Programmable Logic Controllers

Objectives
• Define PLC.
• Explain where the PLC came from.
• Explain why their use is valuable.
• Explain where they are used.
• Detail what PLCs can do.
• Explain how PLCs know what they are
supposed to do.
 What Is a
Programmable Controller?
• A programmable logic controller, usually
called a PLC or programmable controller,
is a solid-state, digital, industrial computer.
• Simply, a programmable controller is a
computer, much like a desktop personal
computer.
• A PLC is an industrially hardened
computer.
 Where Did the
PLC Come From?
• In the 1960s, electromechanical relays,
timers, counters, and sequencers were the
standard.
• Many control panels contained hundreds
of these devices and a mile or more of
wire.
 Where Did the
PLC Come From?
• Reliability was low and maintenance costs
were high.
• Cost was high to modify or upgrade control
panels.
• In 1968 the General Motors Hydramatic
division specified a device that would
become what we know today as the
programmable logic controller.
 Early PLCs
• Only relay replacers
• Did not have timers or counters
• No sequencer instructions
• No math instructions
• No data manipulation instructions
 Why a PLC?
• Easily changeable
• Programmable
• Reliable
• Smaller
• Fast switching
 Why a PLC?
• Able to withstand harsh factory
environment
• Consumes less power
• Easier to troubleshoot
• Easy to install
 Why Use a PLC?
• The question “why use a PLC?” should
really be rephrased to “why automate?”
– The PLC is the tool that provides the control
for the automated process.
 Automating Helps a
Manufacturing Facility
• Gain complete control of the
manufacturing process
• Achieve consistency
• Improve quality and accuracy
• Work in difficult or hazardous
environments
• Increase productivity
 Automating Helps a
Manufacturing Facility
• Shorten lead time to market
• Lower cost of quality, scrap, and rework
• Offer greater product variety
• Allow a quick changeover from one
product to another
• Control inventory
 A PLC Upon First Glance
• A black box with wires bringing signals in
and other wires sending signals out
• Some sort of magic being done inside that
somehow decides when field devices
should be turned on or off
 Actually There Is No Magic
• The PLC is a computer and someone has
to tell it what to do.
• The PLC knows what to do through a
program that was developed and entered
into its memory.
• Without a set of instructions telling the PLC
what to do, it is nothing more than a box
full of electronic components.
 What Makes a PLC Work?
• The heart of any computer is the
microprocessor.
– The microprocessor, also called the processor
or central processing unit (CPU), supervises
system control through the user program.
 What Makes a PLC Work?
• The processor reads input signals and
follows the instructions that the
programmer has stored in the PLC’s
memory.
 What Makes a PLC Work?
• As a result of the solved program, the PLC
writes information to outputs, or field-
controlled devices, to turn them on or off.
• When the PLC is running and following the
program’s instructions, this is called
solving the user program.
• The PLC is running or in RUN MODE.
 What Makes a PLC Work?
• The user program (ladder program) is the
list of instructions that tells the PLC what to
do.
• The library of instructions available to the
PLC is called the instruction set.
• The instruction set determines how much
flexibility the programmer has.
 Common PLC Inputs
• Pushbuttons
• Selector switches
• Limit switches and level switches
• Proximity sensors
• Photo switches
• Relay contacts
• Motor starter contacts
An Overview of a PLC System
 An Overview of a
PLC System
• Incoming signals, or inputs, interact with
instructions in the user program to help the
PLC determine when an input instruction is
either true or false.
 Advantages of PLC:
• Use of s/w programming instead of hardware & wires
to control the i/o devices. Amount of wiring is cut-
down by 80%.
• Faster scan time: Operational time of PLC is very fast
as compare to Relays. The speed of PLC logic
operation is determine by scan time, which is a matter
of millisecond.
• Intelligent I/Os & high speed counters.
• Supervisory control & ASCII message handling
capability.
• Reliability & Maintainability: PLC has very high
reliability rate & hence control system maintenance
cost is low and downtime is minimal.
• Flexibility :- Flexibility in programming &
reprogramming in plant. Also flexibility in control
technique. i.e. the control equipment can be easily
reconfigured to accommodate required change in
process online.
• Ability to communicate with computer system in
plant.
• COST :- PLC can scan digital & analog inputs
through relevant sensors. It can execute the logic
w.r.t. the scanned inputs, take necessary decision and
send it to digital / analog outputs. It can also perform
timer, counter, sequencer, PID , and other control
functions. The cost of all this is much less than a
conventional DATA Logger !!
• Versatility :- The ability to combine discrete (Digital)
& Analog logic is a powerful tool for the Control
Engineers. Control of critical start-up parameters, such
as temperature and pressure, can be precisely pre-
programmed for each start-up step.
• As one common device (PLC) performs multiple
functions in a Plant, fewer spare parts are needed.
• Programmable troubleshooting aids reduces downtime.
• The software consist of LAD, which is similar to relay
logic, so even technician can maintain the plant.
• Expandability :- As a process changes, it is inevitable
that changes will be needed or any expansion, these
usually require more outputs.
A PLC can easily change the sequence of process
through software and also accommodates the
additional I/O’s without requiring changes in the
existing wiring ( due to modular design).
If a PID loop is to be added, no panel rework is
necessary; only the wiring of new points and some re-
programming to incorporate them is required.
• Rugged Construction - Can operate in Extremely harsh
field conditions.
• Small in physical Size.
• Pilot Running :-PLC Programme can be simulated
,tested, modified at office if needed, which save valuable
factory time.
• PLC provides error checking & diagnostics. It
periodically carry out internal test to its memory,
processors & I/O system through in-built program.
• Simplicity of ordering Control system components.
• Documentation: An immediate printout of true PLC
circuit, list of inputs & outputs and other client
information is available in minutes, if required.
• Security: A PLC program change cannot be made unless
unlocked and programmed.
 Limitations Of PLC
• People reluctance to change( New technology): It is
difficult to change mind set of people to new
technology.
• Environmental Considerations: Certain process
environments, such as high heat, vibrations, noise level,
interference with electronic devices limit the use of
PLC.
• Fixed circuit operation: If circuit in operation is never
altered, a fixed control system might be less costly than
PLC. The PLC is most effective when periodic changes
in operation are made.
COMPARISION BETWEEN A PLC AND PC
APPLICATIONS