PLC

Programmable Logic Controller PLC is a
special computer device used in industrial

control systems. Due to its robust
construction, exceptional functional features
like sequential control, counters and timers,
ease of programming, reliable controlling
capabilities and ease of hardware usage –
this PLC is used as more than a special
purpose digital computer in industries as
well as in other control system areas. Most
of the industries abbreviate these devices as
“PC” but it is also used for personal
computers; due to this, many manufacturers
named these devices as PLCs.
The programmable logic controller is used
not only for industrial purpose but also in
civil applications such as washing
machine, elevators working and traffic
signals control. Different types of PLCs
from a vast number of manufacturers are
available in today’s market. Therefore, in
the following paragraphs, let us study about
programmable logic controller’s basics,
principles and applications.
Principle of Programmable Logic
Controller:
Programmable Logic Controllers are used
for continuously monitoring the input values
from sensors and produces the outputs for
the operation of actuators based on the
program. Every PLC system comprises these
three modules:
 CPU module
 Power supply module
 One or more I O module
 CPU Module:
CPU Module:
A CPU module consists of central processor
and its memory. The processor is
responsible for performing all the necessary
computations and processing of data by
accepting the inputs and producing the
appropriate outputs.
Power Supply Module:
This module supplies the required power to
the whole system by converting the
available AC power to DC power required
for the CPU and I O modules. The V DC
output drives the computer circuitry.
I O Modules:
The input and out modules of the
programmable logic controller are used to
connect the sensors and actuators to the
system to sense the various parameters such
as temperature, pressure and flow, etc.
These I/O modules are of two types: digital
or analog.
Communication Interface Modules:
These are intelligent I O modules which
transfers the information between a CPU
and communication network. These
communication modules are used for
communicating with other PLC’s and
computers, which are placed at remote
place or far off locate.
The program in the CPU of programmable
logic controller consists of operating system
and user programs. The purpose of the
operating system with CPU is to deal with
the tasks and operations of the PLC such as
starting and stopping operations, storage
area and communication management, etc.
A user program is used by the user for
finishing and controlling the tasks in
automation.
The Principle of operation of the PLC can be
understood with the cyclic scanning also
called as scan cycle, which is given in the
below figure.
A typical PLC scans cycle includes of the
following steps:
 The operating system starts cycling and
monitoring of time.
 The CPU starts reading the data from the
input module and checks the status of all
the inputs.
 The CPU starts executing the user or
application program written in relay
ladder logic or any other PLC
programming language.
 Next, the CPU performs all the internal
diagnosis and communication tasks.
 According to the program results, it
writes the data into the output module so
that all outputs are updated.
 This process continues as long as the
PLC is in run mode.
Applications of Programmable Logic
Controller PLC
The PLC can be used in industrial
departments of all the developed countries in
industries like chemical industry,
automobile industry, steel industry and
electricity industry. Based on the
development of all these technologies,
functionality and application, the scope of
the PLC increases dramatically.
. Application of PLC in Glass Industry
PLCs are used mainly in every procedure
and workshop for controlling the material
ratio, processing of flat glasses, etc.
With the development of PLC and
increasing demand in the real world, the
control mode of the programmable-logic
controller with an intelligent device is
applied in the glass industry. In making of a
float glass, PLC itself cannot finish some
controlling tasks because of the complexity
of the control system and processing of huge
data. For the production of glass, we make
use of bus technology to construct the
control mode of a PLC with a distributed-
control system. This control system deals
with analog controlling and data recording;
the PLC is also used for digital quality
control and position control.
This type of control mode is a big advantage
for PLC and DCS for improving reliability
and flexibility of the control system.
. Applications of PLC in Cement Industry
Along with the best-quality raw materials,
the accurate data regarding process
variables, especially during mixing
processes within the kiln, ensures that the
output provided should be of the best
possible quality. Nowadays a DCS with bus
technology is used in the production and
management industry. By using this existing
DCS control system, the PLC is in user
mode of SCADA. This mode comprises
PLC and configuration software. This
SCADA mode comprises the PLC and host
computer. The host computer consists of
slave and master station. The PLC is used
for controlling the ball milling, shaft kiln
and Kiln of coal.
To know more about these programmable
logic controllers’ function, you can go
through the following project, which is
given as a practical example used mostly
for industrial automation.
Thus, this article has covered the principle
of operation of programmable logic devices
or controller and its applications in various
industries like glass industry, steel industry
and cement industry.

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Programmable Logic Controller PLC is a

special computer device used in industrial

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