Programmable Logic Controller (PLC): The Future in Automation Control

Figure 1. PLC System Overview1 Kyle Emerson ENGL 202C 3/27/2014

Audience and Scope

This document is intended to assist electrical engineering students who are taking courses that specialize in controls engineering. This description would appear in an Introduction to Controls Engineering textbook and would inform students about the basics of PLCs. While nested within a control system chapter, this will provide the text with an explanation of what a PLC is, what components are incorporated, and how it operates.

Introduction: What is a Programmable Logic Controller (PLC)?

A Programmable Logic Controller, otherwise known as a PLC, is a special, digital computer used for automatic control of electromechanical processes and devices. These processes and devices operate within mechanical systems, but are controlled electrically. The PLC was designed to replace sequential, hardwired relay circuits that were used to control industrial manufacturing systems. In the past, when changes needed to be made to a system, the entire circuitry needed to be rewired and reconfigured by unplugging devices and physically moving them around. PLCs execute tasks by performing the logical operations within a software program instead of with real components. With this realization, PLCs not only lower costs by reducing the number of components needed, they provide a more flexible way to adjust and make changes to existing systems. PLCs are used in several industries like manufacturing lines, robotics, and production processes where they control pneumatic machines, hydraulic pumps, conveyor belts, and so on. In order to fully understand this complex device, the main components are introduced before the process of operation is explained.

Figure 2. PLC Hardware Diagram2

PLCs Main Components

1. Power Supply & Rack The power supply provides steady DC power to the CPU and other modules that are attached to the rack. A typical power supply will work with 120 VAC or 24 VDC sources. However, with the small electronic circuitry involved with PLCs, the power supply will reduce the voltage to supply around 1-15VDC. The rack, shown in Figure 2, holds all the components of the PLC together. I/O modules are attached and the rack can be extended to include as many modules required of the system. The rack includes communication links to help the modules communicate information to the CPU for processing and program execution. 2. Central Processing Unit (CPU) The CPU can be thought of as the brain of the PLC. It controls all the operations in the PLC and executes the logic stored in memory. The CPU is typically located on the rack next to the power supply, as seen in Figure 2. CPUs vary in complexity and contain several internal structures including: i. Arithmetic Logic Unit (ALU): Most CPUs contain an ALU which performs mathematical operations such as adding, subtracting, multiplying, dividing, and comparing. Microprocessor: The microprocessor of the CPU is the device that carries out the program by controlling complex functions and communicating to the I/O modules. a. The microprocessor is clocked with a clock line which helps regulate the rate at which it performs its operations. b. A reset line is hard-wired to the microprocessor and will reset the program when activated. Memory Chip: The CPU needs to have a memory chip, to ensure that data is stored properly and efficiently. This chip contains registers that store system memory, I/O status memory, and user control information. Data can be written or read from these registers and used to manipulate the system. a. A register is a temporary memory location where data can be stored for handling later. Other Integrated Circuits (ICs): These ICs will help monitor input/output processing and also aid communications within the CPU.

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3. Input/Output (I/O) Modules & Assembly The I/O modules, sometimes called I/O cards, provide the physical connection from the PLC to the I/O devices and equipment. These modules are extremely important since they provide the interface between high voltage devices and machines in the real world and low power microelectronics within the controller. To do this, the modules will condition the input and output signals to isolate them from the circuitry in the PLC.

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I/O assemblies use opto-isolator circuits which allow small signals to reach the CPU to reduce the effects of voltage spikes generated from the input sources.

Figure 3. PLC Scanning Process4

How A PLC Works

A PLC operates by using a scanning process to execute commands within the program. This process is illustrated above in Figure 3. One cycle through this program is called one scan time and this happens very quickly, milliseconds or less. The process repeats itself as long as the program continues to run. A scan cycle can be simplified into a culmination of three main steps. These steps include, checking the inputs, executing the program, and updating the outputs. 1. Check Input Status The scan cycle begins when the PLC samples the status on the input terminals. Typically, the inputs originate from other modules or feedback sensors. For digital or discrete signals, the input is read from sensors that determine if something is in an ON or OFF state depending on whether it is energized or not. These types of sensors include simple switches, proximity switches, physical relays, and so on. For analog, continuoustime, signals the numerical value is read from a feedback sensor and stored in the memory of the PLC to be manipulated later. These sensors monitor parameters such as position, temperature, speed, pressure, voltage, current, etc. All of these inputs provide necessary information for the PLC to operate its program. 2. Execute The Program The PLC then takes the information from the input terminals and executes the logic in the program. Each instruction within the program is completed in sequential order. Through the programmable logic, the inputs will trigger certain tasks and logic operations such as timers, counters, comparators, or internal relay systems to change the status of the outputs

in the system. The CPU will control all of the operations of the PLC based on the program stored in its memory. 3. Update Output Status The final step in this scanning process is to update the outputs based on the status presented in the PLC program. Again, after determining the status of the inputs and executing the logic in the program, the outputs will turn ON or OFF. These output signals are connected to electromechanical devices such as DC motors, AC motors, solenoid valves, lights, alarms, linear electric actuators, and many more. In most systems, these output devices will be monitored with sensors to provide feedback for automation control, as seen in Figure 4.

Figure 4. PLC Block Diagram3

Conclusion
PLC-based control systems have incredible advantages over other automation control systems. This device offers excellent flexibility, fast error detection, and the ability to make simple changes. It also provides faster operating speed and increased reliability. Within the PLC, the CPU, I/O Assembly, and power supply and rack all work together to perform repeated scanning cycles by sampling the inputs, executing the program, and setting the outputs. PLCs are very complex devices, but with basic training and practice, one can begin using PLCs to control some of the more complex systems in industry.

Works Cited: Figure 1: http://www.pacontrol.com/PLC.html Figure 2: http://www.plcdev.com/book/export/html/9 Figure 3: http://johndayautomotivelectronics.com/how-signal-chains-and-plcs-impact-our-lives/ Figure 4: http://selectautomation.blogspot.com/2009/11/plc-basic-block-diagram_26.html