Programmable Logic Controller

(PLC)
By
NISHANT V. CHAUDHARI
M.A.E. ALANDI
 PLC
• NEMA defines a PROGRAMMABLE LOGIC
CONTROLLER as:
“A digitally operating electronic apparatus which
uses a programmable memory for the internal
storage of instructions by implementing specific
functions such as
– logic sequencing
– timing
– Counting
– arithmetic to control
through digital or analog input/output modules,
various types of machines or processes”.
 PLC History
• The Hydramatic Division of the General
Motors Corporation specified the design
criteria for the first programmable
controller in 1968
• Their primary goal was to eliminate the
high costs associated with inflexible, relay
controlled systems
• The specifications required a solid-state
system with computer flexibility able to:
1. Survive in an industrial environment.
2. be easily programmed and maintained by
plant engineers and technicians.
3. be reusable
• Such a control system would reduce
machine downtime and provide
expandability for the future
• Some of the initial specifications included the
following:
– The new control system had to be price competitive with the use
of relay systems.
– The system had to be capable of sustaining an industrial
environment.
– The input and output interfaces had to be easily replaceable.
– The controller had to be designed in modular form, so that
subassemblies could be removed easily for replacement or
repair.
– The control system needed the capability to pass data collection
to a central system.
– The method used to program the controller had to be simple, so
that it could be easily understood by plant personnel.
– The system had to be reusable.
 Conceptual Design of PLC
• The first programmable controllers were more or less
just relay replacers.
• Their primary function was to perform the sequential
operations that were previously implemented with relays
• These operations included ON/OFF control of machines
and processes that required repetitive operations, such
as transfer lines and grinding and boring machines etc.
• These programmable controllers were a vast
improvement over relays
• They were easily installed, used considerably less space
and energy, had diagnostic indicators that aided
troubleshooting, and unlike relays, were reusable if a
project was scrapped.
 Today’s PLC
• Many technological advances in the
programmable controller industry continue today.
• These advances not only affect programmable
controller design, but also the philosophical
approach to control system architecture.
• Changes include both hardware (physical
components) and software (control program)
upgrades
• The following list describes some recent PLC
hardware enhancements:
– Faster scan times are being achieved using new,
advanced microprocessor and electronic technology.
– Small, low-cost PLCs, which can replace four to ten
relays, now have more power than their predecessor,
the simple relay replacer.
– High-density input/output (I/O) systems provide
space-efficient interfaces at low cost.
– Intelligent, microprocessor-based I/O interfaces have
expanded distributed processing.
– Typical interfaces include PID (proportional integral-
derivative), network, CAN-bus, field-bus, ASCII
communication, positioning, host computer, and
language modules
 Hardware Components of a PLC
System
• Processor unit (CPU)
• Memory
• Input/Output modules
• Power supply unit
• Programming device
• Communication modules
• Remote I/O modules
PLC Block Diagram
Major CPU Components
Input Output Interface
Functional Interaction of PLC system
Programming Devices
Typical Areas Of Application
Typical Areas Of Application
 Market share

% installed PLCs

Micro: 15 to 128 I/O points 32%

Medium: 128 - 512 I/O points 29%
Large: > 512 I/O points 20%
Nano: < 15 I/O points 7%
PC-based 6%
Software PLC 4%
Embedded control 2%
Type of PLCs
Micro PLC
Small PLC
Medium PLC
Large PLCs
Large PLCs
Very Large PLCs
Global players
 PLC Programming Languages
As Per IEC 61131-3 Standard

• Ladder Diagram (LD)

• Sequential Function Chart (SFC)
• Function Block Diagram (FBD)
• Structured Text (ST)
• Instruction List (IL)
Ladder Diagram
 TON
Timer On Delay EN
Timer ? DN
Preset ?
Accum ?
TONR_01
?? TONR ...
?
Timer On Delay with Reset
0
TimerEnable ACC ?
?? 0
? PRE DN

Reset

??
?
Structured Text
TONR_01.Preset := 500;
TONR_O1.Reset := reset;
TONR_01.TimerEnable :=
limit_switch1;
TONR(TONR_01)
timer_state := TONR_01.DN;
I/O connection Diagram
PLC System
Local Rack Configuration
Remote Rack Configuration
I/O Addressing
Logic Functions (AND)
OR Function
NOT
Example of hardwiring changes as
opposed to soft wiring changes
PLC Scan

Read the Data from Sensors

or Input Devices

Execute the user’s Logic

Program

Update the output Devices or

Actuators
System Programming and
Implementation
PLC Panel
Control System Organization
Individual Control
Centralized Control
Distributed Control