What is a PLC?

A Programmable Logic Controller is a microprocessor - based system, used to control machines and processes, in a wide variety of industries.

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Formal Definition of PLC A digitally operating electronic apparatus, A digitally operating electronic apparatus, which uses a programmable memory for the which uses a programmable memory for the internal storage of instructions, for implementing internal storage of instructions, for implementing specific functions, such as: logic, sequencing, specific functions, such as: logic, sequencing, timing, counting, and arithmetic, to control, timing, counting, and arithmetic, to control, through digital or analog input/output modules, through digital or analog input/output modules, various types of machines or processes.* various types of machines or processes.*
* According to NEMA (National Electrical Manufacturing Association)
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Historical Development of PLC

The first PLC was designed by Gould Corporation in 1968 for General Motors (GM). The main reason for their design was to replace hardwired electrical relays used to control automatic transfer lines. Thus instead of rewiring relays, reprogramming is employed to change the sequence of machine operation. They are designed for ease of programming and maintenance. The first controllers were capable of ON/OFF control only. Analog signal processing supported. Communication capabilities introduced. State-of-the-art PLCs are capable of advanced functions, and the trend in their development is towards computer capabilities.
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Hardware Components of PLC

Main Components: 1. Central Processing Unit (CPU) 2. Memory (ROM, RAM, EPROM, EEPROM,...) 3. Input modules (DI, AI) Power 4. Output modules (DO, AO) Supply 5. Power supply (PS)

Sensors

Program Memory

CPU

Input Module

Output Optional Components: Module Processor 6. Programming device (PG.) Actuators 7. Special Modules: Communications Processor (CP): (PC, modem, Printer, PLC, Network, ..etc.) Simulators Interface Modules (IM): Local Expansion, Remote/distributed I/O Function Modules: HSC, Closed loop control, Weighing, positioning

Bus System

8 . Operator panel (HMI).

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Why Use PLCs?

Programming Flexibility Easier Trouble shooting reduces downtime High Reliability ( High MTBF) Space saving Computational capabilities Cost effective Ability to withstand harsh environment Expandability and Modularity
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Principle of Operation of a PLC

Cyclic Scan
1. Read All Inputs 2. Store Inputs in PII 3. Process Program 4. Store outputs in PIQ 5. Update Physical Outputs

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Criteria For Selecting a PLC Number of Inputs and Outputs Memory Capacity Scan Time Expansion Capabilities Special Expansion Modules Communication Capabilities Software Working Environment Vendor Support & Services Cost
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