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LOGIC
CONTROLLERS
Richard A. Wysk
IE450 - Manufacturing Systems
PURPOSE OF Programmable
Logic Controllers (PLCs)
FUNCTIONS OF
CONTROLLERS
1) on-off control,
2) sequential control,
4) motion control.
CONTROL DEVICES
1) mechanical control - cam, governor, etc.,
2) pneumatic control - compressed air,
valves, etc.
3) electromechanical control - switches,
relays, a timer, counters, etc,
4) electronics control - similar to
electromechanical control, except uses
electronic switches.
5) computer control.
PROGRAMMABLE LOGIC
CONTROLLER
VENDORS
Rockwell
GE/Fanuc
Schnieder
etc.
PLC
CPU
Input
Input
Module
Flag
System
Output
User Ladder
Diagram
Working
memory
registers
Output
Module
PLC
Configuration
SWITCHE
S
Non-locking
Locking
Normally Open
Normally Closed
P1
SPDT
DPST
P2
Multiple Throw
Multiple Pole
Break-before-make
Make-before-break
TERM
S
DPST
B
Output
Input
Knob
How is this switch classified?
TYPES OF
SWITCHES
RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"
contact
coil
input
Relay coil
Output contact
COUNTE
Digital counters output in the form of a relay contact when a
R
preassigned count value is reached.
input
Register
Accumulator
reset
contact
output
Input
Reset
Output
Count
12
TIME
A timer consists of an internal clock, a count value register, and
an accumulator. It is used forRor some timing purpose.
Clock
Accumulator
reset
Register
Clock
contact
Contact
output
Reset
Output
Count
Time 5 seconds.
PB1
LS2
R1
R1
R1
TIMER
R2
PB1
LS1
LS2
PR=5
TIMER
5
R1
Motor
R2
PLC ARCHITECTURE
Programmable controllers replace most of the relay panel wiring
by software programming.
Program
Loader
PC
Switches
Printer
Processor
I/O
Modules
Memory
Power
Supply
Machines
Cassette
Loader
EPROM
Loader
External Devices
Peripherals
A typical PLC
PLC
1. Processor
Microprocessor based, may allow arithmetic
operations, logic operators,
block memory moves, computer interface,
COMPONENTS
local area network, functions, etc.
2. Memory
Measured in words.
ROM),
PLC
3. I/O
Modular plug-in periphery
COMPONENTS
AC voltage input and
output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g.., high speed timers,
Stepping motor controllers, etc. PID, Motion
4. Power supply AC power
5. Peripheral
CRT programmer,
Operator console,
Printer,
Simulator,
EPROM loader,
Cassette loader,
Graphics processor, and
Network communication interface. MAP, LAN
LADDER
A ladder diagram (also called contact symbology) is a means of
DIAGRAM
graphically representing
the logic required in a relay logic
system.
Rail
Rung
start
PB1
emergency stop
PB2
R1
R1
R1
A
Ladder Representation
PLC WIRING
DIAGRAM
Input
01
02
Output
PLC
01
02
20
11
12
20
03
20
11
External
switches
Stored program
SCA
A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to
the bottom. Usually, all the outputs are updated based on the status of the internal
N
registers. Then the input states are checked and the corresponding input registers are
updated. Only after the I/Os have been resolved, is the program then executed. This
process is run in a endless cycle. The time it takes to finish one cycle is called the scan
time.
Output
Input
begin
Idle
Scan cycle
Resolve
logic
1) Relay,
PLC
INSTRUCTIONS
LOGIC STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize,
etc.
Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.
(In the notes we use the symbol "~" to represent
negation. AND and OR are logic operators. )
AND and OR
LOGIC
PB1
PB2
R1
R1 = PB1.AND.PB2
AND
PB3
PB4
R2
R2 = PB2.AND.~PB4
PB1
R1
R1 = PB1 .OR. PB2
OR
PB2
R1
PB1
PB2
pb3
RELAY
A Relay consists of two parts, the coil and the contact(s).
Contacts:
a. Normally open
-| |-
b. Normally closed
-|/|-
c. Off-on transitional
-||-
d. On-off transitional
-| |-
()
Coil:
a. Energize Coil
-( )-
b. De-energize
-(/)-
c. Latch
-(L)-
d. Unlatch
-(U)-
True
Timers:
False
a. Retentive on delay
-(RTO)-
-(RTF)-
c. Reset
-(RST)-
Counter:
RTF
stop
True
counting
resume
counting stop
a. Counter up
-(CTU)-
b. Counter down
-(CTD)-
c. Counter reset
-(CTR)-
SEQUENCE
Sequencers are used with machines or processes involving
repeating operating cyclesR
which can be segmented into
steps.
Output
Step
ON
OFF OFF
5 sec.
ON
ON OFF
10 sec.
OFF OFF ON
3 sec.
OFF
9 sec.
ON OFF
Dwell time
A-B
PLC
I/O points are numbered, they
correspond to the I/O slot on
the PLC.
For A-B controller used in our lab
I/O uses 1-32
Internal relays use 033 - 098
Internal timers/counters/sequencers use 901-932
Status 951-982
Programming a PLC
PROGRAMMING EXAMPLE
1
Bar code reader
microswitch
Stopper
Conveyor
Part
Robot
id description
MSI microswitch
R1 output to bar code reader
C1 input from bar code reader
R2 output robot
R3 output robot
C2 input from robot
R4 output to stopper
C3 input from machine
C4
input from machine
Machine
state
1
1
1
1
1
1
1
1
1
explanation
part arrive
scan the part
right part
loading cycle
unloading cycle
robot busy
stopper up
machine busy
task complete
SOLUTIO
N
Input
MS1
Output
01
11
C1
C2
02
03
13
C3
04
14
C4
05
01
12
Programmable
Controller
PLC
11
14
14
02
14
04
05
03
03
12
13
R1
R2
R3
R4
15
EXAMPLE 2 TRAFFIC
LIGHTSMain street
Jefferson street
Cycle time
Street
Red
Main
Jefferson
3
5
Yellow
1
1
Green
4
2
WIRING DIAGRAM
input
output
64
Programmable
Controller
Jefferson Red
65
Jefferson Yellow
66
Jefferson Green
67
Main Red
70
Main Yellow
71
Main Green
RUNG1
RUNG2
RUNG3
RUNG4
PROGRAM
(1)
901
901
RUNG7
RUNG8
902
67
902
RTO
901
901
902
903
903
904
904
RTO
71
901
RUNG11
RUNG12
RST
904
904
905
J. Green
20
M. Green
71
RUNG9
RUNG10
30
66
903
RTO
902
M. Red
RST
66
901
80
RST
67
RUNG5
RUNG6
901
901
RTO
RST
70
40
M. Yellow
PROGRAM
(2)
RUNG13
901
RUNG14
RUNG15
RUNG16
RUNG17
RUNG18
RUNG19
RUNG 20
905
RTO
70
903
905
906
RST
65
906
RTO
65
901
902
906
907
RST
J. Yellow
10
64
907
RTO
64
901
10
907
RST
J. Red
50