The Principle of PLC - VFD & its usage in Automation Industry

1 2
Mr. Kunal Yogeshkumar Parikh , Mayur Jain
1
Sr. R & D Engineer, Department of R & D, Hermes Technologies PVT. LTD, Gandhinagar-382023, Gujarat,
India
2
Student of M. Tech, Department of EE, Indus University, Rancharda, Thaltej Ahmedabad-382115, Gujarat,
India
Abstract -This paper gives the introduction of Programmable logic controller, discusses the various
topics of Programmable Logic Controller. In this paper we have discussed the usage of PLC in
Automation industry as well the complete detail of PLC with Variable Frequency Drive (VFD).
Keywords -PLC; Ladder Diagram; Automation Industry; VFD; HMI

I. INTRODUCTION
Automation has become the heart of industries nowadays.A programmable Logic Controller is
defined as a specialized computer used for the control and operation of manufacturing process and
machinery in industry. It uses a programmable memory to store instructions and execute functions
including on/off control, timer, counter, compare, compute/math, move/logical, file and data
handling. Programmable Logic Controllers(PLC) is used in almost every aspect of industry to
enhance and expand production[1].
The PLC is a microcontroller based device with input/output circuitry that monitors the status of field
connected sensor(input) and controls the attached (output) actuators (motor-starters, Solenoids, Speed
drives, Valves, etc) accordint to a user created logic program stored in the memory[1].

In the above experimental setup, a normaly open start push button is wired to the first input(I0,0), a
normally sclosed Stop pushbutton is wired to the second input.
A VFD is a device used in a drive system consisting of three main sub systems which are induction
motor, main drive controller assembly and drive operator interface. They are all are used for
applications which are run at different speeds. The revolutions per minute (rpm) of the driven shaft
need to be increased or decreased depending on load changes, application requirements or other
circumstances [2].
Various control schemes can be used to operate the induction motor in speed control mode of
operation using PLC ladder programming which is used in industry.

@IJRTER-2016, All Rights Reserved 490

 International Journal of Recent Trends in Engineering & Research (IJRTER)
Volume 02, Issue 11;November - 2016 [ISSN: 2455-1457]

II. COMPLETE DETAIL ABOUT PLC & VFD

The usage of a PLC in industry was to directly replace the electromechanical relays as logic elements,
substituting instead a solid-state digital computer with a ladder diagram programming, able to emulate
the interconnection of number of relays to perform specific logical tasks. A Programmable Logic
Controller, PLC or Programmable Controller is a digital computer used for automation of
electromechanical processes [1]. All Programmable Logic Controller (PLC) is having a microprocessor
to compute any task which is given as PLC ladder diagram in PLC software. In an effort to make a
simple and easy PLCs programming, their programming language was designed to resemble ladder
logic diagrams. Hence, any Programmable Logic Controller (PLC) user can easily understand and even
performs the same control functions which are developed by programmer.

(I0.1), and normally closed overload relay contacts (part of the motor starter) are connected to the
third input (I0.2). These I0.1 and I0.2 inputs are usedto control normally opencontacts in a line of
ladder logic programmed into the PLC.
Initially, I0.1 status bit is logic 1 because the normally closed (NC) Stop Pushbutton is closed. I0.2
status bit is logic1 because the normally closed (NC) overload relay (OL) contacts are closed. I0.0
status bit is logic 0, however, because the normally open start pushbutton has not been pressed.
Normally open output Q0.0 contact is also programmed on Network as a sealing contact. With this
simple network, energizing output coil Q0.0 is required to turn on the motor.
When the Start pushbutton is pressed, the CPU receives logic from input I0.0. This causes the
I0.0 logic to output Q0.0. The motor starter is energized and the motor starts.contact to close.
All three inputs are now logic. The CPU sends setup is shown in below diagram.

@IJRTER-2016, All Rights Reserved 491

 International Journal of Recent Trends in Engineering & Research (IJRTER)
Volume 02, Issue 11;November - 2016 [ISSN: 2455-1457]

Figure 4: Communication between PLC and VFD

Figure 5: Experimental Set up for Communication

between PLC and VFD

@IJRTER-2016, All Rights Reserved 492

 International Journal of Recent Trends in Engineering & Research (IJRTER)
Volume 02, Issue 11;November - 2016 [ISSN: 2455-1457]

III. COMMUNICATION BETWEEN DRIVE AND PLC

A PLC is a solid state, industrial computer that performs discrete or sequential logic in a factory
environment. it was originally developed to replace mechanical relays, timer, and counters [3].
A Variable Frequency Drive (VFD) is used for applications wherein speed control is of an essential
importance due to load changes wherein the speed needs to be increased or decreased accordingly.

In this above scenario, we can see that numbers of VFDs are connected to Communication module
and this communication module is attached from PLC CPU. The communication module can be
Modbus/Ethernet etc.
From PLC Ladder Logic Diagram we can decide whether we want to read the parameter of VFD or
we want to write the parameter to VFD. This complete experimental
PROCESS
First, the PLC sequentially scans the input devices and updates a memory by indicating their status
on PLC Ladder diagram as well as Human Machine Interface (HMI). Next, the PLC executes its
control programming, or ladder logic. As it processes the ladder logic, the PLC updates a memory
table which indicates whether output devices which is connected to PLC should be make it ON or
OFF. Finally, the PLC uses the output coil to actually change the condition ofthe output devices
which is connected as coil in PLC ladder diagram.
IV. CONCLUSION
From above Experimental Setup and details of PLC and VFD we can conclude the advantages of
PLC as the Flexibility, Low Cost, Testing, and Visual observation.
Being an economical motor, induction motors are used extensively in industries today. So, if speed
of three phase induction motor can be controlled by PLC then wherever there is a use of induction
motor its speed as well as other parameters can be controlled.

REFERENCES
[1] Avvaru Ravi Kiran, B.Venkat Sundeep, Ch. Sree Vardhan, Neel Mathews!4, “The Principle of Programmable Logic
Controller and its role in Automation”, International Journal of Engineering
Trends and Technology- Volume4, Issue3- 2013
[2] Rinchen Geongmit Dorjee, “PLC and Fuzzy Logic Control of a Variable Frequency Drive”, International Journal of
Engineering Trends and Technology (IJETT) – Volume 16 Number 4 – Oct 2014

@IJRTER-2016, All Rights Reserved 493

 International Journal of Recent Trends in Engineering & Research (IJRTER)
Volume 02, Issue 11;November - 2016 [ISSN: 2455-1457]

[3] Anshul Tiwari, Abhay Pratap Singh, Aditi Dixit, Debojyoti Sen, “PLC APPLICATION FOR SPEED
CONTROL OF INDUCTION MOTORS THROUGH VFD”, Global Journal of Advanced Engineering Technologies
Volume 5, Issue 1- 2016 ISSN (Online): 2277-6370
[4] Ritu Phogat, Lokeshwar, “Implementation of Door Control System Using Ladder Language”, International
Journal of Science and Research (IJSR) ISSN (Online): 2319-7064
[5] Chitra.S., Vijaya Raghavan, “Conveyor Control Using Programmable Logic Controller”,International Journal
of Advancements in Research & Technology,
Volume 3, Issue 8, August-2014 25 ISSN 2278-7763

@IJRTER-2016, All Rights Reserved 494