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– Instruction List
– Structured Text
Advantages of PLC’s
• Built specifically for the Industrial Conditions
• Takes less space compared to conventional control panels
• Can be interface with Computers easily
• Date Processing & Reporting Capabilities
• Flexibility in terms of I/O modules
• Easier to program (using ladder logic) & Reprogrammable as well
• Built to last in industry (under rough conditions)
• Highly Reliable
– 1 PLC fails in 1000
Basic Control Diagram
• Some Micro Logix series (or in general some PLC’s) have fixed I/O’s,
thus they are low cost but inflexible
Power Supply
Allen Bradley Control Logix
Power Supply
Control Logix Controllers
• Physical Housing for the CPU, I/O modules and Power Supply
• The back plane provides the paths and electrical connections to connect
modules, power supply and CPU
• Modules can be plugged in and out easily. The ability to quickly change
I/O modules make PLC’s very robust and useful
• Can also handle remote I/O
I/O Modules
• Input Modules:
– Either Analog or Digital (available for DC, TTL Logic and AC)
however AC modules are not commonly used (in case of AC the
PLC converts it into low voltage DC)
Input Output
Module Module
Siemens
S7 Simatic S5 Simatic
Omron & Yokogawa
Applications
• Mainly to replace old hard wired systems with systems
which are more flexible
• Reduce downtime of Process plant.
• Ladder Logic
– A symbolic representation of an Circuit Diagram of Relay logic
hardware
– Mimics Relay logic
• Quite popular because it is quite easy to understand and requires
minimum training of Engineers
• What is a Relay?
– How does a relay operate?
Relays
• Which contact & switch would you use for counting boxes
on a conveyer?
– Normally Open
• Which contact & switch would you use for Home Alarm
system?
– Normally Closed
– Why Normally Closed???
Contacts
• When the rung condition changes from false to true, OSR will be true for once
scan only
• Often used for pulse, timings and to perform operation only in one cycle
– Addition of numbers based on OSR (the numbers will be added only once)
Basic Terminologies
• Coils (Outputs):
– Coils are output symbols
– Output can be off different forms (motor, valves, counters, timers)
– Ladder logic evaluates the inputs and operates the coils based on the
evaluation
– Coils (binary) are of different types:
• Output Energize
• Output latch
• Output Unlatch
• Contacts appear on the left hand side and Coils on the right
Contacts
Ladder Diagram
• Looks quite similar to a step ladder
• Uprights (power rails because they represent power) hold together
different rungs
• Power can flow from left to the right
• PLC will continuously monitor the inputs and generate outputs based on
evaluation
• Consider the following rung, two normally open switches control the
output ‘light’. Explain the operation!!!!
Ladder Diagram
• Multiple Contacts:
– A ladder can have multiple contacts put on the same rung
• Branching:
– Contacts can also be added in parallel to already existing contacts
Scan Times
• This process of monitoring inputs and generating outputs is called scanning
• Scan Cycle:
– First checks all the inputs before it enters the ladder
– Evaluates the logic to decide which outputs have to be changed (however doesn't
toggle them yet)
– Finally changes all the outputs by copying the output image tables to the
corresponding output channel
• The amount of time it takes the PLC to check input, evaluate logic and then update I/O
tables is called scan times
Scan Times
• Scan times can be divided into two parts:
– I/O scan
– Program scan
• Increasing the size and complexity (math operations) increases scan times
• Rockwell Scan Order:
– Input Scan
– Program Scan
– Output Scan
– Service Communication
– Overheads (timers, bits, counters)
Boolean Logic Design
• Objectives:
– Boolean Algebra and Conversion to Ladder Logic
• Boolean Algebra:
– Was developed in 1800 by an Irish Mathematician James Bool
– Found to be very useful in designing digital circuits and is still very commonly
used
• Basic Operators:
– AND, NOT, OR
• Other Operators:
– Exclusive OR, NAND, NOR
Boolean Algebra
• How to convert NAND, NOR and EOR (which don’t have equivalent
descriptions in Ladder logic) to Basic operations
Boolean Logic Ladder Logic
Boolean Logic Ladder Logic
Boolean Logic Ladder Logic
Example with Given Circuit
Example with Given Circuit
• Simplified circuit is then drawn as Ladder logic.
• This ladder logic generates the same outputs and the original complex
function
Multiplexer in Ladder Logic