Programmable Logic

Controllers
Professor Charlton S. Inao
Defence University
Bishoftu ,Ethiopia
Guest Professor, Adama Science and
Technology University
Adama, Ethiopia
04/09/16

General Objectives
To explain and understand the following PLC

concept:

Programmable logic controller;

Structure of PLC and system components;
Programming Languages;( LAD,STL,FBD)
Logic Gates application for PLC
Counter
Shift Register
Jump
Programming Applications
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Programmable Logic Controllers

Defined by NEMA as a digital electronic
apparatus with a programmable memory for
storing instructions to implement specific
functions (logic, sequencing, timing, counting, and
arithmetic) to control machines and processes.

Considered as the first industrial-based computer

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Advantages of Using PLC

Shorter Project
Implementation
Easier Modification
Without Cost Penalty
Project Cost Can be
Accurately Calculated
Shorter Training Time
Required
Design Easily Change
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Using Software

A Wide Range of
Control Operations
Easy
Maintenance
High

Reliability

Standardization of
Controller Hardware
Able to Withstand
Harsh Plant
Environment

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Functions of PLC
Conventional Relay Logic Replacer

Sequence Control

Timer and Counter Functions

Auto / Semi / Manual Control of
Machines and Processes

Arithmetic Operations

Sophisticated
Control

Analog Control (Temperature,

Pressure, etc.)
PID (Proportional Integral
Derivation)
Stepper / Servo Motor Control

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Functions of PLC
Process Monitoring and Alarm

Supervisory Control

Interfacing with Computers

Factory Automation network
Wide Area Network

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Basic Control System

Open Loop System

INPUT

LOGIC

OUTPUT

-Pushbuttons

-Relays

-Motors

-Limit Switches

-Timers

-Solenoid valves

-Level Switches

-Counters

-Lamps

-Flow Switches

-Alarm/annunciator

PLC
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-Relays/contactors
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Basic Control System

Closed Loop System

Controller

Error

Set value

Final Control
Element

Process
Variable
Temperature

Flow

_
Process
Variable

Transmitter
Primary
Element / Transducer

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Hardware Components
Central Processing Unit (CPU)
Micro PLC less than 100 I/Os
Small PLC 0 to 128 I/Os
Medium PLC 0 to 256 I/Os
Large PLC 0 to 512 I/Os
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Power Supply
100 240 Volts AC
100 / 110 Volts AC
200 / 220 Volts AC
24 Volts DC
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Inputs
DC 24 Volts
AC 110 / 220 Volts

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Outputs
Transistor type (24 Vdc )
Relay / Contact type (24Vdc / 220 Vac)
TRIAC type (110 / 220 Vac)
PNP-type Transistor
Input

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NPN-type Transistor
Input

Source

Sink

Generates power

Transmits power

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Relay

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Example: Omron Relay

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Peripheral Devices
Programming Console
CX-Programmer Software
Conversion Cables
Connecting Cables
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Software Components
1. Ladder Diagram Language a symbolic instruction type
language
2. Boolean Language- Basic level language that composed
of three (3) Boolean logic operation: AND, OR, NOT
Mnemonic Instruction written in abbreviated
form using 3 or 4 letters that generally imply
the the operation of the instruction
3. Functional Blocks Language high level instructions that
permit the user to program more complex functions
using the ladder diagram format
- Instruction set is composed of blocks that executes
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or performs specific function

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4. English Statement Language considered derivative of

computer language such as BASIC.
-also known as Control Statements

Note:
OMRON PLCs uses both Ladder Diagram
Language and Boolean Language.
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Key Points to Know in Selecting or Using PLC

I. Know the process to be controlled
II. Determine the type of control
Distributed control
Centralized control
Individual machine control

III. Determine I/O interface requirements

Estimate digital and analog I./Os
Check for I/O specifications
Determine if remote I/O is required
Allow for future expansion

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IV. Define peripheral devices

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Steps in PLC Programming

Draw the Schematic Diagram
Draw Control Diagram
Develop PLC Ladder Diagram
I/O Assignment
Convert to Mnemonic (Boolean)
PLC Layout
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Basic Structure of PLC

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PLC Specfications

Programming Format
1) Ladder diagram
2)Mnemonic List
3) Function Block Diagram

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NOR,NAND,EX-OR

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Timer: On delay and Off delay

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Cascaded timer/ On-OFF Cycle

Timer

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Two Input control; Resetting a

Latch

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Counter

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Shift Register -Mitsubishi

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Shift Register

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M 0.0
0UT

Shift Register
Siemens
Configuration

I0.0
i

I0.1

SFT

I 0.2

RST
Q 0.0

M 0.0
M 0.1

Q 0.1

M 0.2

Q 0.2

M 0.3

Q 0.3

M 0.4
M 0.5

Q 0.4
Q 0.5

M 0.6

Q 0.6

M 0.7

END

Q 0.7

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Problem: Belt Sanding Machine

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Transfer Station

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Electric Relay Ladder Logic

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Liquid Level Sorter

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Wiring Diagram(Siemens
LOGO)

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Liquid Level Sorter Electrical

Ladder Diagram

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Liquid level Sorting |Machine PLC Ladder Ladder Diagram

M2.0

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Artillery Cartridge Polishing

Machine

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The designed and developed automated artillery cartridge polishing machine is intended for
defence application to recondition the 122mm and 130mm diameter cartridges. The machine
is intended to replace the traditional way of polishing the artillery cartridge with a modern
and automated machine for HOMICHO Ammunition Factory. The Artillery cartridge
polishing machine is a pneumatic type polishing machine which is basically used for
polishing the external and internal surfaces of 122mm and 130mm artillery cartridges. The
abrasive head can be moved to any point over the polishing area.
The longitudinal and traverse movements of the polishing head are controlled using a
programmable Language Control (PLC) integrated with pneumatically controlled cylinders.
The PLC program is written using a ladder logic programming method using software for
precise control of all the movements of the actuators in the two directions. Different
directional control valves with pressure relieve valves are mounted to perform different
functions.
Standard design approaches and manufacturing sequences are followed to design and
fabricate the polishing machine. The complete machine includes electric motor, pneumatic
cylinders, polishing abrasives and a pneumatic line. The overall dimension of the machine is
2585x705x470mm and its spindle is designed to hold firmly different caliber cartridges and
can be rotated at 800 RPM with a 5Kw spindle motor.
Since quality of the polishing machine is dependent on different polishing parameters like,
polishing abrasives used, depth of polishing, RPM of the spindle and the feed rate of the
polishing head, the surface quality of polished cartridges when it compared with previously
polished parts it can expected to be in the range of 0.2 and 0

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Cartridge polishing machine PLC Ladder diagram

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Hydraulic Missile Autoloader

Mobile Machine

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End
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