 Introduction

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 Programmable logic controller
 A programmable logic controller (PLC) is
 a special form of microprocessor - based
controller
 uses a programmable memory to store
instructions
 to implement functions such as logic,
sequencing, timing, counting and arithmetic in
order to control machines and processes

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 Programmable Logic Controllers
 Programmable Logic Controllers, programmable
controllers, or PLCs are specialized industrial
computers.
 The PLC,
 accepts inputs from switches and sensors (measures
or senses the system),
 evaluates these based on a program (logic), and
 changes the state of outputs to control a machine or
process.

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 Programmable logic controller
 The term logic is used because programming is primarily
concerned with implementing logic and switching
operations,
 e.g. if A or B occurs switch on C, if A and B occurs switch
on D.
 Input devices,
 e.g. sensors such as switches, and
 output devices in the system being controlled,
 e.g. motors, valves, etc.,
 are connected to the PLC.

 The operator then enters a sequence of instructions, i.e.

a program, into the memory of the PLC.
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PLC with Input and Output

5
 Programmable logic controller
 The controller then,
 monitors the inputs and outputs according to
this program and carries out the control rules
for which it has been programmed.

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Programmable logic controller

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 Programmable logic controller
 PLCs are similar to computers
 but whereas computers are optimised for
calculation and display tasks,

 PLCs are optimised for control tasks

and the industrial environment.

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 Programmable logic controller
 Thus PLCs are:
 rugged and designed to withstand vibrations,
temperature, humidity and noise.
 have interfacing for inputs and outputs already
inside the controller
 are easily programmed
 have an easily understood programming language
which is primarily concerned with logic and
switching operations.

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 PLC: manufacturers
Switzerland
SAIA, Weidmüller
Europe:
Siemens (60% market share) [Simatic],
ABB (includes Hartmann&Braun, Elsag-Bailey, SattControl,…)
[IndustrialIT],
Groupe Schneider [Télémécanique],
WAGO,
Phoenix Contact ...
World Market:
GE-Fanuc,
Honeywell,
Invensys (Foxboro)
Rockwell, (Allen-Bradley,…)
Emerson (Fisher Control, Rosemount, Westinghouse)
Hitachi, Toshiba, Fujitsu, Yokogawa
…

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(1) Compact
Monolithic construction
Kinds of PLC
Monoprocessor
Fieldbus connection
Fixed casing
Fixed number of I/O (most of them binary)
No process computer capabilities
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
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

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Small modular PLC

courtesy ABB
courtesy Backmann

mounted on DIN-rail, 24V supply

cheaper (€5000)
not water-proof,
no ventilator
extensible by a parallel bus (flat cable or rail)

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 Specific controller (railways)

data bus

three PLCs networked by a data bus.

special construction: no fans, large temperature range, vibrations
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Compact or modular ?
field bus
€ extension

compact PLC
(fixed number of I/Os)

modular PLC (variable number of I/Os

Limit of local
I/O

# I/O modules

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 Soft-PLC (PC as PLC)
• PC as engineering workstation
• PC as human interface (Visual Basic, Intellution, Wonderware)
23 12 • PC as real-time processor (Soft-PLC)
4 2 2 • PC assisted by a Co-Processor (ISA- or PC104 board)
3
3 • PC as field bus gateway to a distributed I/O system

I/O modules

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Market share
% installed PLCs

Micro: 15 to 128 I/O points 32%

Medium: 128 - 512 I/O points 29%
Large: > 512 I/O points 20%
Nano: < 15 I/O points 7%
PC-based 6%
Software PLC 4%
Embedded control 2%

Source: Control Engineering, Reed Research, 2002-09

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 Global players

Total sales in 2004: 7’000 Mio € Source: ARC Research, 2005-10

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 Comparison Criteria – Example
Brand Siemens Hitachi
Number of Points 1024 640
Memory 10 KB 16 KB
Programming Language • Ladder logic • Ladder Logic
• Instructions • Instructions
• Logic symbols • Logic symbols
• Basic
• Hand-terminal
• Hand-terminal
Programming Tools • Graphic on PC • Graphic on PC
Download no yes
Real estate per 250 I/O 2678 cm2 1000 cm2

Label surface 5.3 mm2 6 mm2

per line/point 7 characters 6 characters

Network 10 Mbit/s 19.2 kbit/s

Mounting DIN rail cabinet

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 General PLC architecture
RS 232 Ethernet

Real-Time flash serial port ethernet

CPU ROM
Clock EPROM controller controller
extension
bus
parallel bus buffers

fieldbus analog- digital- external

Digital
controller digital analog Digital Output I/Os
Input
converters converters

signal power signal

relays
conditioning amplifiers conditioning

field bus direct Inputs and Outputs

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 The signal chain within a PLC
y y(i) y(i)

time time time

analog filtering analog- 011011001111

digital- analog
variable & sampling digital analog amplifier variable
(e.g. 4..20mA) scaling converter converter e.g. -10V..10V

processing
1
binary transistor
binary
variable filtering sampling or
(e.g. 0..24V) relay variable
0001111

non-volatile
counter memory
y

time
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Hardware

 Processor unit or central processing unit (CPU) is

the unit containing the microprocessor,
 Power supply unit is needed to convert the mains
a.c. voltage to the low d.c. voltage (5 V)
 Programming device is used to enter the required
program into the memory of the processor

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Hardware

 Memory unit is where the program is stored

that is to be used for the control actions

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NVRAM – Non Volatile RAM

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Hardware

 Input and output sections are where the

processor receives information from external
devices and sends information to external
devices
 The inputs
 switches, other sensors such as photo-electric
cells, temperature sensors, or flow sensors, etc.
 The outputs
 motor starter coils, solenoid valves, etc.
 Input and output

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Hardware

 Input and output devices can be classified

based on signals
 Discrete/digital
 analogue

 Devices giving discrete or digital signals are

ones where the signals are either off or on.
 switch is an example for this.

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Hardware

 Digital devices can be considered to be essentially

discrete devices which give a sequence of on−off
signals.
 Rotary encoder is an example

 Analogue devices give signals whose size is

proportional to the size of the variable being
monitored.
 For example, a temperature sensor may give a voltage
proportional to the temperature.

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Hardware

 Communications interface is used to receive and

transmit data on communication networks from or to
other remote PLCs .

 Used for,
 device verification,

 data acquisition,

 synchronization between user applications and

 connection management

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Hardware

Basic communications model

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Hardware

 CPU, Buses and Memory will be same as

any of the other microprocessor based
systems

 The difference is found in the Input and

output units

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Hardware

 The input/output unit provides the interface between

the system and the outside world
 connections to be made through input/output channels to
input devices such as sensors and output devices such as
motors and solenoids.
 programs are entered from a program panel
 Every input and output has a unique address

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 Hardware

 Provide isolation and signal conditioning

functions so the sensors and actuators can be
directly connected to them without the need for
other circuitry.
 Electrical isolation from the external world is
usually by means of optoisolators
(optocouplers)

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Hardware

Optoisolator

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 Hardware
 The digital signal that is generally compatible with the
microprocessor in the PLC is 5 V d.c.
 Signal Conditioning:
 However, signal conditioning in the input channel, with
isolation, enables a wide range of input signals to be
supplied to it
 A range of inputs might be available with a larger PLC,
 e.g. 5 V, 24 V, 110 V and 240 V digital/discrete, i.e.
on−off, signals.
 A small PLC is likely to have just one form of input,
 e.g. 24 V.

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Hardware

Input levels
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 Output
 The output from the input/output unit will be
digital with a level of 5 V.
 After signal conditioning with relays, transistors
or triacs, the output from the output channel
might be
 24 V, 100 mA switching signal,
 d.c. voltage of 110 V, 1 A or
 240 V, 1 A a.c., or
 240 V, 2 A a.c., from a triac output channel (Figure
1.10).
 With a small PLC, all the outputs might be of one
type,
 e.g. 240 V a.c., 1 A.
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Output

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 PLC Systems

 There are two common types of

mechanical design for PLC systems;
 A single box, and
 the modular/rack types.

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 Single Box

 The single box type (or, as sometimes termed,

brick) is commonly used for
 small programmable controllers and
 is supplied as an integral compact package complete
with power supply, processor, memory, and
input/output units.

 Typically such a PLC might have

 6, 8, 12 or 24 inputs and
 4, 8 or 16 outputs and
 a memory which can store some 300 to 1000
instructions.
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 Modular/rack types

 Systems with larger numbers of inputs and

outputs are likely to be modular and designed
to fit in racks.

 The modular type consists of separate

modules for power supply, processor, etc.,
which are often mounted on rails within a
metal cabinet.

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 Modular/rack types

 The rack type can be used for all sizes of

programmable controllers and has the various
functional units packaged in individual
modules which can be plugged into sockets in
a base rack.


 The mix of modules required for a particular

purpose is decided by the user and the
appropriate ones then plugged into the rack.

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 Programming PLC

 Programming PLCs
 Programming devices can be
 a hand-held device,
 a desktop console or
 a computer.

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 Siemens - SIMATIC STEP 7

 Fully complies with the international standard

IEC 61131-3 for PLC programming languages.
 With STEP 7, programmers can select between
different programming languages.
 ladder diagram (LAD) and
 function block diagram (FBD),
 Instruction List (STL) programming language
 a Sequential Function Chart (SFC) called
 SIMATIC S7-Graph which provides an efficient way to
describe sequential control systems graphically.
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 Siemens - SIMATIC STEP 7
 Features of the whole engineering system
include,
 system diagnostic capabilities,
 process diagnostic tools,
 PLC simulation,
 remote maintenance, and
 plant documentation.
 S7-PLCSIM is an optional package for STEP 7
that allows,
 simulation of a SIMATIC S7 control platform and
testing of a user program on a PC, enabling testing
and refining prior to physical hardware installation.
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