R. V.

College of Engineering,Bangalore
Department of Electrical and Electronics Engineering

7th Semester
Report on

PROGRAMMABLE LOGIC CONTROLLER

SUBMITTED BY

Balaji Govindaraj Abbigeri 1RV14EC408

1. Introduction:

1.1 Programmable Logic Controllers (PLCs):

A Programmable Logic Controller (PLC) is a specialized computer like device like device
used to replace banks of electromagnetic relays in industrial process control. The PLC is also
knows as a programmable of controller (PC). The title PLC for programmable controller
could be confused in common usage with PC used to mean personal computer. To avoid
this confusion we shall refer to the programmable controller as a programmable logic
controller or PLC.

You can think of the programmable logic controller as a heavy-duty computer system
designed for machine control. Like a general-purpose computer, the plc is based on digital
logic and can be field-programmed .The programming language is a bit different because the
purpose of the PLC is to control machine. The PLC is used to time and sequence function that
might be required in to control machines. The PLC is used to time and sequence function that
might be required in assembly lines, robots, and chemical processing. It is designed to deal
with the harsh condition of the industrial environment. Some of the physical environment
problem could include vibration and shock, dirt, and vapors, and temperature extremes. Some
input device includes limit and pressure switches, temperature and optical sensor, and analog-
to-digital converts (ADCs). Some output device values, motors and cylinders, and Digital-to-
Analog convertors (DAC).

Before the advent of solid-state logic circuit systems were designed and build exclusively
around electronic mechanical relays. Relays are far from obsolete in modern design, but have
been replaced in many of their former roles as logics-level control device, relegated most
often to those applications demanding high current and or high voltage switching.

System and processes requiring on/off control abound in modern commerce and industry,
but such control system are rarely built from either electro mechanical relays or discrete
logics gates. Instead, digital computers fill the need, which may be programmed to do a
variety of logic functions.

In the late 1960s an American company named Bedford Associate released a computing
device they called the MODICON Digital Controller, and later became the name of a
company division devoted to the design, manufacture, and sale of these special-purpose
control computes. Other engineering firms developed their own version of this device, and it
eventually came to be known in non-proprietary terms as a PLC, or Programmable Logic
Controller. The purpose of a PLC was to directly replace electro mechanical relays as logic
elements, substituting instead a solidstate digital computer with a stored program, able to
emulate the interconnection of many relays to perform certain logical task.

A PLC has many input terminals, through which it interprets high and low logical
states from sensor and switches. It also has many output terminals, through which it output
high and low signal to power light, solenoids, contactors, small motors, and other devices
leading themselves to on/off control. In an effort to make PLC easy to program, their
programming language was designed to resemble ladder logic diagrams. Thus, an industrial
electrician engineer accustomed to reading ladder logic schematics would feel comfortable
programming a PLC to perform the same control functions.

PLC are industrial computers, and as such their input and output signals are typically 120
volts AC, just like the electro mechanical control relays they were designed to replace.
Although some PLC has the ability to input and output low-level DC voltage signal of the
magnitude used in logic gate circuits, this the exception and not the rule.

1.2 What is a PLC?

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A Programmable Logic Controller (PLC) is an industrial computer control system that
continuously monitors the state of input device and makes decision based upon a custom
program to control the state of output devices.

Almost any production line, machine function, or process can be greatly enhances using this
type of control system. However, the biggest benefit in using a PLC is the ability to change
and replicate the operation or process while collecting and communication vital information.

Another advantage of PLC system is that it is modular. That is, you can mix and match the type of
Input and Output device to best suit your application

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 According to NEMA (National Electrical Manufacture Association)

PLC is a digitally operated electronic system, designed specially for the use in industrial
environment, which use programmable memory for internal storage of user oriented instruction for
implementing specific function such as logic, sequencing, timing, counting & arithmetic to control,
though digital & analog input &output for various type of machines & processes.

Both the PLC & its associated peripherals are designed so that they can be easily integrated into an
industrial control system & easily used in all intended functions.

Need for PLC

Hardwired panel were very time consuming to time and debug and change.
The following requirement for computer controller to replace hardware panel.
Solid state not mechanical
East to modify input and output device
Easy programmed and maintained by plant electrician
Be able to function in an industrial environment

1.3 History of Programmable Logic Controller (PLCs):

1968: Design of PLCs developed for General Motors Corporation to eliminate costly
Scrapping or assembly line relays during model changeovers.

1969: First PLCs manufactured for automotive industry as electronic equivalent of relays.

1971: First application of PLCs outside the automotive industry.

1973: Introduction of smart PLCs for arithmetic operations, printer control move, Matrix
operations, CRT interface etc.

1974: Introduction of analog PID (Proportional, integral, derivative) control, which made
possible the accessing of thermocouples, pressure sensor etc.

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1975: First use of PLCs in hierarchical configuration as part of an integrated Manufacturing
system.

1977: Introduction of very small PLCs based on microprocessor technology.

1978: PLCs gain wide acceptance, sales approach $ 80 million.

1979: Integration of plant operation through a PLC communication system.

1980: Introduction of intelligent input and output module to provide high speed, accurate
control in positioning applicants.

1981: Data highways enable user to interconnect many PLCs up to 15000 feet from Each
other. More 16-bit PLCs become available. Color graphic CRTs are available from several
suppliers.

1982: Larger PLCs with up to 8192 I/O become available.

1983: Third party peripherals, including graphic CRTs, operators interface, I/O networks,
panel displays, and documentation packages, become available from many sources.

2. Functional Description

A programmable controller manufacture by any company has several common function parts.
Figure illustrates a generic PLC architecture.

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The diagram shows Power Supply, I/O central processor, memory and programming and
peripheral device subsection. Each is discussed below.

2.1 Input

Input define as real-world signals giving the controller real-time status of process variable.
These signals can be analog or digital, low or high frequency, maintained or momentary.
Typically they are presented to the programmable controller as a varying voltage current or
resistance value. Signal from thermocouples (TCs) and resistance temperature dectors
(RTDs) are common examples of analog signals. Some flow meter and strain gauge provide
variable frequency signals, while pushbuttons, limit switches, or even electro mechanically
relays contacts are familiar example of digital, contact closuer type signals. One additional
type of input signal, the register input, reflect the computer nature of the programmable
controller.

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Inputs are device that supply a signal/data to a PLC. Typical examples of input are push
buttons, switches, and measurement devices. Basically, an input device tells the PLC, Hey,
somethings happening out here you need to check this out to see how it affects the control
program.

A discrete input also referred to as a digital input, is that is either in an ON or OFF condition.
Pushbuttons, toggle switch, limit switches, proximity switches, and contact cloures are
examples of discrete sensor which are connected to the PLC discrete input may be referred to
as logic 1 or logic high. In the OFF condition a discrete input may be referred to as logic 0 or
a logic low.

An analog input is a continuous, variable signal. Typically analog inputs may vary from 0 to
20 milliamps, 4 to 20 milliamps, or 0 to 10 volts. In the following example, a level
transmitter monitors the level of liquid in a tank. Depending on the level transmitter, the
signal to the PLC can either increase or decrease as the level increases or decreases.

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 2.2 Output

There are three common categories of outputs: Discrete, Register, and Analog. Discrete
output can be pilot light, solenoid valves, or enunciator Windows (lamp box). Register output
can be drive panel meters or displays; analog outputs can drive signals to variable speed drive
or to I/P converters and thus to control values.

Outputs are device that await a signal/data from the PLC to perform their control function
light, horns, motors, and values are all good examples of output devices. These device stay
put, minding their own business until the PLC says, You need to turn on now or youd
better open up your value a little more, etc.

A discrete output is an output that is either in an ON or OFF condition. Solenoids, contactor

coils, and lamps are examples of actuator device connected to discrete outputs. Discrete
outputs may also be referred to as digital outputs. In the following example, a lamp can be
turned on or off by the PLC output it is connected to.

An analog output is a continuous, variable signal. The output may be as simple as a 0-10
VDC level that drives an analog meter. Examples of analog meter output are speed, weight,

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and temperature. The output signal may also be used on more complex application such as a
current-to-pneumatic transducer that controls an air-operated flow-control value.

The PLC program is executes as part of a repetitive process referred to as scan. A PLC scan
starts with the CPU reading the status of inputs. The application program is executed using
the status of the inputs. Once the program is completed, the CPU performs internal
diagnostics and communication tasks. The scan cycle ends by updating the outputs, and then
stars over. The cycle time depends on the size of the program, the number of I/Os, and the
amount of communication required.

2.3 Control Processor Unit (Real Time):

The central processor unit (CPU), or central control unit (CCU), perform the tasks necessary
to fulfill the PLC function. Amount these are scanning, I/O bus traffic control, program
execution device communication, special function or data handling execution (enhancement),
and self-diagnostics.

One common way of rating how a PLC perform these task is it scan time> Scan time is
roughly defined as the time it takes for the programmable controller to interrogate the input
device, execute the application program, and provide updated signals to the output devices.
Scan time can vary from 0.1 millisecond 1K (1024) word of logic to more than 50
millisecond per 1K of logic. Therefore, when selecting a programmable controller other
performance factor must be considered. The user should take into account the application as
well as the speed of the controller.

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 2.4 Memory unit:

The memory unit of the PLC serves several functions. It is the library where the application
program is store. It is also where the PLCs executive is stored. An executive program
functions as the operating system of the PLC. It is the program that interprets, manages, and
executes the users application program. Finally, the memory unit is the part of the
programmable controller where process data from tables. Typically, an image of these data
tables. Typically, images of these data tables are used by the CPU and, when appropriate,
send to the output modules.

Memory can be volatile or non-volatile. Volatile memory is erased if power is removed.

Obviously this undesirable, and most units with volatile memory provide battery back up to
ensure that there will be no loss of power outage. Non-volatile memory does not change state
on loss of power and is used in cases in which extended power outages or long transportation
time to job site (after program entry) are anticipated.

The basic programmable controller memory element is the word. A word is collection of 4, 8,
16, or 32 bits that is used to transfer data about the programmable controller. As word length
increase more information can be stored in a memory location.

2.5 Programmer Units:

The programmer unit provides an interface between the PLC and the user during program
development, start-up, and troubleshooting. The instruction to be performed during each scan
are coded and inserted into memory with the programmer.

Programmers vary from small hand-held units. These units the size of a large calculator to
desktop standalone intelligent CRT-based units. These units come complete with
documentation, reproducing, I/O status, and on-line and off-line programming ability. Many
PLC manufactures now offer controller model that can use a personal computer as the
programming tool.

Under these circumstance, the manufacture will sell a program for the personal computer that
usually allows the computer that module installed in programmable controller.

Programming units are the liaison between what the PLC understands (words) and what the
engineer desired to occur during the control sequence. Some programmers have the ability to
store programs on other media, including cassette tapes and floppy disks. Another desirable
feature is automatic documentation of the existing program. This is accomplished by a printer
attached to the programmer. With off-line programming the user can write a control program
on the programming unit, then take unit to the PLC in the field and load the memory with
new program, all without removing the PLC. Selection of these feature depends on user
requirement and budget. On-line programming allows caution modification of the program
while the PLC is controlling the process or the machine.

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 3. General PLC Architecture:

PLC inputs must convert a variety of logic levels to the 5V dc logic level used on the data
bus. This can be done with circuit similar to those shown below. Basically the circuit
conditions the input to drive an up to coupler. This electrically isolates the external electrical
circuitry from the internal circuitry. Other circuit components are used to guard against
excess or reversed voltage polarity.

PLC output must convert the 5V dc logic levels on the PLC data bus to external voltage
levels. This can be done with circuits similar to those shown below. Basically the circuit uses
an opto coupler to switch external circuitry. This electrically isolated the external electrical
circuitry from the internal circuitry. Other circuit components are used to guard against
excess or reversed voltage polarity.

Advantage of PLC:

Small size
Faster response
Wiring reduced up to 80%
On-line changes
Low Maintenance Cost
Easy for Troubleshooting

Disadvantages of PLC:

Too much work required in connecting wires

Difficulty with change or replacement
Requiring skilful work force finding error

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 Fixed program application

Reference

1. Internet Advertisement.

2. College Seminar.

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