INTRODUCTION
Process Control
Computer
Area Host
Computer
Network
BZ
Limit switch Sensor Motor Solenoid Lights Buzzer
Control Components
Fig. 1.1:
It could also be an application as small as a single PLC controlling a single or
some output devices.
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1. INTRODUCTION
Pushbutton Revolvin
Mechanic Robot
& g Indicato
al Arm
Selector Light rs
structure
Switch
Switche
s
PLC
Relays
Magneti Termin
Sensor c al
Contact Block
or
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1. INTRODUCTION
abruptly. In this application, the control system operates as a stand-alone
operation
The PLC may be used to control a simple and repetitive task, or a few of them
may be interconnected together with other host controllers or host computers
through a sort of communication network, in order to integrate the control of a
complex process.
Input Devices
Intelligence of an automated system is greatly depending on the ability of a PLC
to read in the signal from various types of automatic sensing and manual input
field devices.
Push-buttons, keypad and toggle switches, which form the basic man-machine
interface, are types of manual input device. On the other hand, for detection of
workpiece, monitoring of moving mechanism, checking on pressure and or
liquid level and many others, the PLC will have to tap the signal from the
specific automatic sensing devices like proximity switch, limit switch,
photoelectric sensor, level sensor and so on. Types of input signal to the PLC
would be of ON/OFF logic or analogue. These input signals are interfaced to PLC
through various types of PLC input module.
INPUT
Photoelectr
Limit
Timer ic
Switch
Switch
Rotary Proximity
Encoder Switch
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1. INTRODUCTION
Output Devices
An automatic system is incomplete and the PLC system is virtually paralysed
without means of interface to the field output devices. Some of the most
commonly controlled devices are motors, solenoids, relays indicators, buzzers
and etc. Through activation of motors and solenoids the PLC can control from a
simple pick and place system to a much complex servo positioning system.
These type of output devices are the mechanism of an automated system and
so its direct effect on the system performance.
However, other output devices such as the pilot lamp, buzzers and alarms are
merely meant for notifying purpose. Like input signal interfacing, signal from
output devices are interfaced to the PLC through the wide range of PLC output
module.
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1. INTRODUCTION
Power
Supply
Signals Signals
from Central to
Switche Input Processing Output Solenoi
s Unit (CPU) ds
Interfa Interfa
Sensor ce ce Motors
etc Memory etc
Fig. 1.3: Block Diagram
of PLC
Memory
There are various types of memory unit. It is the area that hold the operating
system and user memory. The operating system is actually a system software
that co-ordinates the PLC. Ladder program, Timer and Counter Values are
stored in the user memory. Depending on user’s need, various types of
memory are available for choice:
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1. INTRODUCTION
(b) Random Access Memory (RAM)
RAM is commonly used memory type for storing the user program and data.
The data in the volatile RAM would normally be lost if the power source is
removed. However, this problem is solved by backing up the RAM with a
battery.
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1. INTRODUCTION
SCAN TIME
The process of reading the inputs, executing the program and updating the
outputs is known as scan. The scan time is normally a continuous and
sequential process of reading the status of inputs, evaluating the control logic
and updating outputs. Scan time specification indicates how fast the controller
can react to the field inputs and correctly solve the control logic.
PROGRAM
0 1
1000
I/O
Update
1000
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1. INTRODUCTION
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1. INTRODUCTION
• Modification can be quite difficult.
• Troubleshooting can be quite troublesome as you may require a skillful
person.
• Power consumption can be quite high as the coil consumes power.
• Machine downtime is usually long when problems occur, as it takes a
longer time to troubleshoot the control panel.
• Drawings are not updated over the years due to changes. It causes
longer downtime in maintenance and modification.
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1. INTRODUCTION
• The PLC self diagnostic functions enable easy and fast troubleshooting of
the system.
• Modification of control sequence or application can easily be done by
programming through the console or computer software without changing
of I/O wiring, if no additional Input or Output devices are required.
• In PLC System spare parts for relays and hardware timers are greatly
reduced as compared to conventional control panel.
• The machine cycle time is improved tremendously due to the speed of PLC
operation is a matter of milliseconds. Thus, productivity increases.
• It cost much less compared to conventional system in situation when the
number of I/Os is very large and control functions are complex.
• The reliability of the PLC is higher than the mechanical relays and timers.
• An immediate printout of the PLC program can be done in minutes.
Therefore, hardcopy of documentation can be easily maintained.
Th
U
R Motor (1.5 kw)
V
Y
W
B
Circuit
Breake Mg
r
PB1
PB2
E Mg
Start TH
Start Push
Push-
-button
button
I
Mg
Fig.
1.5
When the push-button PB1 is pressed, current I will flow through the circuit and
energize magnetic contact Mg which in turn closes the Mg contacts. The
contact Mg parallel the push-button PB1 is for self-holding so that PB1 can be
released. The other Mg contacts closes to switch on the 3-pbase motor.
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1. INTRODUCTION
To connect the above circuit in a PLC system to PLC wiring circuit, we need to
identify the input and output devices. The input devices are start push-button
(PB1) and stop push-button (PB2) and the output device in this case is only one
magnetic contactor that controls the 3-phase motor. The wiring circuit is shown
in Fig. 1.6
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