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Chapter

1
Programmable Logic Controller (PLC) Overview

Objectives
Describe the invention and the development history of programmable logic controller (PLC) systems. Discuss the benefits of PLCs over electromechanical relay logic systems. Distinguish between fixed and modular PLC devices.

Goodheart-Willcox Co., Inc.

Objectives
Discuss different types of Intel and Motorola microprocessors. Explain different types of random access memory (RAM) devices and their use in PLC systems. Explain different types of read only memory (ROM) devices.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Objectives
Explain the use of the address decoder circuit in a PLC system. List the major components of a PLC power supply. Describe Allen-Bradley programmable controller devices.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Programmable Logic Controller (PLC)


All devices have:
Discrete input ports Discrete output ports

Larger, more advanced PLCs have:


Variable input ports Variable output ports

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

PLC Block Diagram

Goodheart-Willcox Co., Inc.

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Fixed PLC
If all units are in one fixed enclosure. Number of input ports cannot be expanded. Number of output ports cannot be expanded.
(Energy Concepts, Inc.)
Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.

Modular PLC
If each unit is placed in different racks. Input modules can be added if needed. Output modules can be added on modular PLC systems.
(Energy Concepts, Inc.)
Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.

Central Processing Unit (CPU)


Microprocessor. Unit. Memory. Support chips.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Microprocessor Unit (MPU)


Brain of the central processing unit. Carries out or executes program instructions.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Arithmetic Logic Unit (ALU)


Carries out math and logic instructions. Registers:
Hold data for the arithmetic logic unit.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Cache
Instruction cache:
Temporarily holds incoming instructions.

Data cache:
Temporarily holds incoming data.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Bus
Bus width:
How many conductors comprise the address bus and data bus.

Address bus:
Helps the CPU to find physical locations in memory.

Data bus:
Transfers data between CPU components, such as between the I/O and RAM. The wider the data bus, the more data that can be transferred at one time.
Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.

Instruction Set
CISC-based microprocessor RISC-based microprocessor

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Memory Devices
Two types of internal memory devices for a CPU:
Random access memory (RAM). Read only memory (ROM).

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Random Access Memory (RAM)


Static RAM (SRAM):
Stores data bits in its internal flip-flop.

Dynamic RAM (DRAM).


Holds binary data in the form of charged capacitors.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Random Access Memory (RAM) (Cont.)


Data on the DRAM:
Must be refreshed every few microseconds due to the discharge of the capacitors.

Data on the SRAM:


Remains unchanged until either a new data is written over the existing data, or power to the chip is turned off.

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Permission granted to reproduce for educational use only.

Read Only Memory (ROM)


Masked ROM, or preprogrammed ROM:
Usually programmed by the manufacturer at the factory. Customer must order several thousand chips from a factory.

Programmable ROM (PROM):


Programmed or burned only once by the programmer.

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Permission granted to reproduce for educational use only.

Read Only Memory (ROM) (Cont.)


Erasable programmable ROM (EPROM), or ultraviolet-erasable programmable ROM (UVEPROM):
Programmed by the programmer and can be erased by placing it under ultraviolet light.

Electrically erasable programmable ROM (EEPROM), or flash ROM:


Programmable ROM that is programmed and erased by injecting an electrical current through it.

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Permission granted to reproduce for educational use only.

Basic Input/Output System (BIOS)


On power up, the firmware, or the software in ROM:
Carries out several instructions that check the input, output, and other peripheral devices connected to the CPU. Serves as a communication interface between PLC hardware and the PLC program.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Address Decoder Circuit


MPUs use an address decoder to enable:
ROM. RAM. I/O port devices. Support chips.

When the MPU communicates with a chip, only that chip is connected to the address, data, and control lines of the CPU.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Peripheral Chips
Also called support chips. Used to enable the microprocessor to communicate with input/output devices. Supports the MPU with a different task.

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Discrete Input Modules


Terminals receive input signals from switches or other input devices. Converts the input signal to a digital signal prior to sending it to the CPU.

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Discrete Input Modules (Cont.)


Octal transceiver Full-wave rectifier Optoisolator

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Discrete Input Modules (Cont.)


Zener diode:
Semiconductor device that can maintain a steady voltage level. When phototransistor becomes saturated, ensures that a steady +5 V is applied to the CPU circuit board.

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Permission granted to reproduce for educational use only.

Discrete Output Modules


Octal latch:
Output bit values remain the same until new input bits write over them. Two octal latches are needed with a 16 output module.

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Discrete Output Modules (Cont.)


Triac:
Solid state relay. Can be used for switching the output voltage on and off in order to connect the load to AC voltage.

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Analog Input/Output Modules


Analog-to-digital converter (ADC):
Converts analog input signals to digital signals.

Digital-to-analog converter (DAC):


Converts digital output signals back to analog signals.

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Allen-Bradley Programmable Controllers


Programmable logic controllers (PLCs) are used to implement specific instructions:
Input/output (I/O) port control. Timing. Counting. Data manipulation. Reporting. Arithmetic. Logic. Communication.

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Allen-Bradley Programmable Controllers (Cont.)


Safety programmable controller:
Used for the monitoring and implementing the safety instructions in case of faults in a control system.

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Allen-Bradley Programmable Controllers (Cont.)


Programmable automation controller (PAC):
A personal computer (PC) with a PLC architecture. Can be used to perform PLC instructions in addition to controlling electric drives and more sophisticated motion and batch control systems.

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Allen-Bradley Programmable Logic Controllers (Cont.)


Four major types of PLCs are categorized according to:
Input/output (I/O) size. Processor. Speed. Memory size.

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Permission granted to reproduce for educational use only.

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