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Unit-4. Programmable Logic Controller

The document discusses programmable logic controllers (PLCs). It defines a PLC as a digital computer used for industrial control systems. The document outlines the history, components, programming, and operation of PLCs. It also provides examples of ladder logic and discusses the advantages of PLCs like flexibility and reliability, as well as disadvantages like proprietary components. PLCs are widely used in industrial automation applications.

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Haripriya Palem
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© © All Rights Reserved
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59 views15 pages

Unit-4. Programmable Logic Controller

The document discusses programmable logic controllers (PLCs). It defines a PLC as a digital computer used for industrial control systems. The document outlines the history, components, programming, and operation of PLCs. It also provides examples of ladder logic and discusses the advantages of PLCs like flexibility and reliability, as well as disadvantages like proprietary components. PLCs are widely used in industrial automation applications.

Uploaded by

Haripriya Palem
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
Download as pptx, pdf, or txt
Download as pptx, pdf, or txt
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(Programmable Logic C o n t r o l l e r)

Contents
 What is PLC?
 History of PLC
 Major components of PLC
 Operational sequence of PLC
 Ladder logic
 Example of starting and stopping of a
motor
 Advantages
 Disadvantages
 Application
What is PLC?
PLC is a digital computer designed for
multiple inputs and output
arrangements, extended temperature
ranges, immunity to electrical noise, and
resistance to vibration and impact. A
PLC is an example of a real time system.
 PLC was introduced in late 1960’s
First commercial & successful Programmable Logic
Controllers was designed and developed by Modicon as a
relay replacer for General Motors.
 Earlier, it was a machine with thousands of electronic
parts.
Later ,in late 1970’s,the microprocessor became reality &
greatly enhanced the role of PLC permitting it to evolve form
simply relay to the sophisticated system as it is today.
Major Components of a Common PLC

POWER

SUPPL
Y

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

5
Major Components of a Common PLC

POWER SUPPLY
Provides the voltage needed to run the primary PLC components

I/O MODULES
Provides signal conversion and isolation between the internal logic-
level signals inside the PLC and the field’s high level signal.
PROCESSOR
Provides intelligence to command and govern the activities of the entire
PLC systems.

PROGRAMMING DEVICE
Used to enter the desired program that will determine the sequence of
operation and control of process equipment or driven machine.

6
PLC operation sequence
1) Self test: Testing of its own hardware and
software for faults.
2) Input scan: If there are no problems, PLC Self test
will copy all the inputs and copy their
values into memory.
Input scan
3) Logic solve/scan: Using inputs, the ladder
logic program is solved once and outputs are
updated. Logic
scan
4) Output scan: While solving logic the output
values are updated only in memory when Output
ladder scan is done, the outputs will be scan
updated using temporary values in
Programming Languages of PLC
Most common languages encountered in PLC
programming are:
1) Ladder Logic
2) Functional Block Diagram
3) Sequential Function Chart
4) Boolean mnemonics
Ladder Logic
 The ladder logic is the oldest programming
language for PLC.
 It is well suited to express Combinational
logic.
 The main ladder logic symbols represent the
elements :

make contact

break contact

relay coil
AND Gate OR Gate

A B Logic(Y) A B Logic(Y)
OFF OFF OFF
OFF OFF OFF
OFF ON ON
OFF ON OFF
ON OFF ON
ON OFF OFF
ON ON ON
ON ON ON

Y
A B Y
B
NOR Gate NAND Gate

A B Logic(Y) A B Logic(Y)
OFF OFF ON OFF OFF ON
OFF ON OFF OFF ON ON
ON OFF OFF ON OFF ON
ON ON OFF ON ON OFF

A B Y Y

B
Block diagram of a PLC
Outputs
LEDs

Inputs
 Reliability.
 Flexibility in programming and reprogramming.
 Cost effective for controlling complex systems.
 Small physical size, shorter project time.
 High speed of operation.
 Ability to communicate with computer systems in
the
plant.
 Ease of maintenance /troubleshooting.
 Reduced space.
 Energy saving.
Disadvantages of PLCs
 PLC devices are proprietary it means that part or
software of one manufacturer can’t be used in
combination with parts of another manufacturer.
 Limited design and cost option
 Fixed Circuit Operations.
 PLCs manufacturers offer only closed architectures.
 Wherever automation is desired the PLCs are
best suited to meet the task.

 Few examples of industries where PLCs are used :


1) Robots manufacturing and control
2) Car park control
3) Train control station system
4) Food processing
5) Materials handling
6)Machine tools
7)Conveyer system etc.

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