THE ROLE OF PLC AND MICROCONTROLLER IN

MANUFACTURING INDUSTRY
Vania Alodia Nasution
2514 100 134
alodia.vania@gmail.com
INTRODUCTION
The development of technology in the world has persisted for a long time,
it continues to grow and improved, and now becoming even more advanced.
These advance technologies have resulted in the development of sophisticated
devices in control engineering, such as Programmable Logic Controller (PLC) and
microcontroller. PLC is a microprocessor-based computer unit that can perform
control functions of many types and varying levels of complexity (Kamel et al,
2014). Groover also stated that a PLC is a microcomputer-based controller that
uses stored instruction in programmable memory to implement logic,
sequencing, timing, counting, and arithmetic functions through digital or analog
input/output (I/O). Based on those two definitions, it can be concluded that PLC is
basically a computer that monitors input/output (I/O) and makes the logic for
controlling a series of machines with different level of complexity.
The story behind PLC began in American automotive industries in the late
1960s, which has transformed the industrial manufacturing world. In the earlier
days, the automotive industries had to change the whole control system when it
decided to change the production model. This changing requires a lot of time as
well as highly trained engineers, making the operations less efficient and costly.
But today, every company who wants to automate a variety of industrial
processes has to turn to this technology. PLC is actually not a new technology, its
function has developed into networking, relay control and advanced datahandling capabilities. The very first PLCs were small with certain limitations such
as the ability to send and receive signals is still low, and there were no
standardize protocols which made the communication between each PLC difficult.
But today, the time for sending and receiving signals has been cut down to
milliseconds, and PLCs became programmable with personal computer which
makes the communication easier.
With the development of technology, PLC is now can be classified into
several categories which are ladder logic, traditional programming, state logic,
human-machine interface, and remote terminal units. The first category is ladder
logic, the most common type of PLC. In this type, the relay logic hardware is
automated, making it really useful in industrial system because many functions
can be maintain but still minimizing the human interaction. The second category
is traditional programming logic controller. This type of PLC uses common
computer languages, such as BASIC, for inputting command and maintaining the
system. Different with ladder logic, this type of PLC includes some level of human
interaction. Next, the state logic controllers which considered to be one of flexible
types of PLC. State logic controllers are commonly used for assisting the tasks
that might change quickly, and allow for simulation of decision-making. While in
human-machine interface controllers, different controllers are combine to allow
for automation and human interaction. The combination making this type of PLC
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is even more advanced than fully automated systems. And the last type is
remote terminal units which are designed to provide a static function. These
systems are ideal for monitoring compared to other control systems because it
can provide a consistent stream of data despite harsh environment or dataprocessing conditions.
Today, we can see many products like remote control, microwaves,
automatic washing machines, and other similar products. These automatic
products require automation to facilitate the process in each operation, therefore
a device for storing and processing data is needed, this device is commonly
called microcontroller. A microcontroller is a compact microcomputer designed to
govern the operation of embedded systems in motor vehicles, robots, office
machines, complex medical devices, mobile radio transceivers, vending
machines, home appliances, and various other devices (Rouse, 2012). According
to Deshmukh, microcontroller allows the controlling, the timing and possible to
carry out simple arithmetic and logical operations. It contains a microprocessor,
memory and input/output on a single chip. Based on the statements above, it can
be said that a microprocessor is a microcomputer which integrate the component
such as microprocessor, memory, and I/O for controlling and carrying out simple
arithmetic and logical operations.
A brief history of microprocessors begins in a small company called Intel
(Integrated Electronics) in the early 1970s. The client of Intel bought the chipset
and the company, and decided to market the chipset as a "general purpose"
microprocessing system for the use of digital logic chips. The development of
chipset was a great success, and in a short time, Intel was able to produce a 4 bit
microprocessor called the 4004. With the continuous improvements,
microprocessors are getting even more advanced and can be classified into
categories according to the memory, architecture, bits and instruction sets.
The first classification is memory devices. In this classification,
microcontrollers are divided into two types: embedded memory microcontroller
and external memory microcontroller. Embedded memory microcontroller has all
the functional blocks available on a chip. For example, 8051 having program &
data memory, I/O ports, serial communication, counters and timers and
interrupts on the chip. On the other hand, external memory microcontroller
doesnt have all the functional blocks available on a chip.
The second classification is memory architecture. This classification divides
microcontroller into two types which are Harvard memory architecture and
Princeton memory architecture. The difference between these two types is in the
memory address, whether the microcontroller has a dissimilar or common
memory address. In Harvard memory architecture, the microcontroller unit has a
dissimilar memory address, while for the Princeton, the memory unit has a
common memory address.
The third classification is bits. The bits category is divided into three types:
8-bits, 16-bits, and 32-bits. In 8-bits, the examples of microcontrollers are Intel
8031/8051, PICx and Motorola MC68HC11 families. In 16-bits, the microcontroller
has a better performance with greater precision compared to 8-bits. The
examples of 16-bits microcontroller are extended 8051XA, PIC2x, Intel 8096 and
Motorola MC68HC12 families. While for 32-bits microcontrollers, it usually used in
medical devices, engine control system, office machines, etc. The examples of
32-bits microcontroller are Intel/Atmel 251 family, PIC3x.
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And the last is instruction set. Microcontrollers are divided into two types in
this classification, which are CISC (Complex Instruction Set Computer) and RISC
(Reduced Instruction Set Computer). CISC allows the programmer to use one
instruction out of many instructions. While RISC allows each instruction to
operate on any register or use any addressing mode and simultaneous access of
program and data.
CONTENT
In industrial automation, PLC plays an important role to control a series of
automated machines. PLC has main functions for logic controlling and
sequencing. However, the PLC has evolved to include several capabilities other
than logic controlling and sequencing. Some of these additional capabilities are:
analog control, arithmetic functions, matrix functions, and data processing and
reporting. In analog control, Proportional-integral-derivative (PID) is available on
some programmable controllers. In today analog control, digital computer is used
to approximate the control schemes. The next function is arithmetic which has
addition, subtraction, multiplication, and division. Use of these functions permits
more complex control algorithms to be developed than what is possible with the
main functions. The third function is matrix function which has the capability to
perform matrix operations on stored values in memory. This function can be used
to compare the actual values of a set of inputs and outputs with the values stored
in the PLC memory to determine if some error has occurred. And the last function
is data processing and reporting. These functions are typically associated with
business applications of PCs.
In the real industry, unlike regular digital computers, PLCs are used to
withstand extreme temperature ranges, immunity to electrical noise, and
resistance to vibration and impact. It is also used for automated assembly lines
that range from household appliances to automobile company. Moreover, it has
an important role in activating functions such as motion control, positioning
control and torque, on that assembly lines. By using PLC, the efficiency of a
company will improve because it is the way that the devices will communicate
with other devices, SCADA systems, or human-machine interfaces. The
production process also will be more traceable and controllable to operators,
engineers, IT staff and executives. It is also being used for automatic start up and
shutdown of critical equipment. A PLC ensures that equipment cannot be started
unless all the permissive conditions for safe start have been established. It also
monitors the conditions necessary for safe running of the equipment and trip the
equipment whenever any abnormality in the system is detected.
To give a better picture about the implementation of PLC in industries, take
a look at the figure below. This figure shows the operation of a PLC in controlling
the conveyor belt operation, such as measuring the number of boxes that has
passed the conveyor. In the system, the position of sensor and other sensor
outputs are connected to the input module of the PLC, and from the output
modules a motor is controlled. When the sensors are activated, then the CPU of
the PLC reads the inputs, and correspondingly processes them according to the
program and produces the outputs to operate the motor so that the conveyor is
controlled. Another real implementation of PLC in industry ranges from
manufacturing industry to film industry, and the most common usage can be
found daily are escalator and lift operation to monitor the safety control system.
Vania Alodia Nasution | 3 | Industrial Automation

Figure 1 Example of PLC in Controlling Conveyor Belt (Source:

http://www.elprocus.com/programmable-logic-controllers-and-types-of-plcs/)

While for the microcontroller, the functions are mainly the same with PLC,
what makes them different is their usage and capacity. PLCs are used for a large
scale of system, like In industries. While microcontrollers, are used for devices
such as fire detector. Besides the main functions, microcontroller also has special
functions, it includes: hardware interrupts, analog/mixed-signal (A/MS), external
reset, switch debouncer, and input pull-up. In hardware interrupts, when the
interrupt is triggered, the controller will suspend normal program execution and
run a special subprogram. While analog/mixed signal, it allows the microcontroller
to handle analog and digital signals on the same chip and even mix and match
analog/digital on the same device. In the external reset, the input able to reset
the microcontroller which makes the program restarted. The next function is
switch debouncer, this function cleans up the signal transition so that the
microcontroller sees just a single transition. And the last function is input pull-up.
This function will prevent the floating that is caused by the input which has not
actively generating a signal and will confuse the robots brain.
In the real industry, especially in electronic devices, the microcontroller
has a big role. Most electronic devices, any device that can measure, store,
control, calculate, or display information, have a microcontroller inside them. This
component can be regarded as the brain of a system or circuit. Similar with the
brain of living organisms. The brain has a very important role that serves as the
control center. However, microcontroller requires a circuit component itself to be
functioning properly. Common devices that use microcontroller in our daily lives
are home appliances. The home appliance industry uses 8-, 16-, and 32- bits
microcontroller-based industry circuit for motor control. The microcontroller
controls and manages all the functions and feature of the appliance. When the
user presses the start button, the input goes to the microcontroller from the
panel keyboard and the microcontroller starts the three-phase motor. Motor
speed will be varied and controlled as per user inputs. In home appliance industry
such as Toshiba is now producing low noise and low vibration automatic washing
machine. Microcontrollers are used to control the motor drive and the system
(efficiently control the torque and the amount of water suitable for the amount of
laundry). Below is the system block diagram for automatic washing machine.
Vania Alodia Nasution | 4 | Industrial Automation

Figure 2 Washing Machine System Block Diagram (Source: http://toshiba.semiconstorage.com/ap-en/application/consumer/washing-machine/mcu.html)

In a washing machine, the microcontroller receives analog inputs such as

water level sensor, water hardness sensor, laundry load sensor, detergent
density sensor, etc, through an external ADC. The microcontroller allows the
washing machine to adjust the water and cut power automatically. It also controls
self-diagnostics, including water supply failure, spin failure, drainage failure, child
lock, overflow protection, and door lid open. Clocks and timers are used to
implement sleep mode and add delays (delay start condition) in operations.
CONCLUSION
As the technology continues to develop, sophisticated devices that will
help the company to improve the productivity also continues to grow and
improved. The common devices that usually used by a company are
Programmable Logic Controller (PLC) and microcontroller. Both of these devices
basically have the same function which is to control a particular system. But what
make them different are the usage and its capacity. PLC is commonly used to
control a series of machines in a company and also able to communicate them
with each other, operators, and even the executives. It can be classified into
several categories which are ladder logic, traditional programming, state logic,
human-machine interface, and remote terminal units. The real implementation of
PLC in industry can be seen in controlling the conveyor belt operation, such as
measuring the number of boxes that has passed the conveyor. While for
microcontroller, the scope and the capacity is much smaller. This is one of the
reason electronic devices use microcontroller not PLC to control and integrate the
whole system of a device. Because of the continuous improvement,
microprocessors are now can be classified into categories according to the
memory, architecture, bits and instruction sets. The use of microcontroller itself
can be seen mainly in electronic devices, from home appliances to gadgets that
we are use every day. For example in a washing machine, the microcontroller
Vania Alodia Nasution | 5 | Industrial Automation

receives analog inputs from sensors that are attached to the machine through an
external ADC. It then starts the three-phase motor and adjusts the water and cut
power according to the command from the user.
.............................................................................
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