PLC was introduced in late 1960s

First commercial & successful Programmable Logic

Controllers was designed and developed by Modicon as a
relay replacer for General Motors.
Earlier, it was a machine with thousands of electronic parts.
Later ,in late 1970s,the microprocessor became reality &
greatly enhanced the role of PLC permitting it to evolve form
simply relay to the sophisticated system as it is today.
How does a PLC differ from a
computer ?
A computer is optimized for calculation and display
tasks.
A computer is programmed by specialists
A PLC is designed for (logic) control and regulation
tasks.
A PLC is programmed by non-specialists
A PLC is well adapted to industrial environment.
BLOCK DIAGRAM OF PLC
 Components of PLC :
1. Inputs Circuits
2. Outputs Circuits
3. CPU (Central Processing Unit )
4. Memory for program and data storage
5. Programming device
6. Communication Device
7. Power Supply
 Input / Output Modules

Digital input modules adapt digital signals e.g. from proximity

sensors

Digital output modules convert the internal signal level of PLC

into digital process signals e.g. Relays

Analog input modules adapt analog process signals e.g. from

transducers

Analog output modules convert internal digital values of the PLC

to analog process signals e.g. temperature controller
Central Processing Unit (CPU)

What is a CPU?

The brain of a PLC

Controlled by a program called the executive or
operating system (OS)
The executive is a collection of supervisory programs
permanently stored in memory
 CPU

Four basic types of CPU operations:

Input and output operation

Arithmetic and logic
Reading or changing contents of memory locations
Jump operations
 Power Supply
A power supply of 120v ac is typically used to drive
the PLC (some units operate on 240v ac).

The power supply converts the 120v ac into dc

voltages of +5v.

These low voltages are used to operate equipment

that many have much higher voltage and power
ratings than the PLC itself.
 Scan Cycle of
PLC
Read input

The Scan is a
continuous
Adjusts Run
output
and sequential Program
process
Disadvantages of PLCs
PLC devices are proprietary it means that part or
software of one manufacturer cant be used in
combination with parts of another manufacturer.
Limited design and cost option
Fixed Circuit Operations.
PLCs manufacturers offer only closed architectures.
Wherever automation is desired the PLCs are best
suited to meet the task.

Few examples of industries where PLCs are used :

1) Robots manufacturing and control
2) Car park control
3) Train control station system
4) Food processing
5) Materials handling
6)Machine tools
7)Conveyer system etc.
TYPES OF PLCS
 There are three types of PLC.
1. Unitary PLC

2. Modular PLC

3. Rack Mounted PLC :

 Unitary PLC
It contains every feature of a basic system in one box.
They are attached to the machine being controlled.
Advantages:
1. Less scanning time
2. Fixed versions are usually small, have less memory so
cost in less .
3. Less troubleshooting time so less downtime.
Disadvantages :
1. A limited number of inputs and outputs.
2. It is not suited for future expansion.
3. If part of the unit fails, it will take much time and
effort to repair, and the entire unit may need replacing.
 Modular PLC
It s a range of modules that slot together to build up a system.
The basic are the power supply, the main module containing the
CPU, the input and output module.
Advantages:
1. Great flexibility in choice of modules. Modules can be easily
installed or removed without affecting other modules
2. The main advantage is that more Input and output terminals can
be expanded.
Disadvantages :
1. Scanning time increases with the increase in input and output
modules.
 Rack Mounted
PLC
This is similar concept to the modular design but the modules
are on standard cards that slot into a standard rack inside a
cabinet. These are flexible and allow expansion of the system.
Leading Brands Of PLC
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D

EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique

JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi
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Thank You!!!