Invention of PLC

The first Programmable Logic Controllers were designed and developed by Modicon as a relay re-placer for GM and Landis. The first PLC, model 084, was invented by Dick Morley in 1969 The first commercial successful PLC, the 184, was introduced in 1973 and was designed by Michael Greenberg.

Relay Cotrol Panel

Too many wiring works Modification can be difficult Troubleshooting can be quite troublesome Power consumption can be quite high

Longer downtime in maintenance and modification works .

PLC Control Panel

Wiring of the system reduced Power consumption is greatly reduced Hardware is greatly reduced PLC self diagnostic functions enable easy and fast troubleshooting. Modification of control sequence can easily be done by programming without changing of wiring.

The reliability of PLC is higher than the relays

Lesser downtime in maintenance and modification works .

Programmable Logic Controller

PLC is a Industrial computer that performs discrete or sequential logic in a factory environment. PLC was originally developed to replace mechanical relays, timers and counters etc. In an automated system the PLC is commonly regarded as the heart of the control system. PLC constantly monitor the state of control system through Input Devices signal and based on the Program Logic to determine the course of action to be carried out through Output Devices

PLC System consists of

CPU Module Memory Board Input Module Output Module Communication Module Power Supply Module

PLC Internal Architecture

The PLC Operation

There are four basic steps in the operation of all PLCs, these steps continually take place in a repeating loop. Input Scan - Detects the state of all input devices that are connected to the PLC

Program Scan - Executes the user created program logic

Output Scan - Energizes or de-energize all output devices that are connected to the PLC. Housekeeping - This step includes communications with programming terminals, internal diagnostics, etc...

Types of PLC
Unitary PLC

CPU, I/O System and Power supply are all constructed as single entity Fixed number of Input and output terminals Non expandable type Inexpensive type

 Modular PLC

Adaptive systems that can be changed easily and simply. They consist of a chassis, rail, or back plane upon which a collection of modules are built into an interfaced system. Required components for a complete system are CPU, power supply, communication and I/O modules. Expandable type Expensive type

PLC Programming Languages

Ladder Diagram Method Functional Block Diagram Method Statement List Method

PLC controlling the emptying & Filling of a Tank

Communication Network Topology

PLC System Network Bus Topology

PLC System Network Ring Topology

PLC System Network Star Topology

PLC System Wireless Network

Communication Links Commonly Used

AS-Interface DeviceNet EtherNet/IP ControlNet Profibus Modbus

AS-Interface
Actuator Sensor Interface is an industrial networking solution used in PLC. It is designed for connecting simple field I/O devices in discrete manufacturing and process applications using a single 2-conductor cable. This cable is designed to make use of a cable piercing technology. When an AS-Interface module is installed on the network, piercing needles penetrate the cable jacket and displace the internal copper strands without cutting them. This allows AS-Interface modules to be installed anywhere on the network without cutting and preparing the cable first. The result is a faster installation without the chance of inadvertent shorts between the leads.

DeviceNet
DeviceNet was originally developed by American company Allen-Bradley DeviceNet is a open network system used in the automation industry to interconnect control devices for data exchange. It uses Controller Area Network as the backbone technology and defines an application layer to cover a range of device profiles. Typical applications include information exchange, safety devices, and large I/O control networks. Making it low-cost and robust compared to the traditional RS-485 based protocols

EtherNet/IP
Ethernet Industrial Protocol is a communications protocol developed by Rockwell Automation, designed for use in process control and other industrial automation applications. It is built on the TCP/IP protocols, but the "IP" in EtherNet/IP stands for "Industrial Protocol", it is not an abbreviation for "Internet Protocol". It is an industrial application layer protocol used for communication between industrial control systems and their components, such as a programmable automation controller, programmable logic controller or an I/O system.

ControlNet
ControlNet is an open industrial network protocol for industrial automation applications, as a fieldbus. Features which set ControlNet include the built-in support for fully redundant cables and the fact that communication on ControlNet can be strictly scheduled and highly deterministic. ControlNet can operate with a single RG-6 coaxial cable bus, or a dual RG6 coaxial cable bus for cable redundancy.

Profibus
PROFIBUS (Process Field Bus) is a standard for field bus communication in automation technology. PROFIBUS is not an openly published and royalty-free protocol

Modbus
Modbus is a serial communications protocol published by Modicon in 1979 for use with its programmable logic controllers(PLCs). Simple and robust Developed with industrial applications in mind Openly published and royalty-free Easy to deploy and maintain

SCADA

SCADA is a type of application SCADA stands for Supervisory Control and Data Acquisition Any application that gets data about a system in order to control that system is a SCADA application

SCADA System consists of

Master Terminal Unit Remote Terminal Unit Communication System HMI & SCADA Application

Master Terminal Unit

MTU is defined as the master or heart of a SCADA system and is located at the operators central control facility. The MTU initiates all communication with remote sites and interfaces with operator. the MTU send the data from RTU to the operators display console, store the information, and then send an operators initiate command to RTU.

MTU consists of

The MTU is usually located in the same building as the HMI and typically connected on ethernet connection. The MTU collects data from DNP3, MODBUS and older MultiTrode remote devices and supplies this data to other systems supporting OPCXML-DA, DNP3 or MODBUS.

Remote Terminal Unit

RTU is a small computer which provides intelligence in the field, and allows the central SCADA master to communicate with the field instruments. It is a stand alone data acquisition and control unit. Its function is to control process equipment at the remote site, acquire data from the equipment, and transfer the data back to the central SCADA system.

RTU consists of

Communication Systems

Wireless System Private Wires System Fiber Optics System Dial-up & Leased Telephone line System

HMI & SCADA Software

A SCADA system provides a HMI allowing the operator to visualize all the functions as the system is operating. The operator can also use the HMI to change set points, view critical condition alerts and warnings, and analyze, archive or present data trends Since the advent of Windows NT, the HMI software can be installed on PC hardware as a reliable representation of the real system at work. Common HMI software packages include Cimplicity (GE-Fanuc), RSView (Rockwell Automation), IFIX (Intellution) and InTouch (Wonderware). Most of these software packages use standard data manipulation or presentation tools for reporting and archiving data and integrate well with Microsoft Excel, Access and Word. Web-based technology is widely being accepted as well. Data collected by the SCADA system is sent to web servers that dynamically generate HTML pages. These pages are then sent to a LAN system at the operators site or published to the Internet.

SCADA Screen on HMI

SCADA Applications
Electric power generation, transmission and distribution: Electric utilities use SCADA systems to detect current flow and line voltage, to monitor the operation of circuit breakers, and to take sections of the power grid online or offline. Water and sewage: State and municipal water utilities use SCADA to monitor and regulate water flow, reservoir levels, pipe pressure and other factors. Buildings, facilities and environments: Facility managers use SCADA to control HVAC, refrigeration units, lighting and entry systems. Manufacturing: SCADA systems manage parts inventories for just-intime manufacturing, regulate industrial automation and robots, and monitor process and quality control. Mass transit: Transit authorities use SCADA to regulate electricity to subways, trams and trolley buses; to automate traffic signals for rail systems; to track and locate trains and buses; and to control railroad crossing gates. Traffic signals: SCADA regulates traffic lights, controls traffic flow and detects out-of-order signals.