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Automated Process Control Through Programmable Logic Controller (PLC) For National Economic Development
Automated Process Control Through Programmable Logic Controller (PLC) For National Economic Development
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Oyebola B. O.
Department of Electrical/Electronic Engineering Technology
Gateway (ICT) Polytechnic Saapade
Email: blessedolalekan@gmail.com
+2348026837573 or +2348039272829
Abstract: Industrial revolution has brought several innovations into production process. Programmable Logic controller (PLC)
is of great impact that brings consistency in manufacturing, accuracy with improved productivity, makes it easy to work in
difficult or hazardous environment. This paper presents a brief review on how an industrial process can be improved through
PLC. This will bring about a system that allows the user to control the process line automatically by sensing and actuation
through some prewritten logic control instruction embedded in the PLC. It is considered a labour saving system that allows
large volumes to move rapidly through a process. This paper describe a brief introduction, fixed and modular PLC hardware,
programming of PLC, industrial application of PLC and economic advantages of PLC automated industrial process for national
development.
Keywords: Programmable, Logic, Controller, Industrial, process
Figure 1: Automated Process Control through
Programmable Logic Controller (Hugh, 2015)
The basic PLC module must be sufficiently flexible and
configurable to meet the diverse needs of different factories
and applications. Input stimuli (either analog or digital) are
received from machines, sensors, or process events in the
form of voltage or current. The PLC must accurately
interpret and convert the stimulus for the CPU which, in
turn, defines a set of instructions to the output systems that Figure 2: Block Diagram of a Programmable Logic
control actuators on the factory floor or in another Controller
industrial environment. A PLC has following sections and each section has unique
job to perform.
2
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The devices that are controlled by the PLC's output
2.1.1 The Sensing Section section screw terminals are the field hardware devices.
This section consists of limit switches, photoelectric
sensors, push buttons etc. These incoming hardware 3.0 FIXED AND MODULAR PLC
devices provides input signal to the PLC. These devices are HARDWARE
also called as field input devices. The term “field input" is
used because this device provides incoming signals that are There are two types of physical configurations, fixed
tangible items that you physically connect to PLC. and modular. In a fixed PLC, all of its components
like, the input section, power supply, CPU and
2.1.2 Input Section associated memory and output section is built into
This section is majorly divided into 2 parts: one self contained unit. All the input and output
First, the physical screw terminals, where incoming screw terminals are built into the PLC package and
signal (input), from the field input devices (limit switch) are fixed, which cannot be moved i.e. not removable.
are connected to the PLC. This type of PLC is also called as a packaged
The second portion of the input section is the PLC's controller. The modular PLC comes as separate
internal conversion electronics. This section converts and pieces. All the parts of modular PLC are purchased
isolates the highvoltage input level from field input separately i.e. piece by piece. It’s like customizing ,
devices. Highvoltage signals from field input devices are There may have 2 or 3 power supplies to choose
converted to +5 volts direct current (VDC) for a valid ON from , a handful of different processors(CPU's) , many
input signal, and a 0 VDC for a valid OFF input signal. separate input modules , many separate output
Incoming signal conversion and isolation is necessary modules and a selection of assemblies , called racks ,
because microprocessor components operate on +5 VDC, chassis , or base plate to hold the pieces together .
whereas an input signal may be of 24 VDC, 120 volts
alternating current (VAC), or 220 VDC. If 120 VAC signal
is inputted, for example, into 5 VDC, circuit will quickly
destroy your PLC. 3.1 PLC Automation
Microprocessor is the heart of any computer; it is also
2.1.3 Controller called as processor, or CPU. The central processing unit
The controller is also known as central processing unit supervises system control through the user program. After
(CPU), or simply as the processor. Central processing unit reading the input signal, the CPU follows the instructions,
controls or supervises the entire process. The central that a programmer or operator has stored in the PLC's
processing unit solves the user program and apparently memory. Depending upon the result of the solved program,
updates the status of the outputs. the field control devices or outputs are turned ON or OFF.
When the PLC is running and following the programmer's
2.1.4 Programmer instructions, it is called as solving the program.
The programmer is a device used by the programmer or
operator to enter or edit program instructions or data. The
programmer can be handheld unit, a personal computer, or 3.2 Action Identification
an industrial computer programming terminal.
A PLC follows the instructions stored in memory. Each
2.1.5 Output Section instruction given by the programmer is placed in PLC
memory in ascending order. A list of instruction is called as
The ON or OFF status of the inputs are read and the
the user ladder program. Instructions are registered into the
information is used to solve the user ladder program and
PLC's memory; The desired instructions for the PLC to
the updated signals is sent to the output section. The output
carry out can be transferred to the controller memory using
section is simply a series of switches, one for each output
either handheld programmer or a personal computer. The
point, that are controlled by CPU and are used to turn
first step is to develop the user ladder program, Figure 2.
output field devices ON or OFF.
Once the user ladder program is verified for correctness,
the next step is to download the program into the
2.2.6 Field Hardware Devices processor's memory. The process of transferring the user
3
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defined PLC program from personal computer's memory available PLC is shown in Figure 4 (Programmable, 2013).
into PLC memory is called as downloading the program. The input module and output module are the connections to
But before downloading the user program, the processor the industrial process that is to be controlled. The inputs to
must be in program mode. If all the inputs and outputs the controller are signals from limit switches, pushbuttons,
signals are wired to the correct screw terminals, the sensors, and other on off devices. In addition, as we will
processor can be put in run mode. In run mode, the describe later, larger PLCs are capable of accepting signals
program will continuously run and solve the programmed from analog devices of the type modeled. The outputs from
instructions. The process of solving the programmed the controller are on/off signals to operate motors, valves,
instruction is sometime called as solving the logic. This and other devices required to actuate the process. The
constant running of the program in a PLC is called as
processor is the central processing unit (CPU) of the
scanning.
programmable controller (Mike, 2008). It executes the
various logic and sequencing functions by operating on the
PLC inputs to determine the appropriate output signals. The
processor is microprocessor very similar in its construction
to those used in personal computers and other data
processing equipment. Tied to the CPU is the PLC
memory, which contains the program of logic, sequencing,
and other input/output operations. The memory for a
programmable logic controller is specified in the same way
as for a computer, and may range from 1k to over 48 k of
storage capacity (Hugh, 2015). A power supply of 115V or
120V ac is specially used to drive the PLC even though the
components of the industrial process that are regulated may
have a higher voltage and power rating than the controller
itself.
Figure 3: A Simple Picture of a Ladder Logic Program
Window 4.0 PROGRAMMING THE PLC
When the PLC is switched into the program mode, all The PLC is programmed by means of a programming
outputs from the PLC are forced OFF regardless of their device. The programming device (sometimes referred to as
rung logic status, and the ladder I/O scan sequence is a programmer) is usually detachable from the PLC cabinet
halted. Run mode is used to execute the user program. so that it can be shared between different controllers.
Input devices are monitored and output devices are Different PLC manufactures provide different devices,
energized accordingly. Test mode is used to operate or ranging from simple teach pendanttype devices, similar to
monitor the user program without energizing any outputs. those used in robotics, to special PLC programming
Remote mode allows the PLC to be remotely changed keyboards and CRT displays.
between program and run mode by a personal computer Most of the programming methods in use today for PLCs
connected to the PLC processor. are based on the ladder logic diagram. This diagram has
been found to be very convenient for shop personnel who
are familiar with circuit diagrams because it does not
require them to learn an entirely new programming
language (http://www.geautomation.com). What is required
is a means of inputting the program into the PLC memory.
There are various approaches for entering and
interconnecting the individual logic elements. These
include:
Entry of the ladder logic diagram
Figure 4: A Picture of a Programmable Logic Controller Lowlevel computertype languages
The components are housed in a suitable cabinet Highlevel computertype languages
designed for the industrial environment. A commercially
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Proceedings of 2nd National Conference on Engineering and Technology2015 (FENGNC 2015)
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Faculty of Engineering, Osun State Polytechnic, Iree, Nigeria
Functional blocks keyboard for entering the individual components on each
Sequential function chart rung of the ladder logic diagram. A CRT capable of
displaying each ladder rung, and perhaps several rungs that
4.1 Entry of the Ladder Logic Diagram precede it, is useful to verify the program. The lowlevel
The first method involves direct entry of the ladder logic languages are generally limited to the types of logic and
diagram into the PLC memory. This method requires the sequencing functions that can be defined in a ladder logic
use of a keyboard and CRT with limited graphics capability diagram (IE 447 CIM, 2013). Timers and counters are
to display symbols representing the components and their essentially required.
interrelationships in the ladder logic diagram. The PLC
keyboard device is often designed with keys for each of the 4.3 Highlevel computertype languages
individual symbols. Programming is accomplished by Highlevel computertype languages are likely to become
inserting the appropriate components into the rungs in the more common in the future to program the PLC. There are
ladder diagram. The components are of two basic types: several of these languages that are beginning to be offered
Contacts and coils. Contacts are used to represent loads commercially. PLC languages are usually quite limited in
such as motors, Solenoids, relays, timers and counters in their ability to operate on signals that are other than
effect; the programmer inputs the ladder logic circuit ON/OFF types. The capability to perform data processing
diagram rung by rung into the PLC memory with the CRT and computation permits the use of more complex control
displaying the results for verification. algorithms, communications with other computerbased
Ladder Logic systems display of data on a CRT console, and input of
Ladder logic is the main programming method used for data by a human operator. Another advantage of the higher
PLCs. As mentioned before, ladder logic has been level languages is the relative case with which a user can
developed to mimic relay logic. The decision to use the interpret a printout of a complicated control program.
relay has objectives: Explanatory comments can be inserted into the program to
• Know general PLC issues facilitate the interpretation. In some application of control
• To be able to write simple ladder logic programs systems, the variables are binary — they can be either of
• Understand the operation of a PLC two possible values, 1 or 0. These values can be interpreted
• PLC History to mean ON or OFF, true of false, object present or not
• Ladder Logic and Relays present, high voltage value or low voltage value, and so on.
• PLC Programming
• PLC Operation 4.4 Logic Control and Sequencing
A logic diagram was a strategic one. By selecting ladder A logic control system is a switching system whose
logic as the main programming method, the amount of output at any moment is determined exclusively by the
retraining needed for engineers and trades people was value of inputs. A logic control system has no memory and
greatly reduced. Modern control systems still include does not consider any previous values of the input signals
relays, but these are rarely used for logic. A relay is a in determining the output signal. Neither does it have any
simple device that uses a magnetic field to control a switch. operating characteristics that perform as a function of time,
When a voltage is applied to the input coil, the resulting PLC (2014). A sequencing system is one that uses internal
current creates a magnetic field. timing devices to determine when to initiate changes in
output variables. There are three basic elements of Logic
4.2 Lowlevel Computertype Languages Control, which are also called Logic Gates: AND, OR and
The second method makes use of a lowlevel computer NOT (Bolton, 2013). There are other elements which are
type language that parallels the ladder logic diagram. Using derived from these three basic elements above like NOR,
the language instructions, the programmer contracts the and NAND, etc. A motor has one start and one stop button.
ladder diagram by specifying the various components and Being power to motor the output, construct the logic flow
their relationships for each rung. This approach can be diagram and, the truth table, Figure 5 and Figure 6.
explained by developing an elementary PLC instruction set.
Our PLC “language” will be a composite of various
manufacturers’ languages, containing perhaps fewer
features than most commercially available PLCs. We will
assume that the programming device consists of a suitable
5
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Proceedings of 2nd National Conference on Engineering and Technology2015 (FENGNC 2015)
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4 3
However, if the job size does not warrant the development
2 1
START
0
of a special controller or if the user is to have the facility of
STOP
0
MOTOR
0
POWER TOMOTOR
0
D D
START
0
1
making simple or independent program changes, or of
1
0
0
(a)
1
1
memory, is the preferred option. The PLC represents such a
0
1
1
1
1
universal controller. (b)
B
It can be used for different applications and, via the
B
program installed in its memory, provides the user with a
Stop
(c)
4 3
benefit in using a PLC is the ability to change and replicate
2 1
PLC helps to control the movement and accumulation of
A ND X1 X2
D
in conjunction with its input signals from the sensors which
X1 A N D X2 (X1 . X2)
D
X1
senses the box position which in turn power the electric
X1 OR X2 (X1 + X2)
OR X2
X1
motor that gives the rollers a reciprocating movement
through a sprocket and chain linkage, (Industrial, 2014).
N OT N OT X1
C
Control panel that is based on a PLC controller can be
FIGU R E Log ic ele m ents A, OR, N
N D OT.
C
B (b) system, number of wires needed for connections is
N orm ally closed co ntacts
e tc.)
(s witch, re lay, B
(c) reduced by 80%.
Ou tp ut loads
(m o tor, lam p soleno , alarm,
etc.)
id
(d) TM R
3s Consumption is greatly reduced because a PLC
Timer
A (e)
CTR consumes less than a bunch of relays.
C o unter A
Diagnostic functions of a PLC controller allow for
4 3 2 1
fast and easy error detection.
Change in operating sequence or application of a
PLC controller to a different operating process can
Figure 6: Symbols for Common Logic and Sequence
easily be accomplished by replacing a program
Components in a Ladder Logic Diagram through a console or using a PC software (not
requiring changes in wiring, unless addition of
5.0 INDUSTRIAL APPLICATIONS OF some input or output device is required).
PLC Needs fewer spare parts.
Every modern industrial system or machine has a It is much cheaper compared to a conventional
controller. Depending on the type of technology used, system, especially in cases where a large number
controllers can be divided into pneumatic, hydraulic, of I/O instruments are needed and when
electrical and electronic controllers. Frequently, a operational functions are complex.
combination of different technologies is used. Furthermore, Reliability of a PLC is greater than that of an
differentiation is made between hardwired programmable electromechanical relay or a timer (Mikroe,
(e.g. wiring of electromechanical or electronic 2003).
components) and programmable logic controllers. The first
is used primarily in cases, where any reprogramming by the
user is out of the question and the job size warrants the
development of a special controller. Typical applications
for such controllers can be found in automatic washing
machines, video cameras, and cars (Srinivas, 2015).
6
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6.0 ECONOMIC ADVANTAGES OF A Productivity can be improved.
PLC AUTOMATED INDUSTRIAL Makes it easy to work in difficult or hazardous
environment.
PROCCESSES FOR NATIONAL Cost effective for controlling complex systems.
DEVELOPMENT Flexible and can be reapplied to control other
Manufacturing in industries forms a significant part of systems quickly and easily.
Nigeria's economic (Ijeoma, 2015). PLCs have been Computational abilities allow more sophisticated
gaining popularity on the factory floor and will probably control.
remain Predominant for some time to come. Most of this is Trouble shooting aids make programming easier
because of the advantages they offer. An advantage of a and reduce downtime.
PLC system is that it can be modular. That is, you can mix Reliable components make these likely to operate
and match the types of Input and Output devices to best suit for years before failure.
your application (AMCI, 2015). This creates flexibility in These relays allow power to be switched on and off without
the control system that has positive growth implication on a mechanical switch. It is common to use relays to make
production and nation economy. simple logical control decisions. The development of low
The economy of Nigeria historically was based on cost computer has brought the most recent revolution, the
agriculture (with cocoa, rubber, and palm products being Programmable Logic Controller (PLC). The advent of the
historically major export), and about 70% of the workforce PLC began in the 1970s, and has become the most common
is still engaged in farming (largely of a subsistence type), choice for manufacturing controls.
Nigeria (2012). The chief crops: cocoa, peanuts, palm oil, It is considered a labor saving system that allows large
corn, rice, sorghum, millet, soybeans, cassava, yams, and volumes to move rapidly through a process, allowing
rubber necessitate finishing processes to preserve and companies to ship or receive higher volumes with smaller
prepare them for export. Industry in Nigeria includes the storage space and with less labor expense. Control
processing of agricultural products and minerals, and the engineering has evolved over time. In the past humans was
manufacture of textiles, construction materials, footwear, the main method for controlling a system (George, 2015).
chemicals, fertilizer, and steel. Fishing and forestry are also More recently electricity has been used for control and
important to national development. early electrical control was based on relays.
Incorporating PLC technology enhances production with
reduction in labour cost hence, tremendous boost on
national economy. Besides, Petroleum is the leading 7.0 CONCLUSION
mineral produced in Nigeria and provides about 95% of Generally, PLC controlled system are durable, reliable
foreign exchange earnings and the majority of government and less maintenance cost. In certain application, they can
revenues. It is largely found in the risky region of Niger be used for static accumulation of cartons and load
delta and in the bights of Benin and Biafra, (Nigeria, 2012). conveyor belt. PLC can be easily tailored to any industrial
The growth and steady production with less human life loss usage including electric gate and all kinds and all forms of
in oil industry have been major challenges to the control, which has the use of sensors. For an effective
government. The life risk in the upstream crude extraction design of this kind of system it is imperative to have a good
is huge; however, usage of automation process control grasp of the basic sensor characteristic. Appropriate use of
system in every stage of production will be of obvious and PLC in production companies will enhance productivity;
measurable reward. reduce risk of life and cost of labour. These have direct
Programmable Logic Controlled Conveyor is impact on economy, improve living standard of human life
emphatically used where conveyor jamming and for national development. The decision makers,
decongestion can be monitored or controlled with governments, chief executive of higher (research)
automated industrial control system through PLC, it institutions and managers should invest to encourage
implies that: training and retraining of technologist for profitable
Consistency in manufacturing can be easily handling of modern PLC in industrial processes.
achieved. A more effective and sensitive sensor is recommended
Complete control of the manufacturing process for better performance. For example a sensor such as
can be achieved. RADAR sensor that could detect contraband goods in
Accuracy and quality can be improved. vehicles. The achievement of a full automation, a real time
7
Faculty of Engineering, Osun State Polytechnic Conference Series (FENGOSPOLYCS)
Proceedings of 2nd National Conference on Engineering and Technology2015 (FENGNC 2015)
On 3rd to 5th August Organized by
Faculty of Engineering, Osun State Polytechnic, Iree, Nigeria
system may be employed and a biometric scanner that will May 2015, from http://www.geautomation.com/products
provide a proper monitoring. /programmableautomationcontrollers
Programmable Logic Controller (2014). Retrieved on 21th
June 2015, from https://en.wikipedia.org/wiki/
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