Summer Training Course

Classic Control And PLC

Submitted by:
Mohamed Hossam Fathi Ahmed
ID No:
20160774

Electrical Eng. Dept.

Higher technological institute

Submitted to:
prof.Dr: Aml Ashraf

Aug.2021
 Abstract
Control engineering or control systems engineering is an engineering
discipline that deals with control systems, applying control theory to
design equipment and systems with desired behaviors in control
environments. The discipline of controls overlaps and is usually taught
along with electrical engineering and mechanical engineering at many
institutions around the world.

The practice uses sensors and detectors to measure the output

performance of the process being controlled; these measurements are
used to provide corrective feedback helping to achieve the desired
performance. Systems designed to perform without requiring human input
are called automatic control systems (such as cruise control for regulating
the speed of a car). Multi-disciplinary in nature, control systems
engineering activities focus on implementation of control systems mainly
derived by mathematical modeling of a diverse range of systems.

The programmable Logic Controller (PLC) is the central controlling unit

in the industry or a process. The effective operation of the process and
safety considerations if programmed appropriately can meet the required
objectives. The present technical paper briefly distinguishes the present
automation systems and the past technologies to identify and explore the
capabilities of PLCs for any process. The relay logic and contactor logics
(RLC) were practiced in the olden days which include the human
intervention and errors. The advent and application of microprocessors,
microcontrollers and new specific tools such as PLCs, Supervisory
control and data acquisition (SCADA) and Distributed control systems
(DCS) have increased productivity, accuracy, precision and efficiency.
These systems reduced human intervention and increased the flexibility in
the process control. The keyword automation clearly state that the
working of a process or repetition in an efficient manner by incorporating
mechanisms and control sequences in the proper order several times with
acceptable deviations in the output of the process.

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 Acknowledgment
At first, Thanks to ALLAH the most merciful the most gracious, for this
moment has come and this work has been accomplished.
Thanks to the Higher Technological Institute of 10thRamdan for
preparing me to be a successful Engineer and lifting me up to achieve this
training in an environment that's full of encouragement and motivation.

Deepest gratitude is to be delivered to Dr. Amal , my role model in

engineering. He understood the nature of my thoughts and guided me step
by step till this work brought to light. Endless trust in my potentials
guided me till the end. Thank you.

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 List of Contents
Chapter (1): Pages
.....................................................................................................................................................
Classic Control .......................................................................................................................... 1
1.Introduction. ...... ...............................................................................................................
1
1.1.Control
systems....... . ..................................................................................................2
1.4 What is a Switch? .......................................................................................................... 3
1.5.Relay....... ........................................................................................................................ 7
1.5.1.Contactor....... ........................................................................................................
10
1.5.2.latching relay....... ..................................................................................................
11
1.6Star-Delta Connection....... ...........................................................................................
12
1.7Circuit breaker....... ...................................................................................................... 18
1.7.1Origins....... ............................................................................................................. 19
1.7.2Operation....... ............................................................................................................ 19
1.7.3Short circuit....... .................................................................................................... 20
1.7.4Standard current ratings....... ............................................................................... 21
1.7.5Types....... ................................................................................................................
22
1.8Overload....... . ................................................................................................................
25
1.9Timers....... .....................................................................................................................
31
1.10Sensors:. ...... ................................................................................................................
33
1.1.1.Limit Switches....... ................................................................................................
33
1.1.2.Reed switch............................................................................................................ 34
1.1.3.Proximity Sensors....... ..........................................................................................
35

Chapter............................................................................................................................... 2
2.PLC....................................................................................................................................37
2.1.Introduction...............................................................................................................37
2.2.How does a PLC work?.............................................................................................37
2.3.Advanced PLC Features............................................................................................38
2.4.The All-In-One PLC..................................................................................................38
2.5.How is a PLC Programmed?....................................................................................38

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Examples of classic control circuits.......................................................................................39
Conclusions...........................................................................................................................42
References.............................................................................................................................43

LIST OF Figures

Figure 1-1 .................................................................................................................................. 3

Figure 1-2-Switch ...................................................................................................................... 4
Figure 1-3 Switches ................................................................................................................... 5
Figure 1-4Float Switches ...........................................................................................................
5
Figure 1-5-Flow-Switch-Symbol ...............................................................................................
6
Figure 1-6-Pressure-Switch-Symbol ......................................................................................... 7
Figure 1-7-Relay ........................................................................................................................
7
Figure 1-8-contactor ................................................................................................................ 10
Figure 1-19-latching relay ....................................................................................................... 11
Figure 1-10-Power circuit of Star-Delta starter ....................................................................... 14
Figure 1-11-Control Circuit of Star-Delta Starter (Open Transition) ......................................
14
Figure 1-12-low-voltage power circuit breaker .......................................................................
23
Figure 1-13-medium-voltage power circuit breaker ................................................................
24
Figure 1-14-Overload Wiring Diagram .................................................................................. 26
Figure 1-15-Thermal Overload ................................................................................................
28
Figure 1-16-Magnetic Overload Relay ....................................................................................
28
Figure 1-17-Gv2 ...................................................................................................................... 31
Figure 1-18 -Gv3 ......................................................................................................................
31
Figure 1-19-Gv7 ...................................................................................................................... 31
Figure 1-20-Timer ................................................................................................................... 31
Figure 1-21 -Limit Switche ......................................................................................................
33
Figure 1-22-Reed switch ......................................................................................................... 34
Figure 1-23-Proximity Sensors................................................................................................ 35
Figure 24-Start-Stop ................................................................................................................ 39
Figure 25-Two Start-Stop ........................................................................................................ 39
Figure 26-Intrtlock .................................................................................................................. 40
Figure 27-timer1 ...................................................................................................................... 40
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Figure 28-Timer 2 ................................................................................................................... 41
Figure 29-Timer 3 ................................................................................................................... 41

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 Chapter 1
Classic Control

1. Introduction
Modern day control engineering is a relatively new field of study that gained
significant attention during the 20th century with the advancement of technology. It
can be broadly defined or classified as practical application of control theory. Control
engineering plays an essential role in a wide range of control systems, from simple
household washing machines to high-performance F-16 fighter aircraft. It seeks to
understand physical systems, using mathematical modelling, in terms of inputs,
outputs and various components with different behaviors; to use control system design
tools to develop controllers for those systems; and to implement controllers in
physical systems employing available technology. A system can be mechanical,
electrical, fluid, chemical, financial or biological, and its mathematical modelling,
analysis and controller design uses control theory in one or many of the time,
frequency and complex-s domains, depending on the nature of the design problem.

1.1. Control systems

Control engineering is the engineering discipline that focuses on the modeling of a
diverse range of dynamic systems (e.g. mechanical systems) and the design of
controllers that will cause these systems to behave in the desired manner. Although
such controllers need not be electrical, many are and hence control engineering is
often viewed as a subfield of electrical engineering.

Electrical circuits, digital signal processors and microcontrollers can all be used to
implement control systems. Control engineering has a wide range of applications from
the flight and propulsion systems of commercial airliners to the cruise control present
in many modern automobiles.

In most cases, control engineers utilize feedback when designing control systems.
This is often accomplished using a PID controller system. For example, in an
automobile with cruise control the vehicle's speed is continuously monitored and fed
back to the system, which adjusts the motor's torque accordingly. Where there is
regular feedback, control theory can be used to determine how the system responds to
such feedback. In practically all such systems stability is important and control theory
can help ensure stability is achieved.

Although feedback is an important aspect of control engineering, control engineers

may also work on the control of systems without feedback. This is known as open
loop control. A classic example of open loop control is a washing machine that runs
through a pre-determined cycle without the use of sensors.

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1.2 What is a Switch?
A Switch is a device which is designed to interrupt the current flow in a circuit. In
simple words, a Switch can make or break an electrical circuit. Every electrical
and electronics application uses at least one switch to perform ON and OFF
operation of the device.

So, switches are a part of the control system and without it, control operation
cannot be achieved. A switch can perform two functions, namely fully ON (by
closing its contacts) or fully OFF (by opening its contacts).

When the contacts of a switch are closed, the switch creates a closed path for the
current to flow and hence load consumes the power from source. When the
contacts of a switch are open, no power will be consumed by the load as shown in
figure 1.

Figure 1-1

Another important function of a Switch is to divert the flow of electric current in a

circuit. Consider the following circuit. When the switch is in position A, the lamp 1
turns ON and while it is in position B, lamp 2 turns ON.

There are numerous applications of switch, found in wide variety of fields such as
homes, automobiles, industrial, military, aerospace and so on. In home and office
applications, we use simple rocker switches to turn ON and OFF appliances like
lights, computers, fans etc. In some applications, multi way switching is employed
(like building wiring), where two or more switches are connected to control an
electrical load from more than one location, like a Two Way Switch, for example.

Types of Switches
Basically, Switches can be of two types. They are:

• Mechanical

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 • Electronic

Figure 1-2-
Switch

Mechanical Switches are physical switches, which must be

activated physically, by moving, pressing, releasing, or touching its contacts.

Electronic Switches, on the other hand, do not require any physical contact in order to
control a circuit. These are activated by semiconductor action.

Mechanical Switches
Mechanical switches can be classified into different types based on several factors
such as method of actuation (manual, limit and process switches), number of contacts
(single contact and multi contact switches), number of poles and throws (SPST,
DPDT, SPDT, etc.), operation and construction (push button, toggle, rotary, joystick,
etc.), based on state (momentary and locked switches), etc.

Figure 1-3 Switches

1.3. Relay

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 Figure 1-4-Relay

A relay is an electrically operated switch. It consists of a set of input terminals for a

single or multiple control signals, and a set of operating contact terminals. The switch
may have any number of contacts in multiple contact forms, such as make contacts,
break contacts, or combinations thereof.

Relays are used where it is necessary to control a circuit by an independent low-power

signal, or where several circuits must be controlled by one signal. Relays were first
used in long-distance telegraph circuits as signal repeaters: they refresh the signal
coming in from one circuit by transmitting it on another circuit. Relays were used
extensively in telephone exchanges and early computers to perform logical operations.

Types:
1.3.1. Contactor

Figure 1-5-contactor

A contactor is an electrically-controlled switch used for switching an electrical power

circuit.[1] A contactor is typically controlled by a circuit which has a much lower
power level than the switched circuit, such as a 24-volt coil electromagnet controlling
a 230volt motor switch.

Unlike general-purpose relays, contactors are designed to be directly connected to

highcurrent load devices. Relays tend to be of lower capacity and are usually designed
for both normally closed and normally open applications. Devices switching more

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than 15 amperes or in circuits rated more than a few kilowatts are usually called
contactors. Apart from optional auxiliary low-current contacts, contactors are almost
exclusively fitted with normally open ("form A") contacts. Unlike relays, contactors
are designed with features to control and suppress the arc produced when interrupting
heavy motor currents.

1.4Circuit breaker

A circuit breaker is an automatically operated electrical switch designed to protect

an electrical circuit from damage caused by excess current from an overload or short
circuit. Its basic function is to interrupt current flow after a fault is detected. Unlike a
fuse, which operates once and then must be replaced, a circuit breaker can be reset
(either manually or automatically) to resume normal operation.

Circuit breakers are made in varying sizes, from small devices that protect low-current
circuits or individual household appliance, up to large switchgear designed to protect
high voltage circuits feeding an entire city. The generic function of a circuit breaker,
or fuse, as an automatic means of removing power from a faulty system is often
abbreviated as OCPD (Over Current Protection Device).

1.5 Overload
An overload is an electrical device used to protect an electric motor from overheating. So it is
essential to have sufficient motor protection. An electrical motor can be operated safely with
the help of overload relays, fuses otherwise circuit breakers. But this relay protects the motor
whereas the circuit breaker otherwise fuse protects the circuit. More purposely, fuses, as well
as circuit breakers, are intended to detect the overcurrent within the circuit, whereas the relay
is intended to detect overheat if an electric motor gets heated. For instance, an overload relay
can explore without the tripping of a CB (circuit breaker). One does not restore the other. This
article discusses an overview of overload relay, types, and its working.

1.6 Timers
Define the timer

It is a device with which it is possible to control the start and turn

times of electric motors .Many types of materials that are divided
in terms of composition or function

Figure 1-6-Timer

1.7 Sensors:
An electrical sensor is a device or integrated circuit that detects a specific
physical parameter and converts it to an electrical signal. The output signal of
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 the electrical sensor is processed and used to provide a measurement or to
trigger an action. Examples include environmental sensors for measuring
temperature or humidity and bio sensors for measuring physiological indicators
such as core temperature or heart rate.
Our large selection of temperature sensor ICs support a wide variety of designs
for both local and remote temperature measurement. These electric sensor ICs
provide high-accuracy, low-power performance with real-time protection, robust
interfaces, and compact packaging for use in industrial, automotive, consumer,
data center and communications applications. Our growing portfolio of bio
sensors provide high-accuracy measurement of body vital signs. These highly
integrated bio sensor ICs offer low power operation in small packages for
accurate body vital measurements such as temperature, heart health, and bio
potential for use in mobile phones, wearable devices and clinical health patches.

1.7.1. Limit Switches

Limit switches are used to automatically detect or sense the presence of an
object or to monitor and indicate whether the movement limits of that object
have been exceeded. The original use for limit
switches, as implied by their name, was to define
the limit or endpoint over which an object could
travel before being stopped. It was at this point
that the switch was engaged to control the limit of
travel

Figure 1-7-Limit Switche

1.7.2. Proximity Sensors

A proximity sensor is a component which is designed to detect the absence or
presence of an object without the need for physical contact. They are non-contact

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devices, highly useful for working with delicate or unstable objects which could be
damaged by contact with other types of sensor.
This non-contact operation also means that most types of proximity sensor
(excluding types such as magnetic proximity sensors) have a prolonged lifespan.
This is because they have semiconductor outputs, meaning that no contacts are
used for output. Proximity sensors are designed to provide a high-speed response
(the interval between the point when the object triggers the sensor and the
point when the output activates). Different types use varying sensing technologies but
they all have the same purpose.

Figure 1-8-Proximity Sensors

Chapter 2

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 2. PLC
2.1. Introduction

programmable logic controller (PLC) or programmable controller is

an industrial computer that has been ruggedized and adapted for the
control of manufacturing processes, such as assembly lines, machines,
robotic devices, or any activity that requires high reliability, ease of
programming, and process fault diagnosis. Dick Morley is considered as
the father of PLC as he had invented the first PLC, the Modicon 084, for
General Motors in 1968.
PLCs can range from small modular devices with tens of inputs and
outputs (I/O), in a housing integral with the processor, to large rack-
mounted modular devices with thousands of
I/O, and which are often networked to other PLC and SCADA systems.[1]
They can be designed for many arrangements of digital and analog I/O,
extended temperature ranges, immunity to electrical noise, and resistance
to vibration and impact. Programs to control machine operation are
typically stored in battery-backed-up or non-volatile memory. PLCs were
first developed in the automobile manufacturing industry to provide
flexible, rugged and easily programmable controllers to replace hard-
wired relay logic systems. Since then, they have been widely adopted as
high-reliability automation controllers suitable for harsh environments.
A PLC is an example of a hard real-time system since output results must be
produced in response to input conditions within a limited time, otherwise
unintended operation will result.

2.2. How does a PLC work?

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he PLC receives information from connected sensors or input devices, processes the data, and
triggers outputs based on pre-programmed parameters.
Depending on the inputs and outputs, a PLC can monitor and record run-time data such as
machine productivity or operating temperature, automatically start and stop processes,
generate alarms if a machine malfunctions, and more. Programmable Logic Controllers are a
flexible and robust control solution, adaptable to almost any application.

Figure 2-1

There are a few key features that set PLCs apart from industrial PCs,
microcontrollers, and other industrial control solutions:

• I/O – The PLC’s CPU stores and processes program data, but input and output
modules connect the PLC to the rest of the machine; these I/O modules are
what provide information to the CPU and trigger specific results. I/O can be
either analog or digital; input devices might include sensors, switches, and
meters, while outputs might include relays, lights, valves, and drives. Users
can mix and match a PLC’s I/O in order to get the right configuration for their
application.
• Communications – In addition to input and output devices, a PLC might also
need to connect with other kinds of systems; for example, users might want to
export application data recorded by the PLC to a supervisory control and data
acquisition (SCADA) system, which monitors multiple connected devices.

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 PLCs offer a range of ports and communication protocols to ensure that the
PLC can communicate with these other systems.
• HMI – In order to interact with the PLC in real time, users need an HMI, or
Human Machine Interface. These operator interfaces can be simple displays,
with a text-readout and keypad, or large touchscreen panels more similar to
consumer electronics, but either way, they enable users to review and input
information to the PLC in real time.

2.3. Advanced PLC Features

In today’s world of the Industrial Internet of Things (iIoT), and Industry 4.0
programmable controllers are called upon to communicate data via Web browser,
connect to databases via SQL, and even to the cloud data via MQTT.

2.4. The All-In-One PLC

An All-in-One PLC integrates the controller with the HMI panel, creating a compact,
easy-to-use automation solution. Users no longer need to establish PLC to panel
communications and can program both the Ladder Logic and HMI design in a single
software environment. An all-in-one approach saves time, reduces wiring, and cuts the
cost of purchasing multiple devices.

2.5. How is a PLC Programmed?

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A PLC program is usually written on a computer and then is downloaded to the
controller
Most PLC programming software offers programming in Ladder Logic, or “C”.
Ladder Logic is the traditional programming language. It mimics circuit diagrams
with “rungs” of logic read left to right. Each rung represents a specific action
controlled by the PLC, starting with an input or series of inputs (contacts) that result
in an output (coil). Because of its visual nature, Ladder Logic can be easier to
implement than many other programming languages.
“C” programming is a more recent innovation.
Some PLC manufacturers supply control programming software.

2.6.Components of PLC

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2.6.1 power supply

The power supply converts facility electrical distribution voltage, such as 230
VAC, 120 VAC or 125 VDC to signal level voltage used by the plc processor and
other modules.

2.6.2 C.P.U. "Central Processing Unit"

It is considered the thinking mind of the PLC device, which reads the program
and performs the arithmetic operations in a very fast way so that it turns on or
disconnects the output at the right time

2.6.3 input and output modules

These modules provide the means of connecting the processor to the field
devices. Examples of these modules are Analog Input Module, Analog output
module, Digital input module, Digital output module etc.

These are used to connect devices between plc and field devices like flow
transmitters, pressure transmitters, control valves, analyzers, substation feeders
for motor control etc

2.7 Ladder Diagram Programming

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 Conclusions
At the end of this summer training and this course, I found that the classic control is very
important for the industry and facilitated many things that the human factor does, and without
it we are still in the era of using everything manually.
I also learned the importance of PLC and to understand PLC it is necessary to understand the classic
control because it is the basis of control in industries

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 References
1- "Systems & Control Engineering FAQ | Electrical Engineering and
Computer Science". engineering.case.edu. Case Western Reserve
University. 20 November 2015. Retrieved 27 June 2017.
2- ACSE - The University of Sheffield". Retrieved 17 March 2015.
3- "WRC Home". USNA Weapons, Robotics and Control Engineering.
Retrieved 19 November 2019.
4- "Control Systems Engineer Salary | PayScale". www.payscale.com.
Retrieved 2019-10-30.
5- Zhang, Jianhua. Mechatronics and Automation Engineering 2º Ed.
Proceedings of the International Conference on Mechatronics and
Automation Engineering (ICMAE2016). Xiamen, China, 2016.
6- Rieger, D. I. Gertman and M. A. McQueen, "Resilient control systems: Next
generation design research," 2009 2nd Conference on Human System
Interactions, Catania, 2009, pp. 632-636.
http://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=5091051&isnu
mber=5090940

7- Parr 1998, p. 438

8- Parr 1998, p. 437
9- Dunn, Alison (2009-06-12). "The father of invention: Dick Morley looks
back on the 40th anniversary of the PLC". Manufacturing Automation.
Retrieved 2020-02-23.
10- Kenney, Muirae (2020-11-24). "The Basics of Ladder Logic". Automation
Industrial. Retrieved 2020-11-24.

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