Programmable Logic Controllers

Prepared By:
Prof. Brijesh Naik
M.Tech. (systems & control IIT Bombay)
Email nbrijesh77@rediff.com
July 2011
 PLC
The PLC is a small, microprocessor-based
process-control computer that can be
connected directly to such devices as
switches, small motors, relays, and solenoids,
and it is built to withstand the industrial
environment.
Basically designed to handle sequential
operations.
Event Based Control/Event oriented control.
The Relay Logic
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A flip-flop can be made from a relay using a principle
called sealing. As seen in Figure 12.3(d), once the relay
is energized, an electrical path through the contacts
takes over the job of providing power to the coil, and
the original A voltage can be removed.
(This process is frequently called latching. However, a
relay catalog uses the term latching relay to mean a
relay that has a built-in mechanical-latching
mechanism.)
To unseal the relay, the power coming through the
contacts must be (temporarily) removed.
The PLC system
 The Ladder Diagrams
Switches and relays became widely used in
industry for controlling motors, machines, and
processes.
A switch can turn a single machine on and off, but
a relay logic network can control an entire
processturning on one machine, waiting until
that operation is done, then turning on the next
operation.
Eventually, the ladder diagram, a special type of
wiring diagram, was developed for relay-and-
switching control circuits.
A Ladder Diagram
Examples of Ladder Programming
Ex 12.1
Ex. 12.2
Ex 12.3
PLC and Components
IO Modules
Continued..
Analog IO
Simple PLC operation with Ladder
Diagram
Input and Output Image Table
 Relay Logic Ladder Diagram and PLC
Ladder Diagram
There is an important fundamental difference between
a relay logic ladder diagram and a PLC ladder diagram.
The relay ladder diagram is basically a wiring diagram,
and a rung becomes active when current can flow from
one power rail to the other; that is, if there is a path for
the current through the contacts, then the load will be
energized.
On the other hand, the PLC ladder diagram is basically
a logic diagram consisting of symbols (called input and
output instructions), and a rung becomes continuous
when there is a logical TRUE path from rail to rail.
Bit Instructions
Batch Mixer
Continued..
 The sequencer
The Sequencer instruction is used when a repeating sequence of
outputs is required.
The Sequencer instruction allows the PLC to implement this
common control strategy.
Operation is as follows: The desired output-bit patterns for each
step are stored (sequentially) as words in memoryas usual, each
bit in the word corresponds to a specific terminal of the output
module.
Every time the Sequencer instruction steps, it connects the next
output pattern in memory
to the designated output module. The address of the first pattern
(word) in the
sequence is given in the Sequencer instruction as the Sequencer
File Address.
The sequencer instructions.
Example of sequencer
Operation overview
solution
An Example of Heater
The PID instruction
Programming Methods and Syntax
Programming Methods
PLC and Networks
PLC and Networks
PLC and Networks
PLC and Networks
Master Control Relay
Communication N/w
topology
Control hierarchy
Cycle time of PLC
 PLC operations
The time taken to complete a cycle of scanning inputs
and updating outputs according to the program
instructions, i.e. the cycle time, though relatively quick,
is not instantaneous and means that the inputs are not
watched all the time but samples of their states taken
periodically.
It also means that if a very brief input cycle appears at
the wrong moment in the cycle, it could be missed.
In general, any input must be present for longer than
the cycle time. Special modules are available for use in
such circumstances.
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Consider a PLC with a
cycle time of 40 ms.
What is the maximum
frequency of digital
impulses that can be
detected?
The maximum
frequency will be if
one pulse occurs every
40 ms, i.e. a frequency
of 1/0.04 = 25 Hz.
PLC switches symbols
Plant Automation
Switches Symbols
PLC operations on Bits
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Shift operations on bits
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applications
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