Programmable Logic

Controllers

Programmable Logic Controllers (PLC)

Programmable Logic Controllers (PLC)

Programmable logic controllers are the most
widely used electronic devices in the control
of production and assembly process in most
automated factories due to its simplicity and
versatility.
A programmable logic controller (PLC) is a
user-friendly,
microprocessor-based,
specialized computer carrying out control
functions of many types and levels of
complexity in industrial applications.

Programmable Logic Controllers (PLC)

It would be appropriate to think of the PLC
as
a
special-purpose
computer.
Nevertheless, a programmable logical
controller has many characteristics similar
to those of a general-purpose computer.
It has
a power supply,
main processor,
memory,
inputs and outputs,
possibly some peripheral equipment.

Programmable Logic Controllers (PLC)

According to National Electrical
Manufacturers Association a PLC is:
A digital electronic device using a
programmable memory to store
instructions and to implement specific
functions such as logic, sequence,
counting, timing and arithmetic to control
machines and processes.

Brief Historical Background

Before the PLCs, automated manufacturing processes had to be
controlled using hardware devices such as rotating cams gears,
levers
and
other
basic
mechanical
devices.
As the complexity grew, so did the need for a more sophisticated
control system. This system contained wired relay and switch
control elements. These elements were wired as required to
provide the control logic necessary for the particular type of
machine operation.
This was acceptable for a machine that never needed to be
changed or modified, but as manufacturing techniques improved
and plant changeover to new products became more desirable
and necessary, a more versatile means of controlling this
equipment had to be developed.

Brief Historical Background

Hardwired relay and switch logic was cumbersome and time
consuming to modify. Wiring had to be removed and replaced to
provide for the new control scheme required. This modification
was difficult and time consuming to design and install and any
small "bug" in the design could be a major problem to correct
since that also required rewiring of the system.
However in mid 1970s advances in micro-electronics have made
a revolution in industrial control. Electronic programmable
controller has replaced relay-based, hard-wired electrical
systems.
The first PLC systems evolved from conventional computers in
the mid 1970s and were mostly used in automotive industry

Brief Historical Background

Communications abilities began to appear in approximately 1973.

The PLC could now talk to other PLCs and they could be far away
from the actual machine they were controlling.

Unfortunately, the lack of standardization coupled with continually

changing technology has made PLC communications a nightmare of
incompatible protocols and physical networks.

The 80's saw an attempt to standardize communications with

General Motor's manufacturing automation protocol(MAP). It was
also a time for reducing the size of the PLC and making them
software programmable through symbolic programming on personal
computers instead of dedicated programming terminals or handheld
programmers. Today the world's smallest PLC is about the size of a
single control relay!

PC vs. PLC
In the late 1980s, PCs have been begun to be
used in automatic industrial control, and this led a
competition between PLCs and PCs. What
distinguishes a PLC from a PC are majorly:
PLCs are constructed for a specific purpose with
a smaller program, whereas PCs perform
general tasks.
PLCs are sequential-type controllers which can
process individual steps in a program in order.

PC vs. PLC
Both PLCs and PCs have their particular strengths
and weaknesses indeed.
In general, what is seen and done in industrial
control of today is that:
PLCs do majority of the control jobs.
PCs handle most of the data and math functions.

PC vs. PLC
PLCs can be programmed, controlled and
operated by a person unskilled in operating
computers.
The PLC can operate any system that has
input/output devices that go on and off ass well
as any system with variable input/outputs.

Advantages & Disadvantages of PLCs

Advantages of PLCs:
Increase in flexibility,
Faster implementation of changes and correction,
Lower cost,
Easy visualization of process running,
Increased visual observations,
Increased operation speed,
Increased reliability and maintainability,
Increased security,
Reprogramming capability,
Elimination of wiring.

Advantages & Disadvantages of PLCs

On the contrary the disadvantages are:

Fixed program applications,

High initial investment cost.

Advantages & Disadvantages of PLCs

A trade off should be done between the
advantages and disadvantages of the PLCs before
installing them to the production system.
As level of automation and computer programming
in manufacturing increases, using PLC control
instead of mechanical systems becomes more
feasible.

PLC Configuration
Basic PLCs are available on a
single printed circuit board. They
are sometimes called single
board PLCs or open frame
PLCs.

PLCs are also available housed in

a single case (sometimes referred
to as a shoe box) with all input
and output, power and control
connection points located on the
single unit.

PLC Configuration
More sophisticated units,
with a wider array of
options, are modularized.
The
modularized
consists of:

PLC

CPU module
Input
and
Output
modules(I/O modules)
A power supply module
Peripheral equipments
Programming Unit

Parts of the PLCs

This module

CPU Module:

consists of a
central processing
unit (CPU) which
acts as the brain of
the system and its
memory

Parts of the PLCs

Input/Output Modules(I/O Modules):

I/O modules allow

the PLC to read
sensors and
control actuators.
There exists a
wide variety of I/O
module types
offered by the PLC
manufacturers.

Parts of the PLCs

Power Supply Module:

Power supply module provides power to

the CPU and often provides power to drive
sensors and low power actuators
connected to I/O modules.

Parts of the PLCs

Peripheral Equipments:
They are used for purposes such as preparing,
storing and loading control programs,system
monitoring and even can be used for communicating
with other computers with which the PLC may be
networked. Some examples can be;
Programmer/Monitor
(PM) which is used to
program instructions and
monitor them,

Racks and chassis for

mounting the other three
parts.

Parts of the PLCs

Programming Unit
The programming unit allows
the engineer or technician to
enter and edit the program to
be executed. In it's simplest
form it can be a hand held
device with a keypad for
program entry and a display
device (LED or LCD) for
viewing program steps or
functions, as shown in Figure.
More advanced systems
employ a separate personal
computer which allows the
programmer to write, view,
edit and download the
program to the PLC.

System Block Diagram