Programmable Logic Controller

PROGRAMMABLE
LOGIC
CONTROLLER
www.sanjayhumania.com
INTRODUCTION
Every system or machine has a controller. Depending on
the type of technology used controllers can be divided into
Pneumatics, Hydraulics, Electrical and Electronics
controllers. Frequently, a combination of different
technologies are used. Further more, differentiation is
made between hard-wired (wiring of Electro-Mechanical
and Electronics components) and Programmable Logic
Controller. In Programmable Controller the desired control
or Automation is achieved through a Program or Software
rather than through physical wiring.
What is Programmable Controller?
The programmable controller is an industrial control system
designed for a shop environment that can be programmed and
maintained by a shop personnel to increase the efficiency of
manufacturing operations. The basic function of a
programmable controller is to provide output commands to a
machine or process that are based on some combination of
input conditions received from the machine or process or other
related conditions. The internal wiring of a programmable
controller is fixed and the logic function which it must perform
in a given application are programmed into its memory and
hence the name PROGRAMMABLE CONTROLLER. A
processor with built in routine SCANS the incoming signals
and in accordance with the programs stored in the memory,
initiates corresponding output signals.
DEFINITION
As per NEMA Standards a programmable
controller is defined as a DIGITALLY
OPERATING ELECTRONIC APPARATUS
which uses a Programmable memory for the
storage of instructions for specific functions
such as logic sequencing, timing, counting,
and arithmetic control through digital or
analog input/output modules, various types
of machines or processes. A digital
computer which is used to performed the
function of a programmable controller is
considered to be within this scope. Excluded
are drum and similar mechanical type
sequencing controller.
CONSTITUENTS OF PROGRAMMABLE
CONTROLLER
The programmable controller has three main units.
PROCESSOR OR CENTRAL PROCESSING UNIT(CPU) AND MEMORY:
The processor reads input signals in response to them it generates output
commands by interpreting the instructions from the program which is stored in
the memory.
INPUT/OUTPUT RACK OR INTERFACE:
This is the interface between the application devices and the processor. The
I/O rack receives information signals from the input devices and transmits
action signals to the controlled devices.
PROGRAMMABLE PANEL OR PROGRAMMING,EDITING AND
MONITORING DEVICE:
Individual instructions which form the programmable controller program are
entered into the memory through the keyboard or program panel. These
instructions are shown in the program panel display in the from of individual
ladder diagram type rungs. The program panel provides a reading of the
programmable controller program for verification. It permits changes (editing)
of existing programs and also aids in machines or process start ups and in
trouble shooting.

PROGRAM MEMORY
ARITH-
METIC
AND
LOGIC
UNIT
DATA MEMORY
CENTRAL CONTROL UNIT OF A PLC
HOW DOES IT DIFFER FROM RELAY LOGIC AND STATIC
LOGIC SYSTEM:
Traditionally electro-mechanical relay could serve various industrial safety
and interlocking systems. The coils and the contacts of the relays were
specifically made for each system for achieving the desired interlocking
system. Though the relays were simple, rugged, it was replaced by solid
logic because it catered to the need of limited space requirement, reliability
and speed. But the solid-state logic had the limitation that it had to be
designed specifically to meet the particular logic requirement before
manufacturing could commence and therefore, it require longer lead time for
design, manufacturing and installation. This was the time when the need of a
programmable controller was felt in which the desired interlocking sequence
need not be wired but can be programmed and stored in its memory. The
basic difference between programmable controller and a relay logic or
hardwired logic type of controller is that the programmable controller
receives instruction in the form of a program which can be quickly and easily
replaced or modified by the user. By contrast the relay or hardwired solid-
state controller have wires connected between individual logic elements. Any
change in the logic of this systems, require actual changes in the wired
connections between those elements. Such changes imply production down
time and labour expenses.
HOW DOES IT DIFFER FROM COMPUTERS
The memory unit of the processor sequentially scans input (sensors, limit switches,
push buttons, photo cells) in cyclical fashion to determine which output (contacts,
motors, starters, solenoids, pilot lamps, converters etc.) it should be turned ON or
OFF. The programmable controller processes instructions in a fixed cycle. The
instructions can be skipped or not performed, but they are all at least examined on
every scan. Computers, on the other hand operate on an interrupt system where by
changing events can alter the order in which the instructions are performed. This
speeds response time in relation to programmable controllers but acts complexity to
programming. The second difference between computers and programmable
controllers is in the manner by which the controller is programmed. Ladder diagram
the same used program electro-mechanical relays, is also used in programmable
controller. Control engineers working with relays are familiar with relay ladder
diagram logic and this makes the programmable controller a shop tool and not a
data process system. The other distinguishing character of programmable
controllers are their rugged construction, equipment is designed to withstand jarring
and freezing and elevated temperature, highly humidity, corrosive atmosphere and
electrical interference. While all PCs are computers, by definition, not all
computers are PCs. the difference is in environmental considerations, programming
methods and maintenance.
I
t
p
E
t
p
ANALOGUE SIGNAL
DIGITAL SIGNAL
BINARY SIGNAL
0 0
1 1
1
t
p
LOGIC CONNECTIONS FOR NOT GATE
TRUTH TABLE
I1 Q1
0
1
1
0
STL LDR CSF
AN I1
= Q1
I1
Q1
I1 Q1
LOGIC CONNECTIONS NOT GATE
ELECTRICAL I1
Q1
ELECTRONIC
R1
R2
R3
+Vcc
I1
Q1
PNEUMATIC
I1
Q1
LOGIC CONNECTIONS FOR OR GATE
TRUTH TABLE
I1 I2 Q1
0
1
0
1
0
0
1
1
0
1
1
1
STL LDR CSF
O I1
O I2
= Q1
I1
I2
Q1
I1
I2
Q1
LOGIC CONNECTIONS OR GATE
ELECTRICAL
I1
I2
Q1
ELECTRONIC
I1
I2
Q1
R1
PNEUMATIC
I1
I2
Q1
LOGIC CONNECTIONS AND GATE
TRUTH TABLE
I1 I2 Q1
0
1
0
1
0
0
1
1
0
0
0
1
STL LDR CSF
A I1
A I2
= Q1
I1 I2 Q1
&
I1
I2
Q1
LOGIC CONNECTIONS AND GATE
ELECTRICAL
I1
I2
Q1
ELECTRONIC
PNEUMATIC
I1
I2
Q1
operand
parameter
Operand ID
Relative address of the statement in a particular block.
The operation tells the programmable controller what to do with the operand. The
parameter indicates the operand address.
CONTROL SYSTEM FLOW CHART (CSF)
CSF represents logic operations with graphics symbols.
LADDER DIAGRAM (LAD)
LAD graphically represents control functions with circuit diagram symbol.
STEP 5 SOFTWARE
The following methods of representations are possible with step5 programming language.
STATEMENT LIST (STL)
STL represents the programme as a sequence of operation mneumonics.A
statement has the following formats
002: A
Operation
I 32.0
STEP5 programming language has the following operand areas.
I (inputs) interfaces from the process to the programmable controller
Q (outputs) interfaces from the programmable controller to the process
F (flags) memory for the intermediate results of binary operations
D (data) memory for intermediate results of digital operations
T (timers) memory for implementing timers
C (counters) memory for implementing counters
P (peripherals) interfaces from the process to the programmable controller
K (constants) defined numeric values
OB, PB, SB,
FB, DB (blocks) program structuring aids
PROGRAM STRUCTURE
The programs of the PLC can either be linear or structured.
LINEAR PROGRAMMING
Programming individual operations in one section (block) is sufficient for handling
simple automation jobs. This is organization block1 (OB1). The PLC scans this
block cyclically (i.e., after it scans last statements it goes back to the first
statement and begins scanning again.
SSTRUCTURED PROGRAMMING
To solve complex tasks, it is advisable to divide a program into individual, self
contained program parts (blocks).
The procedure has the following advantages.
Simple and clear programming even for large program
Easy alteration
Simple programtest
Simple startup
Subroutine techniques (block call from different locations)
Lower scan time extensions through STATUS PLC function
The STEP5 programming language has the
following five block types.
Organization blocks(OBs)
Organization blocks manage the control
program
Program blocks (PBs)
Program blocks arrange the control program
according to functional or technical aspects.
Sequence blocks (SBs)
Sequence blocks are special blocks that
program sequence controls. They are
handled like program blocks.
Function blocks (FBs)
Function blocks are special blocks for programming frequently
recurring or especially complex program parts (e.g., reporting
and arithmetic functions). The parameters can be assigned.
They have an extended set of operation (e.g., Jump operation
within a block)
Data blocks (DBs)
Data blocks store data needed to process a control program.
Actual values, limiting values and texts are examples of data.
Blocks can be nested upto 16 levels in this particular
controller.
STRUCTURE OF PLC PROGRAM
OB1
PB
OB Organisation Block
PB Program Block
FB Function Block
DB Data Block
OB1 PB FB DB
PB
FB
PB
DB
Problem description : A roller conveyor is monitored by a proximity switch R1 as to whether a
package is present. If this is the case, the package is picked up by a cylinder 1.0(lifting cylinder)
and then transferred to another conveyor by means of cylinder2 (transfer cylinder).Cylinder 1.0
is to retract first, followed by cylinder2.0. the cylinders are retracted and advanced by means of
solenoids valves cylinder position are monitored by means of proximity switches. On the feed
side packages have been previously arranged in such a way that they reach the lifting device
individually.
PNEUMATIC CIRCUIT SEQUENCE--: A
+
B
+
A
-
B
-
e.g. 2
PLC PROGRAMMING FOR A+B+A-B-
PROBLEM DESCRIPTION :
A workpiece is to be clamped by activating the start button S1. When the
workpiece is clamped by cylinder 1.0, cylinder 2.0 extends and embosses
the workpiece, cylinder 2.0 returns and cylinder 1.0 returns and declamp
the work piece
PNEUMATIC CIRCUIT SEQUENCE--: A
+
B
+
B
-
A
-
PLC PROGRAMMING FOR A
+
B
+
B
-
A
-
IN PLC THERE ARE ALSO BUILT IN
TIMERS AND COUNTER MECHANISMS
WHICH CAN BE CALLED IN THE
PROGRAMS AND USED DIRECTLY.
ANALOG CONTROLS CAN ALSO BE
DONE EASILY.
PLC CAN ALSO BE USED IN
COMBINATION WITH FUZZY LOGIC
CONTROLS TO HAVE PRECISION
CONTROLS IN THE INDUSTRIES
THANKYOU

Programmable Logic Controller

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Programmable Logic Controller

Încărcat de

Drepturi de autor:

Formate disponibile

PROGRAMMABLE

S-ar putea să vă placă și