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PLC WORKSHOP
SAJID ALI
Presentation Sequence
Basics of PLCs
Functions of PLCs Applications of PLCs Components of PLCs Programming Devices Symbols Programming modes PLC program creation Documentation PLC addressing Programming logic functions Q&A
Functions of PLC
Applications of PLC
Symbols
Components of PLC
Programming Devices
Programming Modes
Documentation
PLC addressing
Q&A
Why PLCs
PLC is a microprocessor based, reprogrammable device that is used for Industrial Automation In addition to the programming flexibility PLCs offer other advantages over traditional control systems. These advantages include:
high reliability small space requirements computing capabilities reduced costs ability to withstand harsh environments expandability
History
Conventional control panel
At the outset of industrial revolution, especially during sixties and seventies, relays were used to operate automated machines, and these were interconnected using wires inside the control panel. In some cases a control panel covered an entire wall.
History
Disadvantages of Conventional control panel
z z z z z z z z
Too many wiring work. Difficult to modify and troubleshoot => Long down time. Power consumption can be quite high Drawings are usually not updated. Lifetime of relay contacts was limited, so some relays had to be replaced. If replacement was required, machine had to be stopped and production too. Also, it could happen that there was not enough room for necessary changes. As far as maintenance, electricians had to be very skillful in finding errors.
History
In the late 1960's PLCs were first introduced. The primary reason for designing such a device was eliminating the large cost involved in replacing the complicated relay based machine control systems. Bedford Associates (Bedford, MA) proposed something called a Modular Digital Controller (MODICON) to a major US car manufacturer. Other companies at the time proposed computer based schemes, one of which was based upon the PDP-8. The MODICON 084 brought the world's first PLC into commercial production. In the mid70's the dominant PLC were Modicon and A-B PLCs. The AMD 2901 and 2903 were quite popular in these PLCs Communications abilities began to appear in approximately 1973. The first such system was Modicon's Modbus. The PLC could now talk to other PLCs and they could be far away from the actual machine they were controlling. They could also now be used to send and receive varying voltages to allow them to enter the analog world.
History
The 80's saw an attempt to standardize communications with General Motor's manufacturing automation protocol (MAP). It was also a time for reducing the size of the PLC and making them software programmable through symbolic programming on personal computers instead of dedicated programming terminals or handheld programmers.
The 90's have seen a gradual reduction in the introduction of new protocols, and the modernization of the physical layers of some of the more popular protocols that survived the 1980's. The latest standard (IEC 1131-3) has tried to merge PLC programming languages under one international standard.
History
Advantages of PLC based control system
Compared to a conventional process control system, number of wires needed for connections is reduced by 80% Diagnostic functions of a PLC controller allow for fast and easy error detection. Change in operating sequence or application of a PLC controller to a different operating process can easily be accomplished by replacing a program through a console or using a PC software (not requiring changes in wiring, unless addition of some input or output device is required).
It is much cheaper compared to a conventional system, especially in cases where a large number of I/O instruments are needed and when operational functions are complex. Reliability of a PLC is greater than that of an electro-mechanical relay or a timer.
PLC Architecture
Typically a PLC system has five basic components. These are the processor unit, memory, the power supply unit, input/output interface section and the programming device. Figure shows the basic arrangement. Programming Device
Memory
Input Interface
Processor
Output Interface
Power Supply
PLC Architecture
PLC Architecture
CPU
The processor unit or central processing unit (CPU) is the unit containing the microprocessor and this interprets the input signals and carries out the control actions, according to the program stored in its memory, communicating decisions as a action signals to the output.
PLC Architecture
Programming Device
The Programming device is used to enter/edit the required program into the memory of the processor. The program is developed in the device and then transferred to the memory unit of the PLC.
Memory Unit
Program is stored in memory unit, and is used for the control actions to be exercised by the microprocessor.
PLC Architecture
The essential elements of a CPU are:
Registers
A register is a byte (8 bits), word ( 16 bits ) or long word (32 bits) of memory which is part of the microprocessor as opposed to general purpose memory. A register is used for temporary storage of data and addresses within the CPU.
ALU
The ALU performs arithmetic and logical operations such as addition and subtraction on data stored in registers.
Control Unit
The control unit is basically a set of counters and logic gates which is driven by the block. Its function is to control the units within the microprocessor to ensure that operations are carried out in the correct order.
Functions of PLCs
Functions of PLC: Function of a PLC is to provide a reprogrammable, reliable, upgradable control solution for Industrial Automation The function of an input module is to convert incoming signals into signals, which can be processed by the PLC, and to pass these to the central control unit. The reverse task is performed by an output module. This converts the PLC signal into signals suitable for the actuators
Applications of PLCs
...over 1,000,000 applications world wide
Overview
Woodworking
Filling plants
Application examples
Applications of PLC are wide ranging as it is designed for Industrial Applications As the Industry is diversified so is the application of PLC. A reliable controller for every machine & system . Where frequent process changes are required. In harsh environments. Where the whole plant is to be controlled by central controller with multiple loops. Accurate Timer and counter functions, memory setting and resetting, mathematical computing operations when required. For reliable, accurate and economical automation
Here a PLC is controlling the conveyor unit (Diversion & Speed) PLC is getting info from:
Sensors for workpiece detection Sensors for conveyor speed detection
1.
And controlling:
Diversion device (pneumatic based) Conveyor speed
2.
Coolant on / off Door open / close Tool changing Vise / chuck open / close
Program
Program
CNCController
A PLC is used here in connection with CNC controller that enables the machine to execute the fore stated steps
Machine Tool
Components of a PLC
Basics of PLC
Hardware
Functions of PLC
Applications of PLC
Symbols
Components of PLC
Programming Devices
Programming Modes
Software
Documentation
PLC addressing
Q&A
Components of a PLC
Components of a PLC
Components of a PLC
Components of a PLC
Components of a PLC
Types of PLC
There are two types of PLC 1) Fixed PLC
Fixed PLC combine all of the main components into a single unit that contains the CPU, input/output sections, and power supply. The number of inputs and outputs cannot be expanded.
2) Modular PLC
A PLC configuration in which each component is split into a separate unit. A modular PLC lets you have as many inputs and outputs as you want.
Basics of PLC
Functions of PLC
Applications of PLC
Symbols
Components of PLC
Programming Devices
Programming Modes
Documentation
PLC addressing
Q&A
Programming Devices
Basics of PLC
Functions of PLC
Applications of PLC
Symbols
Components of PLC
Programming Devices
Programming Modes
Documentation
PLC addressing
Q&A
Programming languages
Basics of PLC
Ladder Diagram Function Block Diagram Instruction List Structured Text Sequential Function Chart
Functions of PLC
Applications of PLC
Symbols
Components of PLC
Programming Devices
Programming Modes
Documentation
PLC addressing
Q&A
Ladder diagram
A graphic programming language Derived from relay logic Contact Rails to the left and the right These contact rails are connected to switching elements
Graphical Method of programming Various Function blocks are provided for the ease of programmer, e.g.
Functions blocks are interconnected into networks, to form a PLC program. Even Ladder Diagram can be used with function blocks
Instruction List
Instruction list is a textual assembler-type language Instruction list is formulated from control instructions consisting of an operator and an operand.
LD
Part_TypeA
OR
AND AND ST
Part_TypeB
Part_present Drill_ok Sleeve_in
Structured Text
Structured text programming is similar to high-level language Loops, control statements and function blocks can be used Structured text enables the formulation of numerous applications, beyond pure function technology,
algorithmic problems (Control) data handling (data analysis, processing of complex data structures etc.).
Used for structuring of sequence-oriented control programs. The elements SFC are
To gain popularity!
Basics of PLC
Functions of PLC
Applications of PLC
Symbols
Components of PLC
Programming Devices
Programming Modes
Documentation
PLC addressing
Q&A
Specification:
Design:
Realization:
Integration / commissioning:
Documentation
One important and crucial component of a system is documentation, Documentation is required for Maintenance Expansion of the system PLC Program Troubleshooting creation Individually these are: Problem description Documentation Positional sketch or technology pattern Circuit diagram Terminal diagram Printouts of control programs in SFC, FBD etc.. Allocation list of inputs and outputs Additional documentation
PLC addressing
Basics of PLC
Functions of PLC
Applications of PLC
Symbols
Components of PLC
Programming Devices
Programming Modes
Documentation
PLC addressing
Q&A
PLC addressing
Memory Area Structure OF FATEK PLC
PLC addressing
Memory Area Structure OF FATEK PLC
PLC addressing
Memory Area Structure OF SIEMENS PLC
PLC addressing
Memory Area Structure OF SIEMENS PLC
z Physical Input Contacts()These are the external physical inputs contacts of the PLC. Its Address in Siemens PLC is I0.. In and for Fatek PLC is X0.Xn. z Physical Output Coils()These are the external physical Outputs Coils/Relays of the PLC. Its Address in Siemens PLC is Q0.. Qn and for Fatek is Y0.Yn.
PLC addressing
Memory Area Structure PLC
Internal Relay ()Do not have any specific function, and they can be freely used within the program (except those assigned to Input or Output Cards and Special I/O Cards). Known as M area in Fatek PLC. Retentive M(M800-1399), Internal Relay(M0-799) and Special relays (M1912-2001) Work Area/Data Register (D) can be used only in the program; not for I/O exchange with external I/O terminals. D (D0-D4095), R(R0-4168)
PLC addressing
Memory Area Structure PLC
Timers(T)/ Counters(C)-
I/O Assignment
The I/O assignment table indicates which PLC inputs are connected to which input devices And which PLC outputs drive which output devices. The assignment of internals, including timers and counters also takes place here.
the electrical circuit is replaced with the ladder diagram of PLC and is connected to the pneumatic circuit accordingly Here a solenoid operated valve is connected to the PLC.
Basics of PLC
Functions of PLC
Applications of PLC
Symbols
Components of PLC
Programming Devices
Programming Modes
Documentation
PLC addressing
Q&A
X0
This is a normally open contact symbol. It will be closed if the coil of the same number is energised. This is a normally closed contact symbol. It will open upon the energising of the coil of the same number
X0
SIMATIC S7-200
CPU 222
(14 I/O Points)
Built-in Features
CPU Status LEDs
Overview
Cartridge Slot
(224(XP),226)
Communication Port(s)
(224(XP),226)
Please sit infront of Individual PCs and Open WinProLadder placed on DeskTop. Practice on Simple Ladder Logic Programming
Practice Session
The figure is showing the relay logic for AND and OR operation
The output signal assumes the value 1, if the input signal has the value 0 and vice versa.
Exercise 1:
Lamp H1 is illuminated as long as switch S1 is not actuated; It is extinguished, if the switch is closed. The purpose of S1 is therefore to switch off the lamp.
Solution:
AND-Operation
The output signal only assumes the value 1, if all input signals have the value 1.
AND-Operation
Exercise 2:
AND-Operation
Solution:
NAND-Operation
The output signal only assumes the value 1, if all input signals have the value 1.
NAND-Operation
Exercise 3:
The output signal only assumes the value 1, if all input signals have the value 1.
NAND-Operation
Solution 3:
OR-Operation
The output signal assumes the value 1, if at least one input signal has the value 1.
OR-Operation
Example 4:
OR-Operation
Solution 4:
NOR-Operation
The output signal assumes the value 1, if at least one input signal has the value 1.
NOR-Operation
Example 5:
NOR-Operation
Solution 5:
Exclusive OR-Operation
The output signal assumes the value 1, if at least one input signal has the value 1.
Exclusive OR-Operation
Example 6:
Exclusive OR-Operation
Solution 6:
Memory Function
a dominant setting flipflop (bistable memory with preferred status 1). A 1-signal at S1 sets the value of Q1 A 1-signal at R only brings output Q1 to value 0
Memory Function
Exercise:
If sensor B1 has a 1-Signal, this indicates an error status in the system. A horn H1 is sounded. The horn can only be switched off by actuating push-button S1. It is possible to switch off the horn, even if the B1signal continues to be applied.
Memory Function
88
Symbolic Addressing
89
Symbolic Addressing
90
Latches
Latch circuit is used to maintain the status of output based on two execution conditions. These conditions are SET & RESET. When SET condition is true, output turns ON and stay ON, until reset condition is true. When RESET condition is true, output turns OFF and stay OFF, until SET condition is true.
SET condition RESET condition Output
National Institute of Design & Analysis
91
Latches
92
Latches
93
TIMER
94
TIMER
95
TIMER
96
97
98
DELAY ON TIMER
99
DELAY ON TIMER
100
DELAY ON TIMER
When switch S1 is on
101
102
EXAMPLE: Write a program to on a motor for 100 seconds When switch S1 is on.
103
104
105
106
TIMER
107
Single-Shot Circuit
Input Signal
Output
T1 T1
108
Single-Shot Circuit
109
COUNTER
110
COUNTER
111
COUNTER
112
COUNTER
113
COUNTER
EXAMPLE: Write a program to count a number of samples ( box, apples, bottles etc) up to 10 and then stop the conveyor motor.
114
COUNTER
115
COUNTER
116
COUNTER
117
EXAMPLE: Write a program to count the existing bottles on a conveyor belt by using S1 at the entrance and S2 at outlet. If bottles are 4 then on alarm AL1. Use S3 pushbutton for reset.
118
COUNTER
119