PLC

PROGRAMMABLE
LOGIC
CONTROLLER
Presented By
 Contents
2

 What is PLC?
 History of PLC
 Major components of PLC
 Operational sequence of PLC
 Advantages
 Disadvantages
 Application
 Ladder logic
 Case Study
3
What is PLC?

PLC is an industrial computer designed

for multiple inputs and output
arrangements.
It is capable of storing the instructions to
implement control functions such as
sequencing, timing, counting,
arithmetic, data manipulation and
communication.
 History of PLC
4
 PLC was introduced in late 1960’s
 First commercial & successful
Programmable Logic Controllers was
designed and developed by Modicon as a
relay replacer for General Motors.
 Earlier, it was a machine with thousands of
electronic parts.
 Later ,in late 1970’s,the microprocessor
became reality & greatly enhanced the role
of PLC permitting it to evolve form
simply relay to the sophisticated system
as it is
today
 Major Components
5

POWER

SUPPL
Y

I M O M
N O U O
P D T D
U U PROCESSOR P U
T U L
From T E To
SENSORS L OUTPUT
Pushbuttons, Solenoids,
contacts, E
contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE
 Major Components
6

POWER SUPPLY
Provides the voltage needed to run the primary PLC components

I/O MODULES
Provides signal conversion and isolation between the internal logic-
level signals inside the PLC and the field’s high level signal.
PROCESSOR
Provides intelligence to command and govern the activities of the entire
PLC systems.

PROGRAMMING DEVICE
Used to enter the desired program that will determine the sequence of
operation and control of process equipment or driven machine.
 PLC operation sequence
7

1) Self test: Testing of its own hardware and

software for faults.
2) Input scan: If there are no problems, Self test
PLC
will copy all the inputs and copy their values
Input scan
into memory.
3) Logic solve/scan: Using inputs, the ladder
logic program is solved once and outputs are Logic scan
updated.
4) Output scan: While solving logic the output Output
values are updated only in memory when scan
ladder scan
updated usingistemporary
done, the outputs
values will 29rMy.ay
in memo
2018
 Programming Languages
8
of PLC
Most common languages encountered in PLC programming
are:
1) Ladder Logic
2) Functional Block Diagram
3) Sequential Function Chart
4) Boolean mnemonics
 Advantages of PLCs:
15

 Reliability.
 Flexibility in programming and reprogramming.
 Cost effective for controlling complex systems.
 Small physical size.
 High speed of operation.
 Ease of maintenance /troubleshooting.
 Reduced space.
 Energy saving.
 Disadvantages of PLCs
16

 PLC devices are proprietary it means that part or

software of one manufacturer can’t be used in
combination with parts of another manufacturer.
 Limited design and cost option.
 Fixed Circuit Operations.
 PLCs manufacturers offer only
closed architectures.
 Applications:
17

 Wherever automation is desired the PLCs are

best suited to meet the task.
 Few examples of industries where PLCs are used :
1) Robots manufacturing and control
2) Car park control
3) Train control station system
4) Food processing
5) Materials handling
6)Machine tools
7)Conveyer system etc.
 Ladder Logic
9

 Ladder logic is a programming language

used to develop software for PLC used in
control applications.
industrial
RUNGES

RAIL RAIL
 Ladder Logic
10

 It is well suited to express

Combinational logic.
The main ladder logic symbols represent
the
elements :
Make contact

Break contact

Relay coil
 Ladder Logic For Basic Gates
11

AND Gate OR Gate

A B Logic(Y) A B Logic(Y)
OFF OFF OFF
OFF OFF OFF
OFF ON ON
OFF ON OFF
ON OFF ON
ON OFF OFF
ON ON ON
ON ON ON

Y
A B Y

B
 Ladder Logic For Basic gate
12

NOR Gate NAND Gate

A B Logic(Y) A B Logic(Y)
OFF OFF ON OFF OFF ON
OFF ON OFF OFF ON ON
ON OFF OFF ON OFF ON
ON ON OFF ON ON OFF

B
A B Y Y
 Block diagram of a PLC
13

LED Outputs
s

Inputs
 Programming Example:
14

 Ladder Logic Program for Start/Stop

of Motor :

X1 X2 Y1

Y1
 CASE STUDY

 Automatic Bottle Rejection System

 This is PLC Program for Automatic Bottle Rejection System.
 Problem Description
• Now a Days the Automation in industries is necessary for Accurate
& Fast Production.
• Let’s Take an Example of soda bottle companies, where the belt
conveyor is used for transferring the bottles from one station to
another station.
• But before bottles reach at soda filling station it is necessary to make
all bottle are in standing position for further processing
• Fallen bottle on the conveyor may create problem in next process. so
here we discuss a simple PLC Logic which handles the fallen bottle.
Case Study (cont..)

 Problem Diagram
Case Study (cont..)

 List of Inputs/Outputs
 Inputs List
• Start PB : I0.1
• Stop PB : I0.0
• Sensor X1 : I0.2
• Sensor X2 : I0.3
 Outputs List
• Cycle ON : Q0.0
• Conveyor : Q0.1
• Cylinder : Q0.2
Case Study (cont..)

 PLC Ladder diagram for Automatic Bottle Rejection System

 Program Description
 In this application, we have used Siemens S7-1200 PLC and TIA Portal Software for
programming. We can also design this logic with relay circuit also.
 Case Study (cont..)

 Network 1 :
 In Network 1, we have taken cycle ON condition for machine. Here we have taken START PB
(I0.1) for starting the cycle and STOP PB (I0.1) for cycle STOP.
 We have taken parallel output of conveyor (Q.1) with cycle ON (Q0.0) so we can operate
conveyor with cycle ON condition.

 Network 2 :
 In Network 2, we have taken sensors X1(I0.2) and X2(I0.3) as inputs. We used NO contact for X2 (I0.3)
sensor and NC contact for X1 (I0.2) sensor.
 When Bottles are transferring on the conveyor, these sensors sense the position of the bottles whether they
are standing or fallen.
 Sensor X2(I0.3) sense down position of the Bottle & Sensor X1(I0.2) Sense top position of the bottle.
 In PLC, we designed the circuit which follows command that if sensor X2(I0.3) sense the bottle & sensor
X1(I0.2) does not sense the bottle then the pneumatic actuator (Q0.2) will come in action & it will reject
the bottle from the conveyor.
 After this, the perfect bottles will go in the soda filling station & whole cycle will be completed.
Thank
You!!!