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Name
Id
: EE091198
College
Unit Code
Course
(Hons)
: COE
: EEIB 413
: Bachelor of Electrical and Electronics Engineering
Unit Title
Year/ Semester
: Year 4 / Semester 1
Lecturer
Session
: Sem2 2015/2016
Figure 1
PLC definitions
PLC is a programmable microprocessor-based device that is used in discrete
manufacturing to control assembly lines and machinery on the shop floor as well as many
other types of mechanical, electrical and electronic equipment in a plant. A PLC is typically
designed for real-time use in rugged, industrial environments. Connected to sensors and
actuators, PLCs are categorized by the number and type of I/O ports they provide and by their
I/O scan rate.
Block diagram
Figure 2
A simplified block diagram of a PLC shown in above Fig. It has three major
units/sections.
The input section converts the field signals supplied by input devices/sensors to
logic-level signals that the PLC's CPU can read.The Processor Section reads these inputs,
Processes the signal, and prepares the output signals.
The output section converts the logic level output signals coming from processor
section to high level signals and used to actuate various output field devices. The
programmer/monitor is used to enter the user's program into memory and to monitor the
execution of the program.
The processor, the heart of CPU is the computerized part of the CPU in the form of
Microprocessor / Micro controller chip. It supervises all operation in the system and performs
all tasks necessary to fulfill the PLC function.
reads the information i.e status of externally connected input devices with
input module.
stores this information in memory for later use.
carries out mathematical and logic operations as specified in application
program.
After solving the user's program, it writes the result values in the memory.
sends data out to external devices like output module, so as to actuate field
hardware.
performs peripheral and external device communication.
Performs self diagnostics.
The power supply provides power to memory system, processor and I/O Modules.
Programming device
The I/O section establish the interfacing between physical devices in the real world
outside the PLC and the digital arena inside the PLC.
The input module has bank of terminals for physically connecting input
devices, like push buttons, limit switches etc. to a PLC. the role of an input module is to
translate signals from input devices into a form that the PLC's CPU can understand.
The Output module also has bank of terminals that physically connect output
devices like solenoids, motor starters, indicating lamps etc. to a PLC. The role of an output
module is to translate signals from the PLC's CPU into a form that the output device can use.
devices can be added if needed. The actual operating process under PLC Control can be
thousands of feet from the CPU and its I/O modules.
The networks communicate between peripherals through a variety of cables which all
have individual advantages and are important factors when considering their application.Most
PLC networks operate in industrial environments and therefore many considerations have to
be taken into account such as protection, speed of communication and interference properties.
This is to ensure the cable will perform to its highest capabilities and meet the requirements
of the network processing. Types of wiring used are:
Coaxial cable
Coaxial cable looks similar to the cable used to carry TV signal. A solid-core copper
wire runs down the middle of the cable. Around that solid-core copper wire is a layer of
insulation covered by braided wire and metal foil, which shields against electromagnetic
interferences. A final layer of insulation covers the braided wire
Twisted-pair cable
Twisted-pair cable is the most common type of cabling you can see in today's Local
Area Networks (LAN) . A pair of wires form a circuit that can transmit data. The pairs are
twisted to provide protection against crosstalk which is generated by adjacent pairs. When
a wire is carrying a current, the current creates a magnetic field around the wire. This
field can interfere with signals on nearby wires. To eliminate this, pairs of wires carry
signals in opposite directions, so that the two magnetic fields also occur in opposite
directions and cancel each other out. This process is known as cancellation.
Two Types of Twisted Pairs are Shielded Twisted Pair (STP) and Unshielded Twisted
Pair (UTP).Unshielded twisted-pair (UTP) cable is the most common networking
media.Unshielded twisted-pair (UTP) consists of four pairs of thin, copper wires covered
in color-coded plastic insulation that are twisted together.
Optical Fibre cables use optical fibres that carry digital data signals in the form of
modulated pulses of light. An optical fibre consists of an extremely thin cylinder of glass,
called the core, surrounded by a concentric layer of glass, known as the cladding. There
are two fibres per cable-one to transmit and one to receive. The core also can be an
optical-quality clear plastic, and the cladding can be made up of gel that reflects signals
back into the fibre to reduce signal loss.
There are two types of fibre optic cable which id Single Mode Fibre (SMF) and
Multi-Mode Fibre (MMF).
Introduction
Ladder logic is widely used to program PLCs, where sequential control of a process
or manufacturing operation is required. Ladder logic is useful for simple but critical
control systems or for reworking old hardwired relay circuits. As programmable logic
controllers became more sophisticated it has also been used in very complex automation
systems.
The motivation for representing sequential control logic in a ladder diagram was to
allow factory engineers and technicians to develop software without additional training to
learn a language or other general purpose computer language. Development, and
maintenance, was simplified because of the resemblance to familiar relay hardware
systems. Implementations of ladder logic have characteristics, such as sequential
execution and support for control flow features, that make the analogy to hardware
somewhat inaccurate. Manufacturers of programmable logic controllers generally also
provide associated ladder logic programming systems. Ladder logic is better thought of as
a set of closely related programming languages rather than one language.
Ladder logic can be thought of as a rule-based language rather than a procedural
language When implemented with relays and other electromechanical devices, the various
rules execute simultaneously and immediately. When implemented in a programmable
logic controller, the rules are typically executed sequentially by software, in a continuous
loop (scan). By executing the loop fast enough, typically many times per second, the
effect of simultaneous and immediate execution is achieved.
The different between PLC physical ladder diagram and PLC programmed ladder
diagram
contact
coil
input
Figure 3
Contact relays
Figure 4
Normally-closed pushbutton switches are just the opposite: they open (stop current)
when actuated (pressed) and return to their normal (closed, passing current) state when unactuated.
This is simple enough to comprehend: the normal status of a momentary-contact
pushbutton switch is the state it is in when no one is touching it. When pressed, the
pushbutton switch goes to the other (opposite) state.
Input relay, output relay, internal relay, timer relay and counter relay.
Input Relays
These are connected to the outside world. They physically exist and receive signals
from switches, sensors, etc. Typically they are not relays but rather they are transistors.
Output Relays
These are connected to the outside world. They physically exist and send on/off signals
to solenoids, lights, etc. They can be transistors, relays, or triacs depending upon the model
chosen.
These do not receive signals from the outside world nor do they physically exist. They
are simulated relays and are what enables a PLC to eliminate external relays. There are also
some special relays that are dedicated to performing only one task. Some are always on while
some are always off. Some are on only once during power-on and are typically used for
initializing data that was stored.
Timer Relays
These also do not physically exist. They come in many varieties and increments. The
most common type is an on-delay type. Others include off-delay and both retentive and nonretentive types. Increments vary from 1ms through 1s.
Counter Relays
These again do not physically exist. They are simulated counters and they can be
programmed to count pulses. Typically these counters can count up, down or both up and
down. Since they are simulated they are limited in their counting speed. Some manufacturers
also include high-speed counters that are hardware based. We can think of these as physically
existing. Most times these counters can count up, down or up and down.