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MOHD FAIRUS BIN ABDOLLAH
Intro to Programmable Logic Controller (PLC)
PLC = Programmable Logic Controller / Programmable
Controller
Relay
control
panel
PLC
control
panel
Principle operation of PLC
Principle operation of PLC
Increased Reliability:
Relays are electromechanical devices -
physical wear and tear occurs every time it
active.
More Flexibility:
Lower Costs:
Originally PLCs were designed to replace relay
control logic. The cost savings using PLCs have
been so significant that relay control is becoming
obsolete, except for power applications.
Generally, if an application
requires more than about
6 control relays, it will
usually be less expensive
to install a PLC.
Advantages of a PLC Control System
Communications Capability:
A PLC can communicate with other controllers
or computer equipment.
They can be networked
to perform such functions
as: supervisory control, data
gathering, monitoring
devices and process
parameters, and
downloading
and uploading of programs.
Advantages of a PLC Control System
ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 5
1)Single-ended
2)Multitask
3)Control management
Application : Single-Ended
Involves one PLC controlling
one process
PLC
Stand-alone unit PLC
cannot be used for Process
communicating with other
PLCs
PLC Configurations
ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 9
Modular
I/O Configurations
Fixed
ns
Modular I/O
When a module
h slides
lid into
i the
h
rack, it makes an
electrical
connection with a
series of contacts
- called the
l backplane The
backplane.
backplane is
y located at the rear
of the rack.
s 5
PLC Hardware Configurations
1. Fixed type
One small package, no
separate/removable units
Processor & I/O packed together
Low cost
Lack of flexibility fixed number of I/O
Might need to replaced the whole unit if
any part in the unit fails.
Fixed Type PLC
ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 9
Modular I/O
2. Modular type When a module
slides
lid into
i the
h
rack, it makes an
Power Supply
Input
Programming
& Output
Processor
Memory
(I/O)
Devices
modules
Power Supply
- 240V/115V AC used to power up PLC
- Power supply convert AC voltage
into low DC voltage (24V/12V/5V)
- For small & micro PLC, power supply
used to power up I/O devices
- For large & complex system, power
for I/O devices is provided by
external AC/DC supplies
Processor / CPU
- Brain of PLC
- Executes the operating system,
manages memory, monitor
inputs, evaluate the user logic
(ladder diagram), activate
appropriate outputs and
communicate with other
module.
- Processor/CPU required OMRON CPU
memory for storing data &
program.
Memory
- A physical space inside the CPU where the program
files and data files are stored and manipulated.
- Program and data are stored in bits either 1s or 0s.
Memory
Volatile (Changeable)
Categories Non-volatile (Fixed)
ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 9
Modular I/O
When a module
slides
lid into
i the
h
rack, it makes an
electrical
connection with a
series of contacts
- called the
backplane The
backplane.
backplane is
located at the rear
of the rack.
ENGG3490: Mechatronics W07. Addapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 10
Provide connection to the machine & process
I/O devices or feld devices are connected to I/O modules
Input & Output Interface Modules
Output interface module convert PLC signals
into external signals used to control the
machine or process.
Input interface module - accept signals from
the machine or process devices and convert
them into signals that can be used by the PLC
Input & Output Interface Modules
Input & Output Interface Modules
Input devices
(push button, limit
switches, various
of sensors, etc) are
wired /connected
to the terminal on
the input modules
Input & Output Interface Modules
Output devices
(motor, light,
valve, motor
starter, etc) are
wired/connected
to terminal on the
output modules
Input & Output Interface Modules
- I/O modules can be located near the field devices by
using Remote I/O hence minimizing wiring connection.
Input & Output Interface Modules
Analog
Discreet
Special
Language TTL
Special
Communic
ation I/O Encoder-
Counter
modules Basic/
Servo
ASCII
Stepper
PID
motor
BCD output
Programming Devices
Handheld/
Console
PLC
Programming
device
PC
software
Software
manufacturers
Uses parallel/serial com
Easier to create, edit,
store, document &
troubleshoot programs
Large display
Program either in DOS /
Windows environment
Programming Device
Console Software