IC0405 - Industrial Automation

PLC TRAINING
Titleofpresentation
PLC
BASIC
CONCEPTS
1
Basics Concepts of PLC
PLC&PCInComparison
Computer PLC
CPU/Memory CPU/ RAM/ Hard disk CPU/ RAM/ Flash Card
Power Supply 220V AC, 1 Ph. 220V AC / 24V DC
Key board, Mouse, Push Button, Selector, Limit

Inputs
Remote station (LAN) Switch, PxS, Bus Interface
Outputs Monitor, Printer, Solenoids, Relays, Lamps,

Projector Etc., Motors, HMI
OS: Windows XP / OS: Firmware / SW:

Software SW: MS Office Machine Logic
Internal Calculator etc., Markers, Timers,

Counters, FBs
2
MachineAutomationOverView
Command Signals Status Signals
Push Buttons, Limit Switch, Proximity, Machine
Controller Selector Switches Reed Switch etc.,
Inputs
BasicsConceptsofPLC
Outputs
Relays, Solenoids, Power contactors
Actuators: Motors, Cylinders, Heaters, Lamps etc.,

HMI
3
Inputs SamplePictures
Push Button Selector Switch
4
Outputs SwitchGearProductsOverView
Power Contactor Aux. Contactor Relay Boards
Over Load Relay Relays
5
Outputs Actuators
Cylinders Solenoid Coils Servo Motor
Manifold Block
6
HistoryofPLC
BeforethePLC,control,sequencing,andsafetyinterlocklogic
formanufacturingautomobileswasaccomplishedusing
hundredsorthousandsofrelays,camtimers,anddrum
sequencersanddedicatedclosedloopcontrollers.Theprocess
forupdatingsuchfacilitiesfortheyearlymodelchangeover
wasverytimeconsumingandexpensive,aselectriciansneeded
toindividuallyrewireeachandeveryrelay.
9
WhatisaPLC?
The PLC is an industrial computer.

It is capable of storing instructions to implement control functions such as
sequencing, timing, counting, arithmetic, data manipulation and communication.
The I/O interfaces provide the connection between the PLC and the
information providers (inputs like pushbuttons, sensors,) and the controllable
devices (outputs like valves, relays, lamps,).
10
WhereisthePLCused?
The PLC controls industrial machines and processes. In different areas of the
industry PLC are being applied, e.g.: materials handling, packaging, palletizing,
milling, boring, grinding, filling,
sorting, weighing,...etc.
11
HowdoesPLCwork?
In the past the movements of industrial machines were controlled by relay

circuits. These relay-controlled systems were replaced by PLC.
The primary function of the PLC was to perform the sequential operations that
were previously implemented with relays.
Before we can talk about the working method of an PLC, we must

understand the function of relay circuits.
12
WhatisaRelay?
A relay is an electrical switch.

It contains:
a coil a switch
and a iron bar
a iron core connected to
the switch
13
HowdoesaRelaywork?
When a current goes through the coil...
14
HowdoesaRelaywork?
a magnetic field is produced in the coil and the iron core in the coil
becomes magnetic.
I
15
HowdoesaRelaywork?
The electromagnetic force pulls in the switch and...
16
HowdoesaRelaywork?
a current can go through the switch.
I I
17
HowdoesthePLCreplaceRelayinanelectriccircuit?
The answer to this question shall be shown with the following example
circuits, A, B, C, and D.
A).
24V technical symbol
internal
of a relay
switch
S1
electro magn.
connection
coil
K1 L1
0V
18
The answer of this question shall be shown with a little example circuit.
B).
24V Function of the electrical circuit:
When the user presses button S1, the relay

S1
K1 pulls in its internal switch and the lamp
L1 turns on.
K1 L1
0V
19
C).
24V 24V
S1
S1
Input Power
PLC
Power Output
K1 L1 L1
0V 0V
20
D).
24V 24V
S1 PLC logic
S1
K1 L1 L1
0V 0V
21
WhatisPLClogic?
The PLC logic is not a mechanical part of the controller.

The PLC logic is a software program, which runs on the
processor in the PLC. This program has to be created with a
special programming tool on a PC. After downloading the
24V
the program into the PLC, the control
automatically starts the program.
S1 SPS logic
L1
0V
22
RELAY LOGIC
Ph. 220V AC SUPPLY N
START PB STOP PB TMR1 PC
PC
TMR1
LADDER PROGRAM
M1
I1 I2
Q1
Q1
TMR1
M1
En Q
Q1 Trig
T#5s Time
23
HowaPLCworks:internal PLC
network Communication
RAM E-EPROM
module
Programming
tool CPU
power cord Input Output

Power supply
modules modules
Machine
24
RAM E-EPROM
module
Programming
tool CPU

Power supply
modules modules
Central
processing unit Machine
25
RAM E-EPROM
module
Programming
tool CPU

Power supply
modules modules
Working- and
Machine
program memory
26
HowaPLCworks:internal
PLC
RAM E-EPROM
module
Programming
tool CPU

Power supply
modules modules
Program editor
Machine
and monitoring
27
RAM E-EPROM
module
Programming
tool CPU

Power supply
modules modules
Sensor signal
Machine
input
28
RAM E-EPROM
module
Programming
tool CPU

Power supply
modules modules
Actuator
Machine
command output
29
RAM E-EPROM
module
Programming
tool CPU

Power supply
modules modules
Control
Machine
communication
30
HowPLCworks:processingcycle
Start PLC from E-EPROM
Read user program & Copy to RAM
Read input signals, store in table
Determine new output state of output module

processing cycle
Write output commands in table
Set output values on output module
31
Pick&PlaceUnit
Schematic:
swivel
device
shuttle up/down
pick cylinder suction cylinder
pad place
Startingposition:vac.off,slideright,up;swivelnotused(frontposition)
Sequenceofmovements:
1)slideleft5)movedown
2)movedown&switchonvacuum6)switchoffvacuum
3)moveup7)moveup
4)slideright
32
Animation:
Sequenceofmovements:
slide left
move down & vacuum on
move up
slide right
move down
vacuum off
move up
33

IC0405 - Industrial Automation

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PLC TRAINING

CPU/Memory CPU/ RAM/ Hard disk CPU/ RAM/ Flash Card

Power Supply 220V AC, 1 Ph. 220V AC / 24V DC

Key board, Mouse, Push Button, Selector, Limit

Outputs Monitor, Printer, Solenoids, Relays, Lamps,

OS: Windows XP / OS: Firmware / SW:

Internal Calculator etc., Markers, Timers,

Relays, Solenoids, Power contactors

Actuators: Motors, Cylinders, Heaters, Lamps etc.,

Push Button Selector Switch

Power Contactor Aux. Contactor Relay Boards

Over Load Relay Relays

Cylinders Solenoid Coils Servo Motor

The PLC is an industrial computer.

In the past the movements of industrial machines were controlled by relay

Before we can talk about the working method of an PLC, we must

A relay is an electrical switch.

When a current goes through the coil...

The electromagnetic force pulls in the switch and...

a current can go through the switch.

When the user presses button S1, the relay

The PLC logic is not a mechanical part of the controller.

START PB STOP PB TMR1 PC

power cord Input Output

power cord Input Output

power cord Input Output

power cord Input Output

power cord Input Output

power cord Input Output

power cord Input Output

Start PLC from E-EPROM

Read user program & Copy to RAM

Read input signals, store in table

Determine new output state of output module

Write output commands in table

Set output values on output module

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