PLC Programmable Logic Controller

What is it?
A PLC is a small computer used for automation of real world processes such as control of machinery in a factory.

Why is it required?
Before the invention of programmable logic controller most industrial control was done using relay control panels. But there are certain major problems associated with the relay control panel. To overcome these problems a programmable control logic was invented.

Relay control panel

To understand those problems we should first know about a relay control panel. Switches and relays can be arranged in circuits to make logical decisions. Output from these circuits can be used to drive loads such as motor, heaters or electromagnetic coils. A relay control panel is comprised of a single to thousands of these circuits.

Relay control panel:

Problems with relay control panel

Mechanical relays and switches failed regularly(coil failure ,contact wear and contamination etc.) Difficult to diagnose problems and replace relays and switches. Difficult to change hardwired logic (example: changing an OR circuit to XOR) Consumed a lot of power.

To address these problems, Richard E. Morley of Bedford Associates invented the first PLC as a consulting project for General Electric in 1968. Bedford Associates is currently named Modicon and is a supplier of PLCs.

What is a PLC:

A digital electronic device that uses a programmable memory to store instructions and to implement specific functions such as logic, sequence, timing, counting and arithmetic operations to control machines and processes.

Differences b/w Relay based & PLC based controller panel

Relay based control panel
Occupies more area.

PLC based control panel

Occupies less area.

Fault rectification is difficult.

Fault rectification is easy.

Modification after installation is difficult. Expansion is difficult. No software required. It needs manual changes.

Easy here even after installation.

Expansion is easy Software is important here. Changes can be made through software.

Efficiency of the relay based control Efficiency of PLC based control system is less. system is high.

Basic PLC components:

Basic PLC components needed to replace relay control panels are:

Isolated power supply Digital input output pins Micro-controller Memory communication system

Simple PLC system layout

Programmer monitor

CPU Input module

microprocessor

memory

Output module

Power supply Racks and chassis

Input devices:
Push Buttons

Output devices:
Lamps

Level switches
Photo sensors

Motor starters
Relay

Operation of PLC:
The actual logic of the control system is established inside the PLC by means of a computer program. That computer program is know as ladder diagram.

RS-logics software is used to prepare the ladder diagrams.

Ladder Diagram Symbols

Used to represent an open switch
Used to represent a closed switch Used to represent any output Used for representing beginning of a rung Used for representing ending of a rung Used for representing latch output

Example of a Motor Control

START

STOP

output

START

STOP

output
Normally Open Contact Normally Closed Contact

Advantages to use PLC

Programmable control system are flexible and easy to maintain. Changes to production requirement only require changes to a project file and not wiring. Programming changes are easy to enter by maintenance personnel and plant engineer. Programming language is similar to electrical diagram. Can survive harsh industrial environment. Component lifetime is long. Components are modular and easy to replace.

Applications of PLC

Filling and capping of bottles Printing of news papers Assembly of automobiles etc.

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Thanks