PROGRAMMABLE

LOGIC CONTROLLERS
Richard A. Wysk

IE450 - Manufacturing Systems

 Agenda
• Review brief history of PLCs and
manufacturing control systems
• Introduce the concepts of discrete control of
manufacturing
• Review the various kinds of instrumentation
used for control.
• Overview ladder logic programming
 Readings
• Chapter 10 of Computer Aided Manufacturing, Chang,
Chang, T.C. and Wysk, R. A. and Wang, H.P., 3rd Edition,
2006.
 Exercise

What are some common examples of

control?
Washing machine, sump pump, microwave,
….
Others?
 Types of control
• Temporal -- control based in time
• State -- control based in state level
• Hybrid – both temporal and state
 Objectives
• To define the basic components of a PLC
• To apply PLC based control to a
manufacturing system
• To be identify instrumentation required to
implement a PLC control system
• To program a PLC
• To implement a PLC control program and
hardware
 PURPOSE OF Programmable
Logic Controllers (PLCs)
• Initially designed to replace relay logic
boards
– Sequence device actuation
– Coordinate activities
• Accepts input from a series of switches
• Sends output to devices or relays
FUNCTIONS OF CONTROLLERS

• 1) on-off control,
• 2) sequential control,
• 3) feedback control, and
• 4) motion control.
 CONTROL DEVICES

1) mechanical control - cam, governor, etc.,

2) pneumatic control - compressed air,
valves, etc.
3) electromechanical control - switches,
relays, a timer, counters, etc,
4) electronics control - similar to
electromechanical control, except uses
electronic switches.
5) computer control.
 PLC
Input
CPU Input
Module
Flag
System
Output
Output Module
User Ladder
Diagram

Working
memory
registers
 PLC
Configuration
 What devices does a PLC interact
with?
• INPUT RELAYS-(contacts)These are connected to the outside world. They
physically exist and receive signals from switches, sensors, etc. Typically they
are not relays but rather they are transistors.
• INTERNAL UTILITY RELAYS-(contacts) These do not receive signals from
the outside world nor do they physically exist. They are simulated relays and
are what enables a PLC to eliminate external relays. There are also some
special relays that are dedicated to performing only one task. Some are always
on while some are always off. Some are on only once during power-on and are
typically used for initializing data that was stored.
• COUNTERS-These again do not physically exist. They are simulated counters
and they can be programmed to count pulses. Typically these counters can
count up, down or both up and down. Since they are simulated they are limited
in their counting speed. Some manufacturers also include high-speed counters
that are hardware based. We can think of these as physically existing. Most
times these counters can count up, down or up and down.
 What devices does a PLC interact
with?
Continued
• TIMERS-These also do not physically exist. They come in many
varieties and increments. The most common type is an on-delay type.
Others include off-delay and both retentive and non-retentive types.
Increments vary from 1ms through 1s.
• OUTPUT RELAYS-(coils)These are connected to the outside world.
They physically exist and send on/off signals to solenoids, lights, etc.
They can be transistors, relays, or triacs depending upon the model
chosen.
• DATA STORAGE-Typically there are registers assigned to simply
store data. They are usually used as temporary storage for math or data
manipulation. They can also typically be used to store data when
power is removed from the PLC. Upon power-up they will still have
the same contents as before power was removed. Very convenient and
necessary!!
 SWITCHES
Non-locking Locking

Normally Open Normally Closed

SPDT
P1
DPST
P2
Multiple Throw Multiple Pole

Break-before-make Make-before-break
 TERMS
Throw - number of states
Pole - number of connecting moving parts (number of individual circuits).

SPDT
A serial switch box (A-B box) has
two 25 pin serial ports to switch from.

A B

Output
DPST Input

Knob
How is this switch classified?
 TYPES OF SWITCHES
1. Basic switch, operated by a mechanical level,
2. Push-button switch,
3. Slide switch,
4. Thumbwheel switch,
5. Limit switch,
6. Proximity switch, and
7. Photoelectric switch.

RATING: voltage, current

 RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"

contact

coil

input

Relay coil Output contact

 COUNTER
Digital counters output in the form of a relay contact when a
preassigned count value is reached.
input
Register 5

Accumulator
reset

contact

output

Input

Reset

Output

Count 0 12 3 4 5 0 1
 TIMER
A timer consists of an internal clock, a count value register, and
an accumulator. It is used for or some timing purpose.

Clock

Accumulator
reset

Register

Clock
contact
Contact
Reset
output

Output

Count 0 1 2 3 4 5

Time 5 seconds.
AN EXAMPLE OF RELAY LOGIC
For process control, it is desired to have the process start (by turning on a motor) five
seconds after a part touches a limit switch. The process is terminated automatically
when the finished part touches a second limit switch. An emergency switch will stop
the process any time when it is pushed.
L1
LS1 PB1 LS2 R1

R1

TIMER R2
R1 PB1
LS1 LS2

PR=5

TIMER

5
Motor
R2

R1
 PLC ARCHITECTURE
Programmable controllers replace most of the relay panel wiring
by software programming.

PC
Program
Loader
Switches

Printer
I/O
Processor
Modules Machines
Cassette
Loader
Power
EPROM Memory Supply
Loader

Peripherals External Devices

A typical PLC
 PLC COMPONENTS
1. Processor Microprocessor based, may allow arithmetic
operations, logic operators, block memory moves,
computer interface, local area network, functions, etc.

2. Memory Measured in words.

ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electronically Erasable Programmable
ROM),
EPROM (Erasable Programmable Read Only Memory),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.
 PLC COMPONENTS
3. I/O Modular plug-in periphery
AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g.., high speed timers,
Stepping motor controllers, etc. PID, Motion
4. Power supply AC power
5. Peripheral Hand held programmer (loader),
CRT programmer,
Operator console,
Printer,
Simulator,
EPROM loader,
Cassette loader,
Graphics processor, and
Network communication interface. MAP, LAN
 LADDER DIAGRAM
A ladder diagram (also called contact symbology) is a means of
graphically representing the logic required in a relay logic
system.

Rail
start emergency stop
PB1 PB2
R1

Rung R1

R1

A
Ladder Representation
PLC WIRING DIAGRAM

Input PLC Output

01 01 02 20 11 A
02 12
20
03
20 11

External
switches

Stored program
 SCAN
A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to
the bottom. Usually, all the outputs are updated based on the status of the internal
registers. Then the input states are checked and the corresponding input registers are
updated. Only after the I/Os have been resolved, is the program then executed. This
process is run in a endless cycle. The time it takes to finish one cycle is called the
scan time.
Output
Input
begin

Idle

Scan cycle

Resolve
logic
 PLC INSTRUCTIONS
1) Relay,
2) Timer and counter,
3) Program control,
4) Arithmetic,
5) Data manipulation,
6) Data transfer, and
7) Others, such as sequencers.
 LOGIC STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize,
etc.
Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.

(In the notes we use the symbol "~" to represent

negation. AND and OR are logic operators. )
 AND and OR LOGIC
PB1 PB2 R1

R1 = PB1.AND.PB2

AND PB3 PB4

R2
R2 = PB2.AND.~PB4

PB1 R1

R1 = PB1 .OR. PB2

OR PB2
COMBINED AND & OR

R1 = PB1 .OR. (PB2 .AND. PB3)

PB1 R1

PB2 pb3
 RELAY
A Relay consists of two parts, the coil and the contact(s).

Contacts:

a. Normally open -| |-
b. Normally closed -|/|-
c. Off-on transitional -||-
d. On-off transitional -| |-

()
Coil:

a. Energize Coil -( )-
b. De-energize -(/)-
c. Latch -(L)-
d. Unlatch -(U)-
 TIMERS AND COUNTERS
Input
True False True
Timers: RTO counting stop counting
resume
a. Retentive on delay -(RTO)- RTF stop counting stop
b. Retentive off delay -(RTF)-
c. Reset -(RST)-
RTO reach PR value, output ON
RTF reach PR value, output OFF
Counter:
PR value in 0.1 second
a. Counter up -(CTU)-
b. Counter down -(CTD)-
c. Counter reset -(CTR)-
 SEQUENCER
Sequencers are used with machines or processes involving
repeating operating cycles which can be segmented into
steps.

Output
Step A B C Dwell time
1 ON OFF OFF 5 sec.
2 ON ON OFF 10 sec.
3 OFF OFF ON 3 sec.
4 OFF ON OFF 9 sec.
 Rockwell/ Allen Bradley PLC
I/O points are numbered, they correspond to the I/O slot on
the PLC.

For A-B controller used in our lab

I/O uses 1-32
Internal relays use 033 - 098
Internal timers/counters/sequencers use 901-932
Status 951-982
 Programming a PLC
Oil is consumed
randomly. The
tank needs to be
refilled by turning
on a pump. Two
hydrostatic
switches are used
to detect a high
and low level.
Ladder Logic for Tank
Logic for Ladder Solution
How does it work?
 PROGRAMMING EXAMPLE 1 Bar code reader
microswitch Stopper

Part Conveyor

Robot
Machine

id description state explanation

MSI microswitch 1 part arrive
R1 output to bar code reader 1 scan the part
C1 input from bar code reader 1 right part
R2 output robot 1 loading cycle
R3 output robot 1 unloading cycle
C2 input from robot 1 robot busy
R4 output to stopper 1 stopper up
C3 input from machine 1 machine busy
C4 input from machine 1 task complete
 Input
SOLUTION
Output
MS1 R1
01 11
C1 R2
02 12
C2 R3
03 13
C3 R4
04 14
C4 Programmable
05 Controller 15
PLC
Rung 1. If part arrives and no
part is stopped, trigger the
bar code reader.
01 14 11 Rung 2. If it is a right part,
activate the stopper.
02 14 Rung 3. If the stopper is up, the
machine is not busy and the
12
robot is not busy, load the
14 04 03
part onto the machine.
05 03 13
Rung 4. If the task is completed
and the robot is not busy,
unload the machine.
EXAMPLE 2 TRAFFIC LIGHTS
Main street

Jefferson street

Cycle time

Street Red Yellow Green

Main 3 1 4
Jefferson 5 1 2
WIRING DIAGRAM
input output

64 Jefferson Red

65 Jefferson Yellow
Programmable
Controller
66 Jefferson Green

67 Main Red

70 Main Yellow

71 Main Green
 PROGRAM (1) 901
RUNG1 RTO
80
901 901
RUNG2 RST
901 902
RUNG3 67 M. Red

902
RUNG4 67
RTO
30
RUNG5 901 902
RST
901 903
RUNG6 66 J. Green

903
RUNG7 66
RTO
901 903 20
RUNG8 RST
902 904 M. Green
RUNG9 71

904
71
RUNG10 RTO
901 904 40
RUNG11 RST
904 905
RUNG12 70 M. Yellow
 PROGRAM (2)
905
70
RUNG13 RTO
901 905 10
RUNG14 RST
903 906
RUNG15 65 J. Yellow

906
65
RUNG16 RTO
901 906 10
RUNG17 RST
902 907
RUNG18 64 J. Red

907
RUNG19 64
RTO
901 907 50
RUNG 20 RST