TABLE OF CONTENTS

1. Introduction 2. History 3. Basic block diagram 4. Operating principle 5. Ladder Logic 6. Storage Memory 7. Timer 8. Counter 9. Basic Motors using Ladder Logic 10.References.

Introduction:A Programmable Logic Controller is a digital computer used for automation of electromechnical process,such as control of machinery on factory assembly lines.A PLC is an example of a hard real time system since output result must be produced in response to input conditions within a bounded time.Main objective of PLC in industries are the implementation of all process & trip logics & interlock.Interlock is the cause and effect matrix logic for process safety.The PLC acquires data,executes cause & effectlogic and produce output as required for the safe operation of the process.Here programme refers to a sequence of instructions that can interpret and execute.Logic refers to the tool which is used to distinguish between the truth and false.Controller refers to the equipment concerned with controlling the operation of an electrical device.

History of PLC:Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was accomplished using hundreds or thousands of relay, cam timers, drum sequencers, and dedicated closed-loop controllers. The process for updating such facilities for the yearly model change-over bwas very time consuming and expensive, as electricians needed to individually rewire each and every relay.Digital computers, being general-purpose programmable devices, were soon applied to control of industrial processes. Early computers required specialist programmers, and stringent operating environmental control for temperature, cleanliness, and power quality. Using a general-purpose computer for process control required protecting the computer from the plant floor conditions. An industrial control computer would have several attributes: it would tolerate the shop-floor environment, it would support discrete (bit-form) input and output in an easily extensible manner, it would not require years of training to use, and it would permit its operation to be monitored.The automotive industry is still one of the largest users of PLCs.

Basic block diagram:-

Operating principle:First,the PLC sequentially scans the input devices and updates a memory table indicating their status.Next,the PLC executes its control programming or ladder logic.As it processes the ladder logic,the PLC updates a memory table which indicates whether output devices should be on or off.Finally,the PLC uses the output table to actually change the condition of the output devices. What can a PLC do? 1. Relay-swithing tasks. 2. Counting,calculatingand compare analog process values. 3. Modify control logic quickly. 4. Responds to change in process parameters within fraction of seconds. 5. Improve overall control system reliability. 6. Cost effective for controlling complex system. 7. Easy and fast trouble-shooting. 8. Operator interact with the process through HMI(Human-Machine Interface).

Ladder Logic:Ladder Logic, or Ladder Diagrams is the most common programming language used to program a PLC.

Ladder logic was one of the first programming approaches used in PLCs because it borrowed heavily from the Relay Diagrams that plant electricians already knew.The symbols used in Relay Ladder Logic consists of a power rail to the left, a second power rail to the right, and individual circuits that connect the left power rail to the right. The logic of each circuit (or rung) is solved from left to right. The symbols of these diagrams look like a ladder - with two side rails and circuits that resemble rungs on a ladder.The picture above has a single circuit or "rung" of ladder.

If Input1 is ON (or true) - power (logic) completes the circuit from the left rail to the right rail - and Output1 turns ON (or true). If Output1 is OFF (or false) - then the circuit is not completed and logic does not flow to the right - and Output 1 is OFF.

Storage Memory:Storage memory stores information related to program execution such as the present status of the inputs ,outputs,timer,counter,register,valve etc.It stores Information like:O0 Outputs I1 Inputs S2 Status B3 Bits T4 Timers C5 Counters R6 Control N7 Integer F8 Float Process inputs and outpus values Preset and accumulated values of timers and counters. Values of temporary storage bits and register. Stores hardware configuration of the system.

I. II. III. IV.

Timer:Timers are devices that count increments of time.There are different kinds of timers available.Two widely used timers are:on-delay(TON) and off-delay(TOF) timers. Timer related general terms:Timer Address:Each timer is given a unique address in the software.Timers have an area reserved for them in the memory number of timers available.PLCs have 128 or 256 or more number of timers available,depending on the PLCs maker. Enable:This is a timers input signal that enables the timer generally,it is given through an input signal or a bit. Preset Time Value:This is the target time by which the event on/off has to be delayed. Accumulated Time Value:-This shows the current timer value once is started. Timer Base:This is the value of time(usually indicated in milliseconds or sconds) by which the timer increments during running. TON(on-delay Timer) TOF(off-delay Timer)

Counter:The counter performs the counting pulses of inputs in a program.It functions very similarly to hardware timers ,from an operating point of view.It measures the pulses of an input singnal and acclording to its type of action,it is classified as:1. Up counter:-increments the count on receiving pulse input. 2. Down counter:-decrement the count on receiving pulse input. 3. Up-down counter:-increment as well decrement the count on receiving pulse inputs. Counter related general terms:I. Counter Address:II. Counter Value:III. Preset Value:-

C-UP(Up- Counter)

C-DN(Down-Count

Basic Motors using Ladder Logic:This section covers some of the basic Start / Stop Motor logic. The purpose of this section is to give PLC programmers a sense of some of the basics in Motor control in ladder logic. We have included some of the most used controls. More advanced section for motor section is available later on in the training section. Assume we have a motor that could be started and stopped from 3 different places. What this mean is that we have 3 sets of Start/Stop buttons that can start and stop the motor. Solution: Rung 0: Here we have put Star1/Start2 /Start3 in parallel and then pass it thru a one shot. We are assuming that the start button could also have a maintained (1) signal as well as momentary (2) signal. So to cover both cases, this will prevent the motor from starting automatically after any of the 3 stop buttons is pressed. It is just a precaution and better as far as security is concerned

Rung 1 : Here we have the stop buttons in series, since pressing any of the buttons should stop the motor and will disallow any of the start button to pass thru.

Note

Maintained signal is a signal that stays on when a push button is pressed. Typically a selector has a maintained signal. When you press on lets say on a start push button, the start bit will stay on until the stop button is press. A momentary signals is a signal that will go on for as long as the operator pushes the button. When the operator release the button the signal will go off. That is why most of the time we use the OSR instruction to lock on the signal.

REFERENCES:-

www.google.co.in www.kronotech.com www.wikipedia.com www.plcs.net www.plctutor.com

TECHNO INDIA COLLEGE OF TECHNOLOGY NEWTOWN,RAJARHAT,KOLKATA-700156

PROGRAMMABLE LOGIC CONTROLLER (PLC)

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Sunil Kumar singh 091870110277 09187005039 AEIE,4th Year