Programmable Logic Controller (PLC)

The Need for PLCs

• Hardwired panels were very time consumingto wire, debug and change.

• GM identified the following requirements for computer controllers to replace hardwiredpanels.

– Solid-state not mechanical.

– Easy to modify input and output devices.

– Easily programmed and maintained by plantelectricians.

– Be able to function in an industrial environment.

The First Programmable LogicControllers (PLCs)

• Introduced in the late 1960’s.

• Developed to offer the same functionality asthe existing relay logic systems.

• Programmable, reusable and reliable.

– Could withstand a harsh industrial environment

– They had no hard drive, they had battery backup

– Could start in seconds

– Used Ladder Logic for programming

Programmable Logic Controller

• A programmable logic controller (PLC) is a specialized computer used tocontrol machines and process.

• It uses a programmable memory tostore instructions and specific functions that include On/Off
control, timing, counting, sequencing, arithmetic, and data handling.

Advantages of PLC Control Systems

Eliminates much of the hard wiring that was associated with conventional relay control circuits.

Increased Reliability: Once a program has been written and tested it can be downloaded toother PLCs.
More Flexibility: Original equipment manufacturers (OEMs) can provide system updatesfor a process by
simply sending out a new program.

Lower Costs: Originally PLCs were designed to replace relay control logic. The costsavings using PLCs
have been so significant that relay control isbecoming obsolete, except for power applications.

Communications Capability: A PLC can communicate with other controllers or computer equipment.

Faster Response Time: PLCs operate in real-time which means that an event taking place in thefield will
result in an operation or output taking place.

Easier to Troubleshoot: PLCs have resident diagnostic and override functions allowing users to easily
trace and correct software and hardware
problems.

PLC Architecture

PLC System
The components that make a PLC work can be divided into three core areas.

The power supply and rack

The central processing unit (CPU)

The input/output (I/O) section

PLCs come in many shapes and sizes. They can be so small as to fit in your shirt pocket while more
involved controls systems require large PLC racks. Smaller PLCs are typically designed with fixed I/O
points. For our consideration, we’ll look at the more modular rack-based systems. It’s called “modular”
because the rack can accept many different types of I/O modules that simply slide into the rack and plug
in.

The Power Supply and Rack

The rack is the component that holds everything together. Depending on the needs of the control
system it can be ordered in different sizes to hold more modules. Like a human spine the rack has a
backplane at the rear which allows the cards to communicate with the CPU. The power supply plugs
into the rack as well and supplies a regulated DC power to other modules that plug into the rack. The
most popular power supplies work with 120 VAC or 24 VDC sources.

The CPU
The brain of the whole PLC is the CPU module. This module typically lives in the slot beside the power
supply. Manufacturers offer different types of CPUs based on the complexity needed for the system.

The CPU consists of a microprocessor, memory chip and other integrated circuits to control logic,
monitoring and communications. The CPU has different operating modes. In programming mode, it
accepts the downloaded logic from a PC. The CPU is then placed in run mode so that it can execute the
program and operate the process

Since a PLC is a dedicated controller it will only process this one program over and over again. One cycle
through the program is called a scan time and involves reading the inputs from the other modules,
executing the logic based on these inputs and then updated the outputs accordingly. The scan time
happens very quickly (in the range of 1/1000th of a second). The memory in the CPU stores the
program while also holding the status of the I/O and providing a means to store values.

I/O System
The I/O system provides the physical connection between the equipment and the PLC. Opening the
doors on an I/O card reveals a terminal strip where the devices connect.There are many different kinds
of I/O cards which serve to condition the type of input or output so the CPU can use it for its logic. It's
simply a matter of determining what inputs and outputs are needed, filling the rack with the appropriate
cards and then addressing them correctly in the CPUs program.
Inputs
Input devices can consist of digital or analog devices. A digital input card handles discrete devices which
give a signal that is either on or off such as a pushbutton, limit switch, sensors or selector switches. An
analog input card converts a voltage or current (e.g. a signal that can be anywhere from 0 to 20mA) into
a digitally equivalent number that can be understood by the CPU. Examples of analog devices are
pressure transducers, flow meters and thermocouples for temperature readings

Outputs
Output devices can also consist of digital or analog types. A digital output card either turns a device on
or off such as lights, LEDs, small motors, and relays. An analog output card will convert a digital number
sent by the CPU to itsreal-world voltage or current. Typical outputs signals can range from 0-10 VDC or
4-20mA and are used to drive mass flow controllers, pressure regulators and position controls

Functionality
The functionality of the PLC has evolved over the years to include sequential relay control, motion
control, process control, distributed control systems, and networking. The data handling, storage,
processing power, and communication capabilities of some modern PLCs are approximately equivalent
to desktop computers. PLC-like programming combined with remote I/O hardware, allow a general-
purpose desktop computer to overlap some PLCs in certain applications. Desktop computer controllers
have not been generally accepted in heavy industry because the desktop computers run on less stable
operating systems than PLCs, and because the desktop computer hardware is typically not designed to
the same levels of tolerance to temperature, humidity, vibration, and longevity as the processors used in
PLCs.

Basic functions
The most basic function of a programmable controller is to emulate the functions of electro-mechanical
relays. Discrete inputs are given a unique address, and a PLC instruction can test if the input state is on
or off. Just as a series of relay contacts perform a logical AND function, not allowing current to pass
unless all the contacts are closed, so a series of "examine if on" instructions will energize its output
storage bit if all the input bits are on. Similarly, a parallel set of instructions will perform a logical OR. In
an electro-mechanical relay wiring diagram, a group of contacts controlling one coil is called a "rung" of
a "ladder diagram ", and this concept is also used to describe PLC logic. Some models of PLC limit the
number of series and parallel instructions in one "rung" of logic.

Timers
The main function of a timer is to keep an output on for a specific length of time.
A good example of this is a garage light, where you want power to be cut off after 2 minutes so
as to give someone time to go into the house.
 The three different types of timers that are commonly used are a Delay-OFF, a Delay-ON, and a
Delay-ON-Retentive.
A Delay-OFF timer activates immediately when turned on, counts down from a programmed
time before cutting off, and is cleared when the enabling input is off.
A Delay-ON timer is activated by input and starts accumulating time, counts up to a
programmed time before cutting off, and is cleared when the enabling input is turned off.
A Delay-ON-Retentive timer is activated by input and starts accumulating time, retains the
accumulated value even if the (ladder-logic) rung goes false, and can be reset only by a RESET
contact.

Counters
Counters are primarily used for counting items such as cans going into a box on an assembly line. This is
important because once something is filled to its max the item needs to be moved on so something else
can be filled. Many companies use counters in PLC's to count boxes, count how many feet of something
is covered, or to count how many pallets are on a truck.

There are three types of counters, Up counters, Down counters, and Up/Down counters.

Up counters count up to the preset value, turn on the CTU (Count Up output) when the preset
value is reached, and are cleared upon receiving a reset.
Down counters count down from a preset value, turns on the CTD (Count Down output) when 0
is reached, and are cleared upon reset.
Up/Down counters count up on CU, count down on CD, turn on CTUD (Count Up/Down output)
when the preset value is reached, and cleared on reset.

Programmable logic relay (PLR)

PLRs are much like PLCs, and are used in light industry where only a few points of I/O are needed, and
low cost is desired. These small devices are typically made in a common physical size and shape by
several manufacturers, and branded by the makers of larger PLCs to fill out their low-end product range.

Most such devices include a tiny postage-stamp-sized LCD screen for viewing simplified ladder logic
(only a very small portion of the program being visible at a given time) and status of I/O points, and
typically these screens are accompanied by a 4-way rocker push-button plus four more separate push-
buttons, similar to the key buttons on a VCR remote control, and used to navigate and edit the logic.

Unlike regular PLCs that are usually modular and greatly expandable, the PLRs are usually not modular
or expandable, but their price can be two orders of magnitude less than a PLC, and they still offer robust
design and deterministic execution of the logics.
Submitted by: - Aditya Shipte (19MCD0002)
Aditya Bhandakkar (19MCD0014)
Avinash Mandora (19MCD0032)