Mechatronics - PLC Report

Introduction to
Programmable Logic
Controller
Section 1
WHAT IS A PLC?
1. WHAT IS A PLC?
• A PLC is an industrial digital computer, which has

been ruggedized and adapted for the control of
manufacturing processes or any activity that requires
high reliability, ease of programming and process
fault diagnosis.
1. WHAT IS A PLC?
A PLC is an industrial Computer. It is for Controlling manufacturing
process which require:
It is designed to fit inside an electrical
control panel. High Reliability.
For High speed automation, and real-
It can store data and do calculations. time process monitoring.
It is rugged. Ease of programming.

Its basic programming language strongly
It can withstand vibrations and extreme resembles an electrical diagram.
temperatures.
Process fault diagnosis.
It can operate 24/7. It can be configured to log and respond
to hardware faults, and process alarms.
1. WHAT IS A PLC?
PLCs were first designed to replace
Electromechanical Relay Logic Systems
VS
1. WHAT IS A PLC?
Electromechanical Relay Logic Systems
Composed of relays, contactors, timers and

counters.
Costly and bulky.
Requires more downtime to keep it running.
Making changes in the logic or the operation of

the machine is as complicated as starting over.
1. WHAT IS A PLC?
PLCs
Can digitally replicate timers, counters, and relays.
Can be fitted inside a smaller control panel.
Scalable and programmable.
Require less power to run compared to relay logic

systems.
Can do more, as it can perform numerical calculations

Section 2
CAPABILITIES OF MODERN PLCS

2. Capabilities of Modern PLCs
Can Read and Send With Built-in functions for Can be Networked and
Variable Signals Data Processing Communicate to other
devices.
Section 3
PARTS OF A PLC
3. Parts of a PLC
Typical Parts of a PLC
3. Parts of a PLC
A CPU is the one that carries out

instructions from the computer
program, performing basic
mathematical, logical, control and
input/output operations.
3. Parts of a PLC
An Input module detects the status

of input signals such as push-
buttons, switches, temperature
sensors.
An Output module controls devices

such as relays, motor starters, lights.
3. Parts of a PLC
The Power Supply supplies DC

power to other modules that plug
into the rack.
Section 4
TYPES OF I/O DEVICES

4. Types of I/O Devices
There are two types of Signals:

These signals are binary, which

means it can only have two
possible states.
These signals are binary, which

means it can only have two
possible states.
Section 5
WAYS TO PROGRAM A PLC

5. Ways to Program a PLC
Different PLC Programming Languages:
GRAPHICAL LANGUAGES TEXTUAL LANGUAGES
Ladder Diagram (LAD) Instruction List (IL)

Function Block Diagram (FBD) Structured Text (ST)
Sequential Function Chart (SFC)
IEC 61131 STANDARD

The IEC 61131 is an IEC standard for PLCs.
The publication describes the different PLC programming languages,
the data types, and standard functions. And it provides guidelines for
the application and implementation of programming languages.
Section 6
LADDER DIAGRAM
6. Ladder Diagram
By definition:
Ladder diagrams are a type of electrical notation and symbology

frequently used to illustrate how electromechanical switches and relays
are interconnected.
(often referred to as “Ladder Logic”)

6. Ladder Diagram
6. Ladder Diagram
6. Ladder Diagram
6. Ladder Diagram
6. Ladder Diagram
Section 7
BASIC PLC PROGRAMMING SYMBOLS

7. Basic PLC Programming Symbols
An Electromechanical Relay is simply an electrically

operated switch.
It has a coil with an iron core placed across it. The

Coil can be supplied with a relatively small current to
magnetize the core and mechanically turn a switch
that can control a much larger current.
Section 8
PLC PROGRAMMING EXAMPLE

8. PLC Programming Example
Problem: Here a mixer motor is to be used

to automatically stir the liquid in a vat
when the temperature and pressure reach
preset values. In addition, direct manual
operation of the motor is provided by
means of a separate pushbutton station.
The process is monitored with
temperature and pressure sensor switches
that close their respective contacts when
conditions reach their preset values.
Section 9
PLC APPLICATIONS
9. PLC Applications
PLCs are used in batch process in chemical, food, energy, oil, and other industries
that require time or event based decisions.
9. PLC Applications
PLCs are used to decrease cycle time and preparation. Automation eliminates error
and minimize human involvement.
A PLC ensures that equipment can not be started unless all the permissive conditions
for safe start have been established.
The PLC can be programmed to function as an energy management system for boiler
control for maximum efficiency and safety.
Section 10
IMPACTS OF PLC
10. Impacts of PLC
Accelerate progress in creating opportunities for business, the economy, and

society. Society needs automation and manufacturing improvements to provide
value for businesses, contribute to economic growth, and progress on some of our
most difficult societal challenges.

Half of the activities (not jobs) carried out by workers could be automated. An
analysis of more than 2000 work activities across more than 800 occupations shows
specific categories of activities are more easily automatable than others. The least
susceptible types include managing others, providing expertise, and interfacing with
stakeholders. Nearly all occupations will be affected by automation, but only about 5
percent of trades could be fully automated.
10. Impacts of PLC
Jobs lost: Some occupations will see significant declines by 2030. Fifteen
percent of the global workforce, or about 400 million workers, could be displaced by
automation in 2016–2030. In the slowest adoption scenario, only about 10 million
people would be replaced. In advanced economies with relatively high wage levels,
such as France, Japan, and the United States, automation could displace 20 to 25
percent of the workforce by 2030, in a midpoint adoption scenario.

Jobs gained: In the same period, jobs will also be created. Even as workers are
displaced, there will be growth in demand for work and, consequently, jobs. Some of
the most massive gains will be in emerging economies such as India, where the
working-age population is overgrowing. Technology itself has historically been a net
job creator, as seen with the personal computer's introduction. Additional economic
growth, including from business dynamism and rising productivity growth, will also
continue to create jobs.
10. Impacts of PLC
Jobs changed: More positions than those lost or gained will be altered as
machines complement human labor in the workplace. Partial automation will
become more prevalent as machines complement social work. In other fields, jobs
with repetitive tasks could shift toward a model of automated systems. At Amazon,
employees who previously lifted and stacked objects are becoming robot operators.

Workers will need different skills to thrive in the workplace of the
future. Demand for advanced technological skills such as programming will increase.
Social, emotional, and higher cognitive skills, such as creativity, critical thinking, and
complex information processing, will also see growing demand. Physical and manual
skills will decline but will remain the single largest category of workforce skills in
2030.
10. Impacts of PLC
Many workers will likely need to change occupations. In a midpoint scenario,
around 3 percent of the global workforce will need to switch occupational categories
by 2030. Growing occupations will include those with difficult to automate activities
such as managers. Other professions that will see increasing demand for work
include teachers, nursing aides, and tech professionals.

Workplaces and workflows will change as more people work alongside
machines. Workflows and workspaces will continue to evolve to enable humans and
machines to work together. As self-checkout machines are introduced in stores,
cashiers can become checkout assistance helpers. Warehouse design may change
significantly as some portions are designed to accommodate robots.

10. Impacts of PLC
Automation will likely put pressure on average wages in advanced
economies. The occupational mix shifts will probably put pressure on wages. Highly
automatable activities dominate many of the current middle-wage jobs in developed
economies. The risk is that automation could exacerbate wage polarization, income
inequality, and lack of income advancement.
References
Bolton, W. (2015). Programmable Logic Controllers, Sixth Edition. 225 Wyman Street, Waltham MA 02451:
Elsevier Ltd.
James Manyika; Kevin Sneader. (June 1, 2018). AI, automation, and the future of work: Ten things to solve
for. Retrieved from https://www.mckinsey.com/featured-insights/future-of-work/ai-automation-and-the-
future-of-work-ten-things-to-solve-for#.
Kamel, K., & Kamel, E. (2014). Programmable Logic Controller. McGraw-Hill Education.
Petruzella, F. D. (2017). PROGRAMMABLE LOGIC CONTROLLERS, FIFTH EDITION. 2 Penn Plaza, New York, NY
10121: McGraw-Hill Education.
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How will automation impact jobs?

How will automation impact jobs?

How will workplaces and workflows change with automation?

How will workplaces and workflows change with automation?

Introduction to

• A PLC is an industrial digital computer, which has

It is rugged. Ease of programming.

Composed of relays, contactors, timers and

Costly and bulky.

Requires more downtime to keep it running.

Making changes in the logic or the operation of

Can digitally replicate timers, counters, and relays.

Can be fitted inside a smaller control panel.

Scalable and programmable.

Require less power to run compared to relay logic

Can do more, as it can perform numerical calculations

CAPABILITIES OF MODERN PLCS

A CPU is the one that carries out

An Input module detects the status

An Output module controls devices

The Power Supply supplies DC

TYPES OF I/O DEVICES

There are two types of Signals:

These signals are binary, which

These signals are binary, which

WAYS TO PROGRAM A PLC

Different PLC Programming Languages:

GRAPHICAL LANGUAGES TEXTUAL LANGUAGES

Ladder Diagram (LAD) Instruction List (IL)

IEC 61131 STANDARD

Ladder diagrams are a type of electrical notation and symbology

(often referred to as “Ladder Logic”)

BASIC PLC PROGRAMMING SYMBOLS

An Electromechanical Relay is simply an electrically

It has a coil with an iron core placed across it. The

PLC PROGRAMMING EXAMPLE

Problem: Here a mixer motor is to be used

Accelerate progress in creating opportunities for business, the economy, and

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