Programmable Logic Controllers

PLC
Programmable

Logic Controllers are used

for : Programming Logical Programming To control a process

INTRODUCTION

In Industry, many manufacturing processes demand a sequence of operations, which are to be performed repetitively. Early automation systems were mechanical in design, timing and sequencing being effected by gears and cams. Slowly these design concepts were replaced by electrical drives, which were controlled by relays.

INTRODUCTION
Advantages of Relays Relays were immune to electrical interference. Relays were able to handle typical industrial input and output signals without special interfacing. Limitations of Relays The electromagnet relays have provided control mechanism over a long period of time. But the relay does have a number of limitations:

Introduction

It suffers from contact wear and reliability problems. Being single input, multi-output, it is often completely unsuited for controlling sequencing in industrial processes. The relays are hardwired. Hardwired systems are very expensive to produce due to the high labour content Modification is difficult and time consuming.

INTRODUCTION

To control ever-increasing configurations of systems, engineers turned to computers. The computer however was not suited to the industrial environment and the use of the computer on the factory floor, was not possible, unless costly interference filtering was used. The other major problem with computers was the need to program using a high level language.

INTRODUCTION

Engineers who understood a process and its control using RELAY LADDER LOGIC could not readily convey this to a computer programmer. So a system similar to electromechanical relays using logical programming to control the process called PLC found favourable.

Definition

A PROGRAMMABLE LOGIC CONTROLLER is a solid-state device, designed to operate in noisy industrial environments and perform all the logic functions previously achieved using Electromechanical relays, drum switches, mechanical timers and counters.

ADVANTAGES OF PLC

The program can be entered on the factory floor by anyone. The outputs may be a mixture of conventional relays and solid-state relays. Designed for an electrically noisy environment no extra filtering is required. They are smaller, faster and more reliable than hardwired systems.

ADVANTAGES OF PLC

Drum switches, timers, counters implemented using software programs.

are

all

BASIC PLC OPERATION

PLC forms the nucleus of control system. It interfaces input devices to capture the data and actuates control through interfaced output devices. The input devices are sensors that monitor the machine or the process being controlled. Depending upon the input status of these sensors the outputs of the PLC may be switched on to energize motors, relays, valves etc. to control the machine or process.

Input Devices

Programmable Logic Controller

Output Devices

Machine or Process Being Controlled

PLC ARCHITECTURE
It

contains: A processor Memory chips Inputs and Outputs Programming devices

Outputs To Plant (Indicator Lamps, Motor Starters, Solenoids, Valves etc)

Output Interface

Programmer Keypad & Display

Processor

PLC

Memory

Input Interface

Inputs from Plant ( Push Buttons, Limit Switches, Sensors, Toggle Switches) Fig(2)

Processor Unit

The processor unit contains a microprocessor chip (for e.g. Zilog Z80). The processor can initiate the operation of counters, sequences, timers and the control relays although no actual physical device exist. These operations are performed using software routines (programmes) within the processor unit. The processor can make all the decisions necessary to control a process.

Processor/Memory Chips

The processor monitors the state of the inputs (ON/OFF), scans and solves the logic of the user program and controls the state of the output devices (ON/OFF). Memory chips are used to store and retrieve information from the memory

PLC INPUTS

The input interface is the circuitry, which connects the PLC input terminals to the processor. The interface has to convert input signals AC or DC from these input devices to low level DC voltages (signals) that is used in the processor. The interface may also have to provide electrical isolation to prevent noise and voltage spikes (transients) on the input lines from distorting the input signals

PLC INPUTS

This isolation is provided by using OPTOCOUPLERS or OPTO-ISOLATORS. Typical input signals to the PLC are provided from: 1) Photocells or Sensors: These are used for example to detect the presence of a component. 2) Push Buttons: These are used to start or stop a process. 3) Toggle Switches: These are used to give a constant high output.

PLC OUTPUTS

The output interface is the electronic circuitry, which connects the processor to the PLC output terminals. These output terminals are connected to the plant to control the different outputs like Indicator lamps, Motor starters, Solenoid coils, Hooters etc.

PROGRAMMING DEVICE

The PLC is programmed with a programming device. The programmer device is remote from the PLC and may be connected to enter a user program and disconnected afterwards. The user program may then be run without the programming device. Therefore, one device may serve several PLCs.

PROGRAMMING DEVICE
There

are 2 types of programming devices:

DESKTOP

They are portable, designed to be moved from site to site, and be operated in areas with high levels of electrical noise, high humidity and temperature. These are basically an industrial IBM computer.

PROGRAMMING DEVICE

Handheld Programmer These are smaller and lighter but have limited display facilities. They are useful in situations where the installation requires constant changes in the circuit. The display is either LEDs, which only allows one line or element of the ladder to be observed at time, or an LCD display which allows overall rungs to be observed and some also have a scroll facility.

DIFFERENCE BETWEEN PLC & MICROPROCESSOR BASED SYSTEM

Logically microprocessor based system and PLC include similar blocks. But physically they are quite different as they are used in different applications and environment. PLCs are designed to work in hostile-noisy environment and is provided with extra protection. In case of microprocessor based systems they are more of general-purpose applications and designed to work in clean environment.

DIFFERENCE BETWEEN PLC & MICROPROCESSOR BASED SYSTEM

PLC uses simple programming language called ladder diagrams, which is easy to understand where as microprocessor uses a language called assembly language which is difficult as compared to Ladder language. A person having no knowledge about microprocessor and its assembly language can easily work on PLC.

APPLICATIONS
1. 2. 3. 4. 5. 6.

7.

CNC machines Conveyors Heat treatment Welding Painting Assembly machines Packaging

PLC MANUFACTURERS

There are many PLC manufacturers. Some of which a ALLEN BRADLEY, SIEMENS, SATICON, SQUARE D, MERLIN GERIN, MEM, MODICON, GEC GEM, AEG, MITSUBISHI, TEXAS. All of these manufacturers are leader in the field. Each offers a full line of programmable controllers plus other associated equipment PLCs offered by Allen Bradley are widely accepted in Indian industry.