BEKC4753

PLC AND AUTOMATION

Reference:
MOHD FAIRUS BIN ABDOLLAH
Intro to Programmable Logic Controller (PLC)
PLC = Programmable Logic Controller / Programmable
Controller

PLC is a special-purpose industrial computers designed

for use to control industrial machine and processes.

It uses a programmable memory to store instructions

and execute specific functions that include On/Off
control, timing, counting, sequencing, arithmetic, and
data handling.
Modular
type
Intro to Programmable Logic Controller (PLC)

PLC replaced hard-wired controller

Relay
control
panel

PLC
control
panel
Principle operation of PLC
 Principle operation of PLC

A mixer motor is used to automatically stir the liquid

in a vat when the temperature and pressure reach
preset value.

Direct manual operation of the motor is provided by

means of a separate pushbutton station.
Process Control Description
Principle operation of PLC
Relay ladder diagram of the mixer process control
PS pressure switch
TS temperature switch
MP manual pushbutton

Motor starter coil is energized when PS and TS closed or MP is pressed

 Principle operation of PLC
The same input and output field devices are used and
hardwired to an appropriate input and output module of the
PLC
 Principle operation of PLC
Next, construct the PLC ladder logic program then
stored into the memory by using programming device.
 Principle operation of PLC
To execute the program, the PLC is placed in the
RUN mode / operating cycle.
Sequence of events:
First, the PS, TS and MP are examined and their status is
recorded in the memory closed contact as logic 1 /
open contact as logic 0.
Next, the ladder diagram is evaluated, with each internal
contact given an OPEN or CLOSED status according to the
recorded 1 or 0 state.
If all of the input states provide logic continuity from left
to right across the rung, the output coil is given a logic 1
and the output module interface contacts will close and
vice versa.
 Advantages of a PLC Control System

Eliminates much of the hard wiring that

was associated with conventional relay
control circuits.
To control a complex
process using
conventional relay
method would require a
lot wiring. This could
lead to wiring error.

PLC will greatly reduce

most of the wiring
which also reduce the
wiring error.
 Since all the
logic is contained
in the PLCs
memory, there
is no chance
of making a
logic wiring
error.

Once a program has been written and tested

it can be downloaded to other PLCs.
 Advantages of a PLC Control System

Increased Reliability:
Relays are electromechanical devices -
physical wear and tear occurs every time it
active.

PLC is a solid state based device have large

mean time between failure (MTBF)
MTBF a statistical analysis of failure potential
 Advantages of a PLC Control System

More Flexibility:

It is easier to create and change a program in a

PLC than to wire and rewire a circuit.

Original equipment manufacturers (OEMs) can

provide system updates for a process by simply
sending out a new program.
End-users can modify
the program in the
field, or if desired
 Advantages of a PLC Control System

Lower Costs:
Originally PLCs were designed to replace relay
control logic. The cost savings using PLCs have
been so significant that relay control is becoming
obsolete, except for power applications.
Generally, if an application
requires more than about
6 control relays, it will
usually be less expensive
to install a PLC.
 Advantages of a PLC Control System

Communications Capability:
A PLC can communicate with other controllers
or computer equipment.
They can be networked
to perform such functions
as: supervisory control, data
gathering, monitoring
devices and process
parameters, and
downloading
and uploading of programs.
 Advantages of a PLC Control System

Faster Response Time:

PLCs operate in real-time which means that an
event taking place in the field will result in the
execution of an operation or output.
Machines that process
thousands of items per
second and objects that
spend only a fraction of
a second in front of a
sensor require the PLCs
quick response capability.
 Architecture PLCs versus Computers
PLC System

ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 5

0: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 6

The architecture of PLC and PC are similar both have motherboard,

processor, memory and expansion slot.
PLC Architecture
PLCs versus Computers
 PLC Size
Size of PLC depending on functionality, cost, physical size and number of
I/O

Size I/O Count

Large > 1024
Medium < 1024
Small < 256
Micro 32
Nano 16
 Application
Major types of application:

1)Single-ended
2)Multitask
3)Control management
 Application : Single-Ended
Involves one PLC controlling
one process
PLC
Stand-alone unit PLC
cannot be used for Process
communicating with other
PLCs

Usually requires a small or

nano size PLC
Application : Single-Ended
 Application : Multitask
One PLC controlling several
processes
1
Process Proces
s2
Might need a data
communications network to PLC
communicates with a central 4
PLC if the PLC is a subsystem of Proces Process
a larger process. s3

Usually requires for medium

size PLC
Application : Multitask
 Application : Control Management

One large PLC control several PLC

other PLCs

This PLC supervises several PLC a

PLCs by downloading
Proc
programs that tell other PLCs 1 PLC b
what has to be done Proc Proc
Proc
3 4
2
Requires large size of PLC
Application : Control Management
 PLC Brands
Allen Bradley
 PLC Brands
Siemens
 PLC Brands
Omron
 PLC Brands
Mitsubishi
 PLC Brands
Keyence
 PLC Brands
National Instruments (PAC)
PLC at FKE UTeM
OMRON PLC CQM1H Training Set

16 sets, located at Makmal PLC &

Kawalan Proses, blok E Lvl 3 FKE, UTeM
Consists of:
CPU
Memory Unit
I/O Module
Input : 16 number (0 -15) , DC
Output : 16 number (0 -15 ), DC & AC
Programming device
Hand console (hardware) &
CX programming (software)
Power supply
 and mix them in any way
you desire.

PLC Configurations
ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 9

Modular
I/O Configurations
Fixed
ns
Modular I/O
When a module
h slides
lid into
i the
h
rack, it makes an
electrical
connection with a
series of contacts
- called the
l backplane The
backplane.
backplane is
y located at the rear
of the rack.

able Logic Controllers By F. D. Petruzella, McGraw-Hill

ENGG3490: 9
Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 10

s 5
 PLC Hardware Configurations
1. Fixed type
One small package, no
separate/removable units
Processor & I/O packed together
Low cost
Lack of flexibility fixed number of I/O
Might need to replaced the whole unit if
any part in the unit fails.
Fixed Type PLC
 ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 9

PLC Hardware Configurations

I/O Configurations

Modular I/O
2. Modular type When a module
slides
lid into
i the
h
rack, it makes an

Divide by compartments electrical

connection with a
series of contacts

Modules plugged into the rack

- called the
backplane The
backplane.
backplane is
located at the rear
Basic modular controller rack, power
of the rack.

supply, CPU module, I/O modules and

ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 10

operator interface (programming and

monitoring)
Choose & mix modules as desired
More option & flexibility
Modular Type PLC
PLC Hardware Components

Power Supply
Input
Programming
& Output
Processor
Memory
(I/O)
Devices
modules
 Power Supply
- 240V/115V AC used to power up PLC
- Power supply convert AC voltage
into low DC voltage (24V/12V/5V)
- For small & micro PLC, power supply
used to power up I/O devices
- For large & complex system, power
for I/O devices is provided by
external AC/DC supplies
 Processor / CPU
- Brain of PLC
- Executes the operating system,
manages memory, monitor
inputs, evaluate the user logic
(ladder diagram), activate
appropriate outputs and
communicate with other
module.
- Processor/CPU required OMRON CPU
memory for storing data &
program.
 Memory
- A physical space inside the CPU where the program
files and data files are stored and manipulated.
- Program and data are stored in bits either 1s or 0s.
 Memory
Volatile (Changeable)
Categories Non-volatile (Fixed)

ROM, RAM, PROM

Types EPROM, EEPROM
 increases your options
and the units flexibility.
Y can choose
You h f
from allll

Input & Output Interface Modules

the modules available
and mix them in any way
you desire.

ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 9

Act as eyes, ears and tongue to the PLC processor

Several I/O modules can be inserted into I/O racks of PLC

I/O Configurations

Modular I/O
When a module
slides
lid into
i the
h
rack, it makes an
electrical
connection with a
series of contacts
- called the
backplane The
backplane.
backplane is
located at the rear
of the rack.

ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 10
 Provide connection to the machine & process
I/O devices or feld devices are connected to I/O modules
Input & Output Interface Modules
 Output interface module convert PLC signals
into external signals used to control the
machine or process.
Input interface module - accept signals from
the machine or process devices and convert
them into signals that can be used by the PLC
Input & Output Interface Modules
Input & Output Interface Modules
Input devices
(push button, limit
switches, various
of sensors, etc) are
wired /connected
to the terminal on
the input modules
Input & Output Interface Modules

Output devices
(motor, light,
valve, motor
starter, etc) are
wired/connected
to terminal on the
output modules
Input & Output Interface Modules
- I/O modules can be located near the field devices by
using Remote I/O hence minimizing wiring connection.
Input & Output Interface Modules

Remote I/O is linked by using cable to the

local I/O at CPU through communication
module

Typical cable used are fibre optic (up to 20

miles) & coaxial cables (up to 2 miles)
Input & Output Interface Modules

Analog
Discreet

Special

Types of I/O modules

Input & Output Interface Modules

Discreet I/O modules

Connect Output devices
ON/OFF nature limited such as Powered by
Most common input devices light, small PLC power
type of I/O such as push motor, supply unit /
interface button, limit solenoid, external power
switch, selector motor starter, supply
switch, etc. etc.
Input & Output Interface Modules
Input & Output Interface Modules

Analog I/O modules

Input and output Contained A/D
Analog output
can have an converter circuit
devices such as
infinite number for input and
valves and
of states (send & D/A converter
analog meter,
receive complex for output
etc.
signal) modules
Input & Output Interface Modules
Input & Output Interface Modules
High speed
counter
Thumb
Speech
wheel

Language TTL

Special
Communic
ation I/O Encoder-
Counter

modules Basic/
Servo
ASCII

Stepper
PID
motor
BCD output
Programming Devices
Handheld/
Console

PLC
Programming
device
PC
software

Also called as Program

Terminal (PT)
 Programming Devices
Often used for small PLC
Handheld
Inexpensive
Easy to use
Contains key, buttons,
LCD display
Limited display
capability
Types: Dumb terminal
and Smart terminal
 Programming Devices
Provided by PLC

Software
manufacturers
Uses parallel/serial com
Easier to create, edit,
store, document &
troubleshoot programs
Large display
Program either in DOS /
Windows environment
Programming Device
Console Software