SRI RAMAKRISHNA ENGINEERING COLLEGE

VATTAMALAIPALAYAM, N.G.G.O. COLONY POST, COIMBATORE – 641 022.

DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING

HANDS ON TRAINING IN INDUSTRIAL

CONTROLLER FOR AUTOMATION

INTRODUCTION TO INDUSTRIAL
AUTOMATION IN PLC
Presented by
S.Kaushik
Department of EIE
Sri Ramakrishna Engineering College
Coimbatore 22.
 Overview

 Automation
 Industrial Automation in late 1960s
 Introduction to PLC
 Leading manufacturers of PLC
 Architecture of PLC
 PLC vs Computer vs Microcontroller
 PLC Applications

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 AUTOMATION

• General
• The technique of making an apparatus, a process, or
a system operate automatically with minimum or no
human intervention

• Industry
• The creation and application of technology to
monitor and control the production and delivery of
products and services

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 AUTOMATION

• Automation provides benefits to virtually all of industry.

Here are some examples:

• Manufacturing, including

• food and pharmaceutical,

• chemical and

• petroleum, pulp and paper

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 AUTOMATION

• Automation provides benefits to virtually all of industry.

Here are some examples:

• Transportation, including

• automotive,

• aerospace, and

• rail

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 AUTOMATION

• Automation provides benefits to virtually all of industry.

Here are some examples:
• Utilities, including

• water and wastewater,

• oil and gas,

• electric power, and

• telecommunications
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 AUTOMATION

• Automation provides benefits to virtually all of industry.

Here are some examples:
• Defense

• Facility operations, including

• security,
• environmental control,
• energy management,
• safety, and
• other building automation

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 INDUSTRIAL AUTOMATION IN LATE 1960S

• Hard wired relay systems and control panels with a

software based control system

• Relay Automation used thousands of

• relays,
• cam timers,
• drum sequencers and
• dedicated closed loop controllers

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 INDUSTRIAL AUTOMATION IN LATE 1960S

Fig 1 Relay Panel

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 INDUSTRIAL AUTOMATION IN LATE 1960S

Fig 2 Cam Timer

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 INDUSTRIAL AUTOMATION IN LATE 1960S

Fig 3 Drum Sequencer

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 INDUSTRIAL AUTOMATION IN LATE 1960S

Fig 4 Pneumatic Closed loop controllers

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 INDUSTRIAL AUTOMATION IN LATE 1960S

• Relay rewiring for a new configuration is difficult

• Relays have some delay in turning ON and OFF a

device

• Relays have some wearable parts and so periodical

maintenance ie required

• Debugging a Relay Control boards are also difficult

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 INTRODUCTION TO PROGRAMMABLE LOGIC
CONTROLLER

• 1968 With a core group of engineers, Richard E.

Morley founded Bedford Associates and invented the
first programmable logic controller or PLC. He
established the Modicon company, deriving its name
from Modular Digital Control.

• 1969 Modicon introduced the "084" PLC, so named

because it was the 84th project of Bedford Associates.

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 INTRODUCTION TO PROGRAMMABLE LOGIC
CONTROLLER

• 1973 The "084" was upgraded and re-introduced as the

"184". The workforce increased from 80 to 170
employees and sales reached $5 million. Offices were
opened in Cleveland, Los Angeles and Rochester.

• 1975 Modicon introduced the "284", the first controller

with a microprocessor and distributed control and the
"384, the first PLC with digitized process algorithms for
continuous control.

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 Dick Morley ( Founder of PLC)

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 Odo Josef Struger (creating the PLC acronym)

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 PLC DEFINITION

The National Electrical Manufacturers Association

(NEMA) defines a PLC as a "digitally operating
electronic apparatus which uses a programmable memory
for the internal storage of instructions by implementing
specific functions, such as logic, sequencing, timing,
counting, and arithmetic to control through digital or
analog I/O modules various types of machines or
processes."

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 LEADING BRANDS OF PLC

AMERICAN 1. Allen Bradley

2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D

EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique

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 LEADING BRANDS OF PLC

JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi

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 Architecture of PLC

POWER
SUPPLY

I M O M
N O U O
P D T D
U U PROCESSOR P U
T L U L
From To
E T E
SENSORS OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE

Fig 1 Architecture of PLC

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 Major components in PLC

POWER SUPPLY

• Provides the voltage needed to run the primary PLC

components

• AC and DC power source can be used depend on the model

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 Major components in PLC

Fig 2 Power Supply of PLC

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 Major components in PLC

Fig 3 Power Supply to PLC

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 Major components in PLC

I/O MODULES

• The I/O system forms the interface by which field devices

are connected to the controller.

• The purpose of this interface is to condition the various

signals received from or sent to external field devices.

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 Major components in PLC

I/O MODULES

• Input devices such as pushbuttons, limit switches, and

sensors are hardwired to the input terminals.

• Output devices such as small motors, motor starters,

solenoid valves, and indicator lights are hardwired to the
output terminals.

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 Major components in PLC

I/O MODULES

Fig 4 Chassis and Rack type PLC

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 Major components in PLC

I/O MODULES

Fig 5 Chassis and Rack type PLC

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 Major components in PLC

I/O MODULES

Fig 6 Input and Output Signals

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 Major components in PLC

Fig 7 PLC with Inputs an Outputs

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Major components in PLC

MICROPROCESSOR

• PLC system there is a need for it to access the data to be

processed and instructions, that is, the program, which
informs it how the data is to be processed.

• Both are stored in the PLC memory for access during

processing.

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 Major components in PLC

MICROPROCESSOR

• There are several memory elements in a PLC system:

• System read-only-memory (ROM) gives permanent

storage for the operating system and
fixed data used by the CPU.

• Random-access memory (RAM) is used for the user’s

program.

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 Major components in PLC

MICROPROCESSOR

• Random-access memory (RAM) is used for data. This is

where information is stored on the status of input and output
devices and the values of timers and counters and other
internal devices.

• The data RAM is sometimes referred to as a data table or

register table.

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 Major components in PLC

MICROPROCESSOR

• Possibly, as a bolt-on extra module, erasable and programmable

read-only-memory (EPROM) is used to store programs
permanently

• The storage capacity of a memory unit is determined by the

number of binary words that it can store.
• Memory size is 256 words, it can store 256^8 =2048 bits if 8-
bit words are used and
• 256^16 = 4096 bits if 16-bit words are used.

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 Major components in PLC

MICROPROCESSOR

• Memory sizes are often

specified in terms of the number of storage locations available,
with 1K representing the
number 210, that is, 1024.

• Manufacturers supply memory chips with the storage locations

grouped in groups of 1, 4, and 8 bits.

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 Major components in PLC

MICROPROCESSOR

• A 4K X1 memory has 4 X 1 = 1024 bit locations.

A 4K X 8 memory has 4 X 8 =1024 bit locations.

• The term byte is used for a word of length 8 bits. Thus the
4K X 8 memory can store 4096 bytes.

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 Major components in PLC

MICROPROCESSOR

• 16-bit address bus we can have 216 different addresses, and

so, with 8-bit words stored at each address, we can
have 216 X 8 storage locations and

• So use a memory of size 216 X 8/210 = 64K X 8, which

might be in the form of four 16K X 8-bit memory chips.

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 Major components in PLC

PROGRAMMING DEVICE – 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.

• Hand-held programmers have limited display capabilities.

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 Major components in PLC

PROGRAMMING DEVICE - Hand Held Device

Fig 8 Hand held Programming Device

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 Major components in PLC

PROGRAMMING DEVICE - Hand Held Device

• There are usually keys for instruction entering and editing,

and navigation keys for moving around the program.

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 Major components in PLC

PROGRAMMING DEVICE – Personal Computer

• 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.

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 Major components in PLC

PROGRAMMING DEVICE – Personal Computer

Fig 9 Computer as Programming Device

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 PLC Scan Time

Fig 1 PLC Scan Time

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 PLC SCAN TIME (Contd.)

• PLC performs a repetitive cycle of operations.

• First, the PLC sequentially scans the input devices

• up-dates a memory table indicating their status

• The PLC executes its control programming, or ladder

logic.
• As it processes the ladder logic, the PLC updates a
memory table which indicates whether output devices
should be ON or OFF

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 PLC SCAN TIME (Contd.)

PLC uses the output table to actually change the condition of

the output devices.

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 PLC SCAN TIME - EXAMPLE

Fig 3 Glue machine

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PLC SCAN TIME - EXAMPLE

Fig 4 Cartoon Position

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 PLC SCAN TIME - EXAMPLE

The controller reads the transducer position during the

input scanning process. If a PLC scans this input just after
the transducer reaches 180°,

The output for the glue gun would turn on at the completion
of the controller processing cycle shown in Figure 3.
For a PLC with a scan time of 10 msec., the output
would turn on 10 msec after the transducer reached 180°

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 THANK YOU

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