PLC Programming for Industrial Applications

Sayyan.N Shaikh 4SN11MAR10 IAR,M-Tec

Introduction
A programmable logic controller (PLC) is a special purpose computer,aimed at implementing control solutions in automation environment. The first PLC was developed by a group of engineers at General Motors in 1968, when the company were looking for an alternative to replace complex relay control systems. It can be used for different applications and, via the program installed in its memory, provides the user with a simple means of changing, extending and optimising control processes. Historically PLCs have been used mainly for onoff or logic type applications but modern PLCs can now cover quite complex control tasks.

HISTORY OF PROCESS CONTROL & AUTOMATION

Technology

Time

 MANUAL CONTROL:
In this all actions related to process control & automation are taken care by the human operators. One of the major drawback of this method is the likely human errors & consequently its effect on quality of the final product. The manual control has its own limitations with regard to mass production techniques & hence this method cannot provide the consumer with quality goods at an affordable price. The safety or efficient use of raw material & energy are all subject to the correctness & accuracy of human action.

 HARD WIRED LOGIC CONTROL:

This was considered to be first step towards automation. Here the contactor & relays together with timers & counters were used in achieving the desired level of automation. Although this method served the purpose for many years, it had certain limitations as listed below :
- Bulky & Complex Wiring. - Involves lot of rework to implement changes in control logic . - The work can be started only when the task is fully defined & this leads to longer project time.

 ELECTRONICS CONTROL:
With the development of electronics, the logic gates started replacing the relays & auxiliary contactors in the control circuits. The bimetalic & motorized timers were replaced by electronic timers..etc. With incorporation of these changes, we got the benefits of :
-Reduced space requirements -Energy saving -Less maintenance & hence greater reliability.etc.

However even with electronics, the implementation of changes in the control logic as well as reducing the project lead time was not possible.

 PROGRAMMABLE LOGIC CONTROLLER:

With the coming of microprocessor & associated peripheral chips, the whole process of control & automation underwent a radical change. Instead of achieving the desired control or automation through physical wiring of control devices, in PLC it is achieved through a program or say software. As the desired Logic control is achieved through a program, these controllers are referred to as Programmable Logic Controllers.

Simple industrial PLC

network binary inputs

analog inputs / outputs binary outputs

PLC in a cabinet
CPU1 CPU2

serial connections redundant field bus connection

inputs/outputs

Kinds of PLC
(1) Compact -Monolithic construction -Monoprocessor -Fieldbus connection
-Fixed casing -Fixed number of I/O (most of them binary) -No process computer capabilities (no MMC) -Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7

(2) Modular PLC -Modular construction (backplane) -One- or multiprocessor system -Fieldbus and LAN connection
-3U or 6U rack, sometimes DIN-rail -Large variety of input/output boards -Connection to serial bus -Small MMC function possible

-Typical products: SIMATIC S5-115, Hitachi H-Serie, ABB AC110

(3) Soft-PLC -Windows NT or CE-based automation products -Direct use of CPU or co-processors

PLC Programming languages

Statement list(IL)- It consist assembler type commands. Structured text(ST)- as in higher-level, problemoriented languages using data types & directives. Sequential function chart(SFC)- It represented by using the flow chart. Function block diagrams(FBD)- It is based on function charts with graphic symbols and logic gates. Ladder diagram(LD)-It is the mostly preferred language by users for PLC programming.

PROGRAMMING EXAMPLE
Bar code re ader microswitch Part Stopper Conveyor

Robot

Machine

Id MSI R1 C1 R2 R3 C2 R4 C3 C4

Description microswitch output to bar code reader input from bar code reader output robot output robot input from robot output to stopper input from machine input from machine

state 1 1 1 1 1 1 1 1 1

explanation part arrive scan the part right part loading cycle unloading cycle robot busy stopper up machine busy task complete

SOLUTION
Input MS1 C1 C2 C3 C4 01 02 03 04 05 Pro grammable Controlle r PLC Outpu t 11 12 13 14 15 R1 R2 R3 R4

01

14

11

02

14

14

04

03

12

05

03

13

Rung 1. If part arrives and no part is stopped, trigger the bar code reader. Rung 2. If it is a right part, activate the stopper. Rung 3. If the stopper is up, the machine is not busy and the robot is not busy, load the part onto the machine. Rung 4. If the task is completed and the robot is not busy, unload the machine.

Advantages Of PLC
REDUCED SPACE:PLC are fully solid state & hence
extremely compact as compared to hard wired controller where in electro mechanical devices are used. 1/10th of power consumed by an equivalent relay logic control. # Modular replacement. # Easy Trouble Shooting. # Error diagnostics with programming unit.

ENERGY SAVING: Average power consumption is just

EASE OF MAINTENANCE:

GREATER LIFE & RELIABILITY:

# It is a Static devices hence lesser number of moving parts, reduces wear & tear.

 ECONOMICAL:
# Considering one time investment ; PLC is most economical system. # Cost of PLC recovers within a short period.

TREMENDOUS FLEXIBILITY:
# To implement changes in control logic no rewiring is required so considerable time is saved. # PLC can carry out complex function such as generation of time delays, counting, comparing , arithmetic operations etc. # On line (I.e. without disturbing the process ) as well as Off line programming is possible. # Suitability for closed loop tasks with several loops & high sampling frequencies. # High processing speed & great flexibility in the processing of both analog & digital signals.

Applications Of PLC
1. Petrochemical industry-- crude separation etc.. 2. Steel industry-- smelter operations, blast furnace, temperature monitoring etc. 3. Power generation-- boiler control from water injection, temperature, fuel, steam flow monitoring etc. 4. Process industries-- air flow control, controlling airfuel ratios etc. 5. Chemical industries-- proportion of chemicals. 6. Nuclear power generation plants. 7. Home automation. 8. PLCs in all phases of automated industrializations.

Conclusion
Hence we see that PLC are widely used in industries. PLCs have been gaining popularity on the factory floor and will remain predominant for

some time to come.

Using PLC better control and management can

achieved.
Better Future for advanced automation.

QUESTIONS???

THANK YOU