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ECE103 - INDUSTRIAL

ELECTRONICS

PLC

PROGRAMMABLE LOGIC CONTROLLE

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

C HISTORY AND DEVELOPMENT


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.

>The new control system had to


meet the following requirements:
Simple programming
Program changes without system intervention
(no internal rewiring)
Smaller, cheaper and more reliable than
corresponding relay control systems
Simple, low cost maintenance

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

C HISTORY AND DEVELOPMENT


>Subsequent development
resulted in a system enabled:
the simple connection of binary signals
the requirements as to how these signals
were to be connected was specified in the
control program
with the new systems it became possible
for the first time to plot signals on a
screen and to store these in electronic
memories

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

C HISTORY AND DEVELOPMENT


>More than three decades have passed:

the enormous progress was made in the development


of micro electronics
great influence also at PLCs
For instance, even if program optimisation and thus a
reduction of required memory capacity initially still
represented an important key task for the programmer,
nowadays this is hardly of any significance.

>EVOLUTION
the range of functions has grown considerably
15 years ago, process visualisation, analogue processing or even
the use of a PLC as a controller, were considered as Utopian..
nowadays, the support of these functions forms an integral part
of many PLCs.

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

EAS OF APPLICATION OF PLC

>Every system or machine has a


controller.
Depending on the type of technology used, controllers
can be divided into:
pneumatic
hydraulic
electrical
electronic
*Frequently, a combination of different technologies is
used.
>Furthermore, differentiation is made
between:
hard-wired programmable (e.g. wiring of
electromechanical or electronic components)
controllers
programmble logic controllers

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

EAS OF APPLICATION OF PLC


>The PLC represents such a universal
controller!
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.

>Application areas of PLCs:


production machines
production lines
production processes
environmentally systems (waste water cleaning,.)
building equipment systems (heating,cooling, lighting,
safety systems)

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

ASKS OF PLC
>The original task of a PLC
the interconnection of input signals according to a specified
program and switching corresponding output signals
both input and output signals are supposed to be logical ones
Boolean algebra forms the mathematical basis for this
operation, which recognises precisely two defined statuses of
one variable: "O" and "1

>New tasks of a PLC


However the tasks of a PLC have rapidly multiplied:
timer and counter functions
memory setting and resetting
mathematical computing operations
*All this represent functions, which can be executed by
practically any of today's PLCs.

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

URRENT PLCs
The PLCs currently on offer in the market have been adaped to the
customer requirements to such an extent that it has become
possible to purchase an eminently suitable PLC for virtually any
application
Miniature PLCs with a minimum number of inputs/outputs (6/4 IOs)
and also large PLC systems with thousands of IOs are available
today
Many PLCs can be expanded by means of additional logic
input/output, analogue input/output, positioning and
communication modules
Special PLCs are available for safety technology, shipping tasks,
mining tasks etc.
Yet further PLCs are able to process several programs
simultaneously multitasking or truly simultaneously
multiprocessing (more processors in one PLC)
Finally, PLCs are coupled with other automation components (HMI,
identification systems, smart actuators, etc.) thus creating
considerably wider areas of application

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

ASIC
OF PLC
>The DESIGN
term 'programmable
logic controller' is defined as
follows by lEC 1131, Part 1:
" PLC is a digitally operating electronic system,
designed for use in an industrial environment, which
uses a programmable memory for the internal storage
of user-oriented instructions for implementing specific
functions such as logic, sequencing, timing, counting
and arithmetic, to control, through digital or analog
inputs and outputs, various types of machines or
processes. Both the PC and its associated peripherals
are designed so that they can be easily integrated into
an industrial control system and easily use in all their
intended
So wefunctions.
can say that programmable logic

controller is therefore nothing more than


a microcomputer, tailored specifically for
certain control tasks `

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

STEM COMPONENTS OF PLC


PLC Program

PLC

SW

HW

FIELD

CONTROLLED PROCESS or CONTROLLED MACHINE

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

STEM COMPONENTS OF PLC


>Function of input and output module
The function of an input module is to convert incoming
signals from sensors 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

>Function of CPU

The actual processing of the signals is effected in the central


control unit (CCU) in accordance with the program stored in
the memory.
Another name for CCU :
CPU = Central processing unit
is often used

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

STEM COMPONENTS OF PLC


>The program of a PLC can be
created in various ways:
via assembler- type commands in 'statement list'
in higher-level, problem-oriented languages such as structured text
in the form of a flow chart such as represented by a sequential
function chart
in Europe, the use of function block diagrams based on function
charts with graphic symbols for logic gates is widely used
in America, the 'Iadder diagram' is the preferred language by users

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

STEM COMPONENTS OF PLC


>Depending on how the central control unit (CCU) is
connected to the input and output modules, ditferentiation
can be made between:
compact PLCs (input module, central control unit and output
module in one housing)
modular PLCs
Modular PLCs may be configured individually. The modules
required for the practical application - which can, for
instance, include digital input/output modules, analogue
modules, positioning and communication modules - are
inserted in a rack, where individual modules are linked via a
bus system. This type of design is also known as series
technology.

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

TERNAL DESIGN OF PLC


>Depending on how the central control unit (CCU) is
connected to the input and output modules, ditferentiation
can be made between:
compact PLCs (input module, central control unit and output
module in one housing)
modular PLCs
Modular PLCs may be configured individually. The modules
required for the practical application - which can, for
instance, include digital input/output modules, analogue
modules, positioning and communication modules - are
inserted in a rack, where individual modules are linked via a
bus system. This type of design is also known as series
technology.

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

TERNAL DESIGN OF PLC

PLC plug-in cardsCOMPACT PLC - FEC FC 34 a PS1 FC


(Festo FPC 405)

Modular PLC - Siemens S7-300

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

ARDWARE DESIGN OF PLC


>The hardware design for a programmable
logic controller is such that it is able to
withstand typical industrial environments
as regard:
- signal levels
- heat
- humidity
- fluctuations in current supply
- mechanical impact

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

C STANDARDS IEC 1131


Previously PLC standards

Previously valid PLC standards focussing mainly on PLC


programming were generally geared to current state of the
art technology in Europe at the end of the seventies.
This took into account non-networked PLC systems, which
primarily execute logic operations on binary signals.
DIN 19 239, for example, specifies programming languages
which possess the corresponding language commands for
these applications.

Previously situation

no equivalent, standardised language elements existed for the PLC


developments and system expansions made in the eighties such as
processing of analogue signals
interconnection of intelligent modules
networked PLC systems etc.
Consequently, PLC systems by different manufacturers required
entirely different programming.

ECE103 - INDUSTRIAL
ELECTRONICS

C STANDARDS IEC 1131

PLC

>The new lEC 1131 standard consists


of six parts:
Part 1: General information
Part 2: Equipment requirements and tests
Part 3: Programming languages
Part 4: User guidelines (in preparation
with
lEC)
Part 5: Messaging service specification (in
preparation with lEC)
Part 7: Fuzzy control programming

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

C STANDARDS IEC 1131

>The new lEC 1131 standard consists


of six parts:
to define and standardise
the design and functionality of a PLC
the languages required for
programming
to the extent where users were able
to operate using different PLC systems
without any particular difficulties

ECE103 - INDUSTRIAL
ELECTRONICS

ONTROL SYSTEM

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

CAL PLC-BASED CONTROL SYSTEM

ECE103 - INDUSTRIAL
ELECTRONICS

I/O DEVICES

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

LC BLOCK DIAGRAM

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

NVENTIONAL VS. PLC CONTROL

ICAL CONVENTIONAL CONTROL PANEL TYPICAL PLC CONTROL PANEL

ECE103 - INDUSTRIAL
ELECTRONICS

VERSION OF CONVENTIONAL TO PLC CONTROL

STARTING AND STOPPING OF A 3-PHASE MOTOR

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

VERSION OF CONVENTIONAL TO PLC CONTROL

PROGRAM - LADDER DIAGRAM

ARD-WIRED CIRCUIT FOR PLC CONNECTION

ECE103 - INDUSTRIAL
ELECTRONICS

VERSION OF CONVENTIONAL TO PLC CONTROL

CTR1

CONVENTIONAL CIRCUIT FOR SORTING MACHINE

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

VERSION OF CONVENTIONAL TO PLC CONTROL

IRING CIRCUIT OF PLC FOR SORTING MACHINE

>DETERMINE THE
INPUT AND OUTPUT
DEVICES USED FOR THE
CONTROL CIRCUIT
>ASSIGN THE I/O FOR
THE PLC
>WIRE ACCORDING TO
THE ACTUAL I/O
>INPUT
DEVICESDEVICES:
INPUT 0 PB1
INPUT 1 LS1
INPUT 2 LS2
INPUT 3 PB2
>OUTPUT DEVICES:
OUTPUT 1000
CONVEYOR MOTOR
OUTPUT 1001
CYLINDER SOLENOID
OUTPUT 1002 ENDCYCLE BELL

ECE103 - INDUSTRIAL
ELECTRONICS

VERSION OF CONVENTIONAL TO PLC CONTROL


LADDER DIAGRAM OF PLC FOR THE SORTING MACHINE

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

EATIC APPROACH FOR THE CONTROL DESIGN USING A


1. DETERMINE THE MACHINE SEQUENCE OF OPERATION Firstly,
you to decide what equipment or process you want to control. The
ultimate purpose of PLC is to control an external system. You need to
determine the sequence of the operation by drawing out the flowchart
2. ASSIGNMENT OF INPUTS AND OUTPUTS all external input and
output devices to be connected to the PLC must be determined. After
identifying, assign the numbers corresponding to the INPUT and
OUTPUT number of the particular PLC used, this must be carried out
before writing the ladder diagram
3. WRITING OF THE PROGRAM write the ladder diagram program by
following the control system sequence of operation as determined by
step 1.
4. PROGRAMMING INTO MEMORY now you can apply power to the
PLC, and you can enter the program in the memory by computer aided
ladder software tool. After completion of the programming, you should
check for coding errors by means of diagnostic function, and if
possible, simulate the whole operation
5. RUNNING THE SYSTEM before the start push-button is pressed,
thoroughly ensure the input and output wiring are correctly connected
according to the I/O assignment. Test run thoroughly until it is safe to

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

MATIC APPROACH FOR THE CONTROL DESIGN USING A

ECE103 - INDUSTRIAL
ELECTRONICS

PLC

ONSIDER A SIMPLE PROJECT CONTROL THE ROBOT MOVEMENT

ECE103 - INDUSTRIAL
ELECTRONICS

PLE PROJECT - PICK AND PLACE ROBOT

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLE PROJECT - PICK AND PLACE ROBOT

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLE PROJECT - PICK AND PLACE ROBOT

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLE PROJECT - PICK AND PLACE ROBOT

PLC

ECE103 - INDUSTRIAL
ELECTRONICS

PLE PROJECT - PICK AND PLACE ROBOT

PLC

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