237-1060-E, 2+2

PLC in Industrial Control

Ing. Marie Martinásková, Ph.D.

Ing. Jakub JURA
Czech Technical University
in Prague

Mechanical Engineering Faculty

Institute of Instrumentation
and Control Engineering

Technická 4, 166 07 Prague 6

 The Head of the
Institute of Instrumentation and
Control Engineering

Prof. Ing. Pavel ZÍTEK, Dr.Sc.

Room 413, Dejvice

Ing. Marie Martinásková, Ph.D.
Lectures, exercises, laboratory

room: 511 Dejvice

phone to the room: 224352528
email:martinas@fsid.cvut.cz
mobil:732605047
Ing. Tomáš Vyhlídal, Ph.D.
Exercises, laboratory

room: 305i Dejvice

phone to the room: 22435….
email:………..@fsid.cvut.cz
 Lectures:
Thuersday 10.45
room 109 Dejvice

Exercises, laboratory:
Thuersday: 12.30
room 109 Dejvice
 Lecture 1
1.The PLC in automation technology

1.1 Introduction
1.2 Areas of application of a PLC
1.3 Basic design of a PLC
1.4 The new PLC standard IEC 1131
 1.The PLC
in automation technology
1.1 Introduction
 PLC
Programmable
Logic
Controller

The first PLC was developed by a group of

engineers at General Motors in 1968, when
the company were looking for an alternative to
replace complex relay control systems.
 The new control system had to
meet the following requirements:

• Simple programming
• Program changes without system
intervention (no internal rewiring)
• Smaller, cheaper and more reliable than
corresponding relay control systems
• Simple, low cost maintenance
 Subsequent development
resulted in a system enabled:
• the simple connection of binary signals
• the requirements as to how these signals
were to be connected was specified in the
control program
• with the new systems it became possible
for the first time to plot signals on a screen
and to store these in electronic memories
 More then three decades have
passed:
• the enormous progress was made in the
development of micro electronics
• great influence also at PLCs
• For instance, even if program optimisation
and thus a reduction of required memory
capacity initially still represented an
important key task for the programmer,
nowadays this is hardly of any significance.
 Evolution…..
• the range of functions has grown
considerably
• 15 years ago, process visualisation,
analogue processing or even the use of a
PLC as a controller, were considered as
Utopian…..
• nowadays, the support of these functions
forms an integral part of many PLCs.
1.2 Areas of application
of a PLC
 Every system or machine has
a controller.
Depending on the type of technology used,
controllers can be divided into:
• pneumatic
• hydraulic
• electrical
• electronic
Frequently, a combination of different
technologies is used.
Furthermore, differentiation is made
between:

• hard-wired programmable (e.g. wiring of

electromechanical or electronic
components) controllers

• programmble logic controllers

 Hard-wired programmable
controllers - 1

• This first type of controller is used

primarily in cases, where any
reprogramming by the user is out of the
question and the large job size warrants
the development of a special controller.
 Hard-wired programmable
controllers - 2

Typical applications for such controllers can

be found in :
• automatic washing machines
• cameras
• video cameras
• mobile phones
• cars
etc.
 Universal controllers -1
However, if the smaller job size does not
warrant the development of a special
controller or if the user is to have the facility
of making simple or independent program
changes, or of parameter changes
(e.g.setting timers and counters), then the use
of a universal controller, where the program
is written to an electronic memory, is the
preferred option…the second one possibility.
 Universal controllers -2
The PLC represents such a universal
controller!

It can be used for different applications and,

via the program installed in its memory,
provides the user with a simple means of
changing, extending and optimising
control processes.
 Universal controllers -3
Application areas of PLCs:
• production machines
• production lines
• production processes
• environmentally systems (waste water
cleaning,….)
• building equipment systems
(heating,cooling, lighting, safety systems…)
 The original task of a PLC
• the interconnection of input signals
according to a specified program and
switching corresponding output signals
• both input and output signals are
supposed to be logical ones
• Boolean algebra forms the mathematical
basis for this operation, which recognises
precisely two defined statuses of one
variable: "O" and "1 "
 New tasks of a PLC
However the tasks of a PLC have rapidly
multiplied:
• timer and counter functions
• memory setting and resetting
• mathematical computing operations

All this represent functions, which can be

executed by practically any of today's
PLCs.
Further Development of PLCs-1
• The demands to be met by PLC's
continued to grow in line with their rapidly
spreading usage and the development in
automation technology
• Visualisation, i.e. the representation of
machine statuses such as the control
program being executed, via display or
monitor.
 Further Development of PLCs -2
• Also supervising, i.e. the facility for human to
intervene in control processes or, alternatively, to
make such intervention by unauthorised persons
impossible.
• Very soon, it also became necessary to
interconnect and harmonise individual systems
controlled via PLC by means of automation
technology – PLC networks.
• Hence a master computer facilitates the means
to issue higher-level commands for program
processing to several PLC systems.
 Networking of several PLCs
• The networking of several PLCs as well as that
of a PLC and master computer is effected via
special communication interfaces.
• To this effect, many of the more recent PLCs are
compatible with open, standardised bus systems,
such as Profibus to DIN 19 245.
• Thanks to the enormously increased
performance capacity of advanced PLCs, these
can even directly assume the function of a
master computer.
PLC - not only for logic control-1
• At the end of the seventies, binary inputs
and outputs were finally expanded with the
addition of analogue inputs and outputs,
since many of today's technical
applications require analogue processing
(force measurement, speed setting, servo-
pneumatic positioning systems etc. at
machine tools).
PLC - not only for logic control-2
• At the same time, the acquisition or output
of analogue signals permits an
actual/setpoint value comparison and as a
result the realisation of automatic control
engineering functions, a task, which widely
exceeds the scope suggested by the
name (programmable logic controller).
 Currently PLCs - 1
• The PLCs currently on offer in the market
have been adaped to the customer
requirements to such an extent that it has
become possible to purchase an eminently
suitable PLC for virtually any application
• Miniature PLCs with a minimum number of
inputs/outputs (6/4 IOs) and also large PLC
systems with thousands of IOs are
available today
 Currently PLCs - 2
• Many PLCs can be expanded by means of
additional logic input/output, analogue
input/output, positioning and
communication modules
• Special PLCs are available for safety
technology, shipping tasks, mining tasks
etc.
 Currently PLCs - 3
• Yet further PLCs are able to process several
programs „simultaneously“ – multitasking or
truly simultaneously – multiprocessing (more
processors in one PLC)
• Finally, PLCs are coupled with other
automation components (HMI, identification
systems, smart actuators, etc.) thus creating
considerably wider areas of application
1.3 Basic design of a PLC
The term 'programmable logic controller' is
defined as follows by lEC 1131, Part 1:
" PLC is a digitally operating electronic system,
designed for use in an industrial environment,
which uses a programmable memory for the
internal storage of user-oriented instructions for
implementing specific functions such as logic,
sequencing, timing, counting and arithmetic, to
control, through digital or analog inputs and
outputs, various types of machines or processes.
Both the PC and its associated peripherals are
designed so that they can be easily integrated into
an industrial control system and easily useď in all
their intended functions. "
So we can say that programmable
logic controller is therefore nothing
more than

a microcomputer, tailored
specifically for certain control tasks
System components of a PLC
PLC Program
System components of a PLC
PLC Program

HW
System components of a PLC
SW
PLC Program

HW
System components of a PLC
SW PLC
PLC Program

HW
PLC and Field
SW PLC
PLC Program

HW

FIELD
PLC, Field and Controlled system
SW PLC
PLC Program

HW

FIELD

CONTROLLED PROCESS or CONTROLLED MACHINE

 Function of input and output
module
• The function of an input module is to
convert incoming signals from sensors
into signals which can be processed by
the PLC and to pass these to the central
control unit.
• The reverse task is performed by an
output module. This converts the PLC
signal into signals suitable for the
actuators
 Function of CPU
• The actual processing of the signals is
effected in the central control unit (CCU) in
accordance with the program stored in
the memory.

• Another name for CCU :

CPU = Central processing unit
is often used
 The program of a PLC can be
created in various ways:
• via assembler- type commands in 'statement list'
• in higher-level, problem-oriented languages such
as structured text
• in the form of a flow chart such as represented
by a sequential function chart
• in Europe, the use of function block diagrams
based on function charts with graphic symbols
for logic gates is widely used
• in America, the 'Iadder diagram' is the preferred
language by users
 External design of PLC
Depending on how the central control unit
(CCU) is connected to the input and
output modules, ditferentiation can be
made between:

• compact PLCs (input module, central

control unit and output module in one
housing)
• modular PLCs
 Modular PLCs
• Modular PLCs may be configured
individually. The modules required for the
practical application - which can, for
instance, include digital input/output
modules, analogue modules, positioning
and communication modules - are inserted
in a rack, where individual modules are
linked via a bus system. This type of
design is also known as series technology.
 Modular PLCs - examples
• Two examples of modular PLCs are
shown on the following figures.
• These represent
– the familiar modular PLC FPC405 FESTO
– the new S7 -300 series by Siemens.
PLC plug-in cards
(Festo FPC 405)
 Modular PLC – card format
• The card format PLC is a special type of
modular PLC, developed during the last
years of previous century.
• With this type, individual or a number of
printed circuit board modules are in a
standardised housing.
• The Festo FPC 405 is representative of
this type of design (Fig.).
Modular PLC - Siemens S7-300
Compact PLC - example
FEC FC 34 a PS1 FC 38
 Various abbreviations for
Programmable Logic
Controllers:

• PLC - Programmable Logic Controller

• FPC - Free Programmable Controller
• PC - Programmable Controller
(Attention! PC = Personal Computer most
often)
 Compact x Modular PLC
• A wide range of variants exists, particularly
in the case of more recent PLCs.
• These include both modular as well as
compact characteristics and important
features such as space saving, flexibility
and scope for expansion.
 Hardware design for a PLC
The hardware design for a programmable logic
controller is such that it is able to withstand
typical industrial environments as regard:
- signal levels
- heat
- humidity
- fluctuations in current supply
- mechanical impact
1.4 The new PLC standard
IEC 1131
 Previously PLC standards
• Previously valid PLC standards focussing mainly
on PLC programming were generally geared to
current state of the art technology in Europe at
the end of the seventies.
• This took into account non-networked PLC
systems, which primarily execute logic
operations on binary signals.
• DIN 19 239, for example, specifies programming
languages which possess the corresponding
language commands for these applications.
 Previously situation
• no equivalent, standardised language elements
existed for the PLC developments and system
expansions made in the eighties such as
– processing of analogue signals
– interconnection of intelligent modules
– networked PLC systems etc.
Consequently, PLC systems by different
manufacturers required entirely different
programming.
 International standard
• Since 1992, an international standard now
exists for programmable logic controllers and
associated peripheral devices (programming
and diagnostic tools, testing equipment,
human-to-machine (HMI) interfaces etc.).
• In this context, a device configured by the
user and consisting of the above components
is known as a PLC system.
 The new lEC 1131 standard
consists of six parts:
• Part 1: General information
• Part 2: Equipment requirements and tests
• Part 3: Programming languages
• Part 4: User guidelines (in preparation with
lEC)
• Part 5: Messaging service specification (in
preparation with lEC)
• Part 7: Fuzzy control programming
 International, European and
German Standards
• Parts 1 to 3 of this standard were adopted
unamended as
European Standard EN 61 131,Parts1 to 3

• As such, they also held the status of

a German Standard, DIN EN 66 1131
 The purpose of the new
standard
• to define and standardise
– the design and functionality of a PLC
– the languages required for programming
to the extent where users were able to
operate using different PLC systems
without any particular difficulties
 The next lectures will be dealing
with this standard in greater detail

• The new standard takes into account as many

aspects as possible regarding the design,
application and use of PLC systems.
• The extensive specifications serve to define
open, standardised PLC systems.
• Manufacturers must conform to the
specifications of this standard both with regard
to purely technical requirements for the PLC as
well as the programming of controllers.
• Any variations must be fully documented for the
user.
 Support of the Standard
• After initial reservations, a relatively large group
of interested people (PLCopen) has been
formed to support this standard. A large number
of major PLC suppliers are members of the
association, i.e. Allen Bradley, Klockner-Moeller,
Philips,Schneider Group to mention a few.
• PLC manufacturers such as Siemens or
Mitsubishi also offer control and programming
systems conforming to IEC-1131.
 New programming systems
• The new programming systems conforming the
Standard IEC 1131 are already available in the
market and others are being developed at the
time and going to press.
• The norm therefore stands a good chance of
being accepted and succeeding.
• Not least, it is hoped that our lectures will also,
to a certain extent, help to contribute to this.
 The END of the Lecture 1

Thank You for Your Attention