Programmable Logic Controllers

Programmable Logic Controllers
• Numerical control and industrial robotics – for

motion control (of cutting tools or end
effectors)
• PLCs and PCs – for discrete control
Discrete Process Control
• Discrete process control systems deal with
parameters and variables that change at
discrete moments in time
• Parameters and variables are themselves
discrete, typically binary, having either of two
possible values, 1 or 0
• The values mean ON or OFF, true or false,
object present or not present, high voltage
value or low voltage value etc, depending on
the application
Contd..
• The binary variables are associated with input
signals to the controller and output signals from the
controller
• Input signals are generated by binary sensors, such
as limit switches or photosensors that are interfaced
to the process
• Output signals are generated by the controller to
operate the process in response to the input signals
and as a function of time like turning switches on
and off etc
Contd..
Discrete process control divided into two

• Logic control: concerned with event driven
changes in the system
• Sequencing: concerned with time driven
changes in the system
Logic control
• Output at any moment determined exclusively
by the values of input
• No memory, does not consider any previous
values of input signal in determining the
output
• Eg: the working of a robot at a forging press
Elements of logic control
• The basic elements are the logic gates AND
,OR and NOT
• Logic gate is designed to provide a specified
output value based on the value of inputs
• For both inputs and outputs, the values can be
either of two levels ,the binary values 0 or 1
• For industrial purposes, 0 is defined to mean
OFF and 1 to mean ON
AND Gate
• Used in automated production system to
indicate that two or more actions have been
successfully completed ,therefore signaling
that the next step in the production process
can be initiated
Inputs output
X1 X2 Y
0 0 0
0 1 0
1 0 0
1 1 1
OR Gate
• Possible use of OR gate in manufacturing –
safety hazards
• Two sensors used to monitor two safety
hazards
• When either hazard is present, the respective
sensor emits a positive signal that sounds an
alarm buzzer
NOT Gate
• Single input
• Reverses the input signal
NAND and NOR gate
• NAND – combines an AND gate and a NOT
gate in sequence
• NOR – combines OR gate and NOT gate
Sequencing
• Sequencing system uses internal timing
devices to determine when to initiate changes
in output variables
• Eg – washing machines , dryers , dishwashers
• Eg of industrial application- to heat a workpart
used in forging application, instead of using a
temperature sensor , a heating cycle may be
used
Contd..
• Outputs generated in an open loop fashion ,
no feedback verification
• Signals occur in the same repeated pattern
within each regular cycle
• Timers and counters used for this purpose
Programmable Logic Controllers
• A microcomputer based controller
• Uses stored instructions in a programmable
memory to implement logic, sequencing,
timing, counting and arithmetic functions for
controlling machines and processes
• Done through digital or analogue input/output
modules
Contd…
• Used in both process industries and discrete
manufacturing, but primarily associated with
the latter to control machines, transfer lines
and material handling equipment
• Before PLC, hardwired controllers composed
of coils ,relays , counters ,timers etc were used
to implement this type of industrial control
Components of the PLC
The basic components are
• Processor
• Memory unit
• Power supply
• I/O module
• Programming device
Processor
• Central processing unit of the programmable
controller
• Executes the various logic and sequencing
functions by operating on the PLC input to
determine the appropriate output signals
• Consists of one or more microprocessors
similar to those used in PCs
Memory Unit
• User /application memory
 Holds data files associated with programs of
logic, sequencing, I/O operations, counter and
timer constants and other variable and
parameter values
 Contents are entered by the user
Contd…
• System memory
 Directs the execution of the control program
and coordinates I/O operations
 Contents entered by the PLC manufacturer
 Cannot be accessed or altered by the user
Power supply
• 120V ac typically used
• Power supply converts it into dc voltages of
+/- 5V
• Battery backup usually provided
I/O Module
• Provides connections to the industrial
equipment or process that is to be controlled
• Inputs to the PLC are signals from limit
switches, push buttons , sensors and other
ON/OFF devices
• Outputs from the PLC are ON/OFF signals to
operate motors ,valves etc required to actuate
the process
Programming Device
• To program the PLC
• Usually detachable from the PLC cabinet so
that it can be shared among different
controllers
• Devices used include teach pendent type
devices , special PLC programming keyboards
and CRT displays
• PCs can also be used
PLC Operating cycle - Scan
• Consists of 3 parts
 Input scan
-the inputs to the PC are read by the processor
-the status of these inputs are stored in the memory
 Program scan
- The control program is executed
- The input values stored in the memory are used in
the control logic
Contd…
 Output scan
- The outputs are updated to agree with the
calculated values
• Scan time: The time to perform the scan
• Depends on the no of inputs that must be
read, the complexity of control functions that
is to be performed and the no of outputs that
must be changed

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Programmable Logic Controllers

• Numerical control and industrial robotics – for

Discrete process control divided into two

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