
supply unit, and programming device.
• Below is a diagram of the system overview of
PLC.
• CPU – Keeps checking the PLC controller to avoid errors. They
perform functions including logic operations, arithmetic
operations, computer interface and many more.
• Memory – Fixed data is used by the CPU. System (ROM) stores the
data permanently for the operating system. RAM stores the
information of the status of input and output devices, and the
values of timers, counters and other internal devices.
• I/O section – Input keeps a track on field devices which includes
sensors, switches.
• O/P Section - Output has a control over the other devices which
includes motors, pumps, lights and solenoids. The I/O ports are
based on Reduced Instruction Set Computer (RISC).
• Power supply – Certain PLCs have an isolated power
supply. But, most of the PLCs work at 220VAC or
24VDC.
• Programming device – This device is used to feed the
program into the memory of the processor.
• The program is first fed to the programming device
and later it is transmitted to the PLC’s memory.
• System Buses – Buses are the paths through which the
digital signal flows internally of the PLC. The four
system buses are:
• Data bus is used by the CPU to transfer data among
different elements.
• Control bus transfers signals related to the
action that are controlled internally.
• Address bus sends the location’s addresses to
access the data.
• System bus helps the I/O port and I/O unit to
communicate with each other.
• Working of PLC (Programmable Logic
Controller)
• The Programmable logic controller functions
in four steps.
• Input scan: The state of the input is scanned which is
connected externally. The inputs include switches,
pushbuttons, and proximity sensors, limit switches,
pressure switches. Ideally, they are transformers and not
relays.
• Program scan: The loaded program is executed to carry out
the function appropriately.
• Output scan: The input sources have a control over the
output ports to energize or de-energize them. The outputs
include solenoids, valves, motors, actuator, and pumps.
Depending on the model of PLC, these relays can be
transistors, triacs or relays.
• Housekeeping
• PLC Applications
• The simple suitable application is a conveyor system. The requirements of
the conveyor systems are as follows:
• A programmable logic controller is used to start and stop the motors of
the conveyor belt.
• The conveyor system has three segmented conveyor belts. Each segment
is run by a motor.
• To detect the position of a plate, a proximity switch is positioned at the
segment’s end.
• The first conveyor segment is turned ON always.
• The proximity switch in the first segment detects the plate to turn ON the
second conveyor segment.
• The third conveyor segment is turned ON when the proximity switch
detects the plate at the second conveyor.
• As the plate comes out of the detection range, the second conveyor is
stopped after 20 secs.
• When the proximity switch fails to detect the plate, the third conveyor is
stopped after 20 secs.
Advantages & Disadvantages
• Advantages
• PLCs can be programmed easily which can be
understood clearly well.
• They are fabricated to survive vibrations,
noise, humidity, and temperature.
• The controller has the input and output for
interfacing.
• Disadvantages
• It is a tedious job when replacing or bringing
any changes to it.
• Skilful work force is required to find its errors.
• Lot of effort is put to connect the wires.
• The hold up time is usually indefinite when
any problem arises
Programming in PLC
• The basic functioning of the PLC relies on the

control logic or the programming technique
used. Programming can be done using
flowcharts or using ladder logic or using
statement logics or mnemonics.
Distributed control system
• A distributed control system (DCS) is a computerised control

system for a process or plant usually with a large number
of control loops in which autonomous controllers are
distributed throughout the system, but there is central
operator supervisory control.
• This is in contrast to systems that use centralized controllers;
either discrete controllers located at a central control room or
within a central computer.
• The DCS concept increases reliability and reduces installation
costs by localising control functions near the process plant,
with remote monitoring and supervision.
• Distributed control systems first emerged in large,
high value, safety critical process industries, and were
attractive because the DCS manufacturer would
supply both the local control level and central
supervisory equipment as an integrated package, thus
reducing design integration risk.
• Today the functionality of SCADA and DCS systems are
very similar, but DCS tends to be used on large
continuous process plants where high reliability and
security is important, and the control room is not
geographically remote.
• As the name implies, the DCS is a system of sensors, controllers, and
associated computers that are distributed throughout a plant. Each of
these elements serves a unique purpose such as data acquisition, process
control, as well as data storage and graphical display. These individual
elements communicate with a centralized computer through the plant’s
local area network – often referred to as a control network.
• As the ‘central brain’ of the plant the DCS makes automated decisions
based on production trends it sees them in real-time throughout a plant.
• As an example the DCS at a power plant might automatically increase
steam generation capacity of multiple turbines in order to keep up with
changing demand for electricity during hot Summer days and then
decrease it as outdoor temperatures cool overnight and demand subsides.
• Whereas a PLC could adjust a single unit operation, the DCS can make
adjustments to each of a plant’s many interacting unit operations.

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PLC(Programmable logic

• The basic functioning of the PLC relies on the

• A distributed control system (DCS) is a computerised control

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