LOGIC DESIGN SEMINAR ---

PROGRAMMABLE LOGIC
CONTROLLERS
 PROGRAMMABLE
LOGIC CONTROLLER

ABHIBRATHA ADHIKARY – 1RV09EE001

ABHINAV U PATIL – 1RV09EE002
ABHISHEK KUMAR – 1RV09EE003
AISHWARYA S – 1RV09EE004
CONTENTS...

•INTRODUCTION
•HISTORY
•WORKING OF PLC
•APPLICATIONS
 WHAT IS PLC????
Programmable Logic Controller - digital computer similar to a PC at its
core ,used for the automation of electro-mechanical processes, such as machine
control systems on factory assembly lines, amusement rides, or lighting fixtures.
industrial computer - Built to withstand very harsh environments.
Unlike general-purpose computers, the PLC is designed for multiple inputs and
output arrangements, extended temperature ranges, immunity to electrical noise,
and resistance to vibration and impact.

Siemens 314C-2 PtP

 a device that a user can program to perform a
series or sequence of events.
Programs to control machine operation are
typically stored in battery-backed or
non-volatile memory.
A PLC is an example of a real time system since
output results must be produced in response to
input conditions within a bounded time, otherwise
Allen-Bradley PLC installed in a control panel
unintended operation will result.
A plc will continually loop through its user defined program waiting for inputs
and giving outputs at the specific programmed times.

This language which is used to program the Programmable Logic Controller

can be used in three formats, ladder, instruction list and logic symbol.
SIMPLE PLC..
network binary inputs

analog inputs /
outputs
binary outputs
 A lil’ abt PLC HISTORY!!! 
go way back to the 60’s- time of INVENTION.
– relay controlled machines
Before the PLC, control, sequencing, and safety interlock logic for manufacturing
automobiles was accomplished using hundreds or thousands of relays, cam timers,
and drum sequencers and dedicated closed-loop controllers
We can think of a relay as an electromagnetic switch.
 Apply a voltage to the coil and a magnetic field is generated-pulls the contacts of
the relay in, causing them to make a connection.
 Here we are using a dc relay to control
an AC circuit. When the switch is open no
current can flow through the coil of the
relay.
As soon as the switch is closed, however,
current runs through the coil causing a
magnetic field to build up.
This magnetic field causes the contacts of
the relay to close.
Now AC current flows through the bell and
we hear it.
gave rise to several
problems-

they failed often as they

were mechanical.

coil failure and contact

wear were difficult to
diagnose and replace

if changeover was needed

that called for rewiring of
each and every relay–time
consuming &
expensive

relays consumed loads of

power
 Richard D. Morley of Bedford Associates, invented
the first Programmable Logic Controller as a
consultation project for the General Electric
Company in 1968.
Bedford Associates changed their name after some
time to Modicon PLC and eventually became the
supplier of PLCs. The Modicon brand was sold in
1977 to Gould Electronics, and later acquired by
German Company AEG and then by French
Schneider Electric, the current owner.

Note: Programmable Logic Controllers first came about as a replacement for automatic control systems
that used tens and hundreds (maybe even thousands) of hard wired relays, motor driven cam timers and
rotary sequencers.
More often then not, a single PLC can be programmed to replace thousands of relays and timers. These
Programmable Logic Controllers were first befriended by the automotive manufacturing industry, this
enabled software revision to replace the laborious re-wiring of control panels when a new production
model was introduced.
 ADVANTAGES
PLC
Cost effective for
controlling complex
systems.
Flexible & can be reapplied
to control other systems
quickly & easily.
Computational abilities
allow more sophisticated
control.
Troubleshooting abilities
make programming easier &
reduce downtime.
Reliable components
make these likely to operate
for years before failure.
WORKING OF PLC….

HOW PLCs WORK.

 The components that make a modular PLC
work can be divided into four core areas.

 The backplane or rack and power supply.

 The central processing unit (CPU).
 The input/output (I/O) section.
 The Program section.
 The rack
above is a
Mitsubishi
'A' series
rack with
eight I/O
slots and a
power
supply unit
(PSU) slot.
 Here it is
again with
the PSU
slotted in
place.
 The CPU - Central Processing Unit.

• How PLCs work is down to the CPU, the CPU is the PLC
part which is the brain of the whole PLC. This module
typically lives in the slot beside the power supply or is
incorporated with a power supply.

• The CPU itself has a few different operating modes.

• Programming Mode.
• Run Mode.
• Stop Mode.
• Reset Mode.
Below is the basic flow chart of how PLCs work through and process the I/O, their
program operation and error checks, know as the Scan process. The Scan-time is how
long it takes the PLC to loop around the whole process back to the start, and can change
depending on how much the Scan process has to do.
The input/output (I/O) section.

Above is a simple PLC wiring diagram

(called a schematic), in this example you can
see the PLC is a 24V DC supply type.
 PROGRAMMING OF PLC
SOME SOFTWARES FOR PLC PROGRAMMING
 Programming
PLC programs are typically written in a special application
on a personal computer, then downloaded by a direct-
connection cable or over a network to the PLC. The
program is stored in the PLC either in battery-backed-up
RAM or some other non-volatile flash memory. Often, a
single PLC can be programmed to replace thousands of
relays.
IEC 61131-3 currently defines five programming languages for
programmable control systems: FBD (Function block diagram),
LD (Ladder diagram), ST (Structured text, similar to the
Pascal programming language), IL (Instruction list, similar to
assembly language) and SFC (Sequential function chart)
PLC PROGRAMMING CABLES
PLC PROGRAMMING
PORT
•The most favoured and widely used form of programming
language is called ladder logic.
•Ladder logic programming uses specific symbols instead of
actual words.
•The input symbols are representations of real world normally open
and normally closed switches, the output symbols represents relays
and lights connected by lines as though to show a wire. So the flow
of current through the switch and relay or light, like relay contacts
and coils can be viewed like a real circuit, like this.
 A SIMPLE EXAMPLE

This above is the simplest of programs that can be written for a

PLC, that I might add, will actually work. A digital input, like a
push-button connected to the first input position on the card.
When the input is made (the gap bridged) it turns on the output,
which supplies power to energize an indicator light outside the
PLC.
THE COMPLETED PROGRAM LOOKS SOMETHING LIKE THIS
•Video demonstration of plc programming
 APPLICATIONS ….
Every system or machine has a controller. Depending on the type of
technology used, controllers can be divided into pneumatic, hydraulic,
electrical and electronic controllers. Frequently, a combination of different
technologies is used. Furthermore, differentiation is made between
hard-wired programmable (e.g. wiring of electro-mechanical or electronic
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.

However, if the job size does not warrant the development of a special
controller or if the user is to have the facility of making simple or independent
program changes, or of setting timers and counters, then the
use of a universal controller, where the program is written to an electronic
memory, is the preferred option. The PLC represents such a universal
controller. It can be used for different applications and, via the
program installed in its memory, provides the user with a simple means
of changing, extending and optimising control processes.

Example of a
PLC application
Aerospace
- Water tank quenching system
Example
As an example, say a facility needs to store water in a tank. The water is drawn from the tank by another
system, as needed, and our example system must manage the water level in the tank.

Using only digital signals, the PLC has two digital inputs from float switches (Low Level and High Level).
When the water level is above the switch it closes a contact and passes a signal to an input. The PLC uses
a digital output to open and close the inlet valve into the tank.

When the water level drops enough so that the Low Level float switch is off (down), the PLC will open
the valve to let more water in. Once the water level rises enough so that the High Level switch is on (up),
the PLC will shut the inlet to stop the water from overflowing. This rung is an example of seal-in
(latching) logic. The output is sealed in until some condition breaks the circuit.

| |
| Low Level High Level Fill Valve |
|------[/]------|------[/]----------------------(OUT)---------|
| | |
| | |
| | |
| Fill Valve | |
|------[ ]------| |
| |
| |
•Manufacturing Industry
- Lead acid battery plant, complete manufacturing system
- Extruder factory, silo feeding control system

•Travel Industry
- Escalator operation, monitored safety control system
- Lift operation, monitored safety control system

•Agriculture
- Glasshouse heating, ventilation & watering system

•Foundry
- Overhead transportation system from casting process
to shotblasting machine

•Leisure
- Roller coaster ride and effects control system
- Greyhound track 'Rabbit' drive system
•Printing Industry
- Offset web press print register control system
- Multi stage screen washing system
•Food Industry
- Filling machine control system
- Main factory feed water pump duty changeover system
•Textile Industry
- Indutrial batch washing machine control system
- Closed loop textile shrinkage system
•Hospitals
- Coal fired boiler fan change-over system
•Film Industry
- Servo axis controlled camera positioning system
•Corrugating
- Main corrugator machine control system
- BOBST platten press drive and control system
•Plastics Industry
- Extruder factory, silo feeding control system
- Injection moulding control system
 A few more applications…

Plc programming in laser printing Internet communication

INTERNET NETWORK
*7 SEGMENT
DISPLAY
*VENTILATION
*LASER PRINTING
SOURCES…

•www.wikipedia.org/wiki/Programmable_logic_con
troller

• www.machine-informationsystem.com

•www.PLCS.net

•www.ieee.org

•www.plcmanual.com
THANK YOU!!!
