EE 126 EXERCISE NO.

1 INTRODUCTION TO PROGRAMMABLE LOGIC CONTROLLER

FRANCIS GEORGE TAGANAHAN LOMAAD KEVIN JOHN YATAR DELA CUESTA JOHN PAUL PORMANES MANZANO RUPERT BATO DE GUZMAN PAOLO FRANI VALDEZ

EE 126 AB 2L

JULY 8, 2013

1 1. INTRODUCTION

1.1 Background

In the early days, it was sufficient for machines to be controlled via basic mechanical devices such as gears, levers, and the like. As time goes on, different developments in technology have given rise to more complex machines requiring more advanced control systems. Wired relays and switch control elements replaced mechanical devices in the effort to catch up with the need for more efficient control systems. Yet as manufacturing techniques continue to improve, these alternatives proved to be troublesome as they require control systems to be rewired whenever changes in product needs to be done. Continuous efforts to develop a new means of modifying control system circuitry without rewiring the entire system gave rise to programmable logic circuits. A Programmable Logic Controller (PLC) is an industrial computer control system that continuously monitors the state of input devices and makes decisions based upon a custom program to control the state of output devices (Hackworth, n.d.). Almost any production line, machine function, or process can be greatly enhanced using this type of control system. However, the biggest benefit in using a PLC is the ability to change and replicate the operation or process while collecting and communicating vital information. Another advantage of a PLC system is that it is modular. That is, one can mix and match the types of input and output devices to best suit ones application. A typical modularized PLC is consist of a processor, a mounting rack, a power supply, a programming unit and different input and output modules.

2 A PLC uses a programming language in order to simulate control systems circuitry. This language is known as ladder logic, which was derived from electromechanical relay system-wiring diagram (Hackworth, n.d.). Ladder logic can be graphically represented using ladder diagrams. A ladder diagram is named so because of its ladder like structure (Sumalde, 2013). It consist of two vertical rails, one in the right and one in the left, with rungs in the middle. The rails are also called power rails as they represent connection to a voltage source. The rungs contain circuit elements like switches, contacts, relays, pilot lamps and the like which are powered by the vertical rails (Hackworth, n.d). As more rungs are added, the closer the diagram resembles a ladder.

1.2 Objectives

In this exercise, the students are to familiarize with the WinSPS 3.41 program and the Bosch CL150 simulator kit. After being able to familiarize themselves with the said program and kit, the students are then to construct ladder diagrams for basic logic gates using series and parallel combinations of normally open (NO) and normally closed (NC) contacts.

3 2. MATERIALS AND METHODS

2.1 Materials

In this experiment, the students used a Bosch CL150 simulator kit and the WinSPS 3.41 program.

2.2 Method

First, the student familiarized themselves in using the WinSPS 3.41 program by learning how to make a new project and by exploring its user interface. After familiarizing with functions of the program, the students proceeded in constructing the ladder diagrams for the following logic gates: NOT, AND, OR, NAND, NOR, XOR and XNOR. Finally, the students simulated the ladder diagrams using the Bosch CL150 simulator kit.

4 3. RESULTS AND DISCUSSION

For this exercise, the students created the ladder diagram for different logic gates using normally open and normally closed contacts. These logic gates are NOT, AND, OR, NAND, NOR, XOR and XNOR.

3.1 NOT Gate

Based on the truth table of a NOT gate, as shown in Table 3-1, when the switch is OFF, the output is ON and the output is OFF when the input is ON. From this, the students derived the ladder diagram of a NOT logic gate.

Table 3-1. Truth table of a NOT gate. INPUT 0 1 OUTPUT 1 0

The ladder diagram of a NOT gate consists of a normally closed contact and a coil. A normally closed contact is used for the circuit to be ON even if the switched is not pressed making it the ladder diagram of a NOT gate. This is illustrated in Figure 3-1.

Figure 3-1. Ladder diagram of a NOT gate.

3.2 AND Gate

Table 3 -2 shows the truth table of an AND gate. It shows that the circuit is only ON if the two switches are both ON.

Table 3- 2. Truth table of an AND Gate. A 0 0 1 1 B 0 1 0 1 OUTPUT 0 0 0 1

Figure 3-2 shows the ladder diagram that the students created for an AND gate. The two normally open contact connected in series indicate that the circuit will be in ON stage if and only if the two switches were pressed.

Figure 3-2. Ladder diagram of an AND gate.

6 3.3 OR Gate

Table 3-3 shows the truth table of an OR gate. It shows that the circuit will be ON if at least one switches is turned ON.

3.3 OR GATE Table 3- 3. Truth table of an OR gate. A 0 0 1 1 B 0 1 0 1 OUTPUT 0 1 1 1

Figure 3-3 shows the ladder diagram that the students created for an OR gate. The two normally open contact connected in parallel indicate that the circuit will be in ON stage even if only one of the switches were pressed.

Figure 3-3. Ladder diagram of an OR gate.

7 3.4 NAND Gate

Table 3-4 shows the truth table of a NAND gate. It shows that the circuit will be OFF only if both switches are ON. It is simply the inverse of an AND gate.

Table 3-4. Truth table of a NAND gate. A 0 0 1 1 B 0 1 0 1 OUTPUT 1 1 1 0

Figure 3-4 shows the ladder diagram that the students created for a NAND gate. The two normally closed contact connected in parallel indicate that the circuit will be in OFF stage if both switches are pressed.

Figure 3- 4. Ladder diagram of a NAND gate.

8 3.5 NOR Gate

Table 3-5 shows the truth table of a NOR gate. It shows that the circuit will be ON only if both switches are OFF. It is simply the inverse of an OR gate.

Table 3-5. Truth table of a NOR gate. A 0 0 1 1 B 0 1 0 1 OUTPUT 1 0 0 0

Figure 3-5 shows the ladder diagram that the students created for a NOR gate. The two normally closed contact connected in series indicate that the circuit will be in ON stage if both switches are not pressed.

Figure 3-5. Ladder diagram of a NOR gate.

3.6 XOR Gate

Table 3-6 shows the truth table of an XOR gate. It shows that the circuit will be ON only if one switch is turned ON and will be OFF if the two switches were either turned ON or OFF simultaneously.

9 Table 3-6. Truth table of an XOR gate. A 0 0 1 1 B 0 1 0 1 OUTPUT 0 1 1 0

Figure 3-6 shows the logic diagram circuit of an XOR gate. Using this diagram, the students created the ladder diagram of an XOR gate as shown in Figure 3-7. Two contacts, one is normally open and the other one is normally closed, located on the first rung shows the top NOT and AND combination at Figure 3-6. While the two contacts, one is normally open and the other one is normally closed, located on the second rung shows the bottom NOT and AND combination at Figure 3-6. By connecting the two rungs in parallel shows the OR gate on Figure 3-6. This ladder diagram indicates that the circuit will be ON if only one of the switches is pressed.

Figure 3-6. Logic diagram circuit of an XOR gate.

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Figure 3-7. Ladder diagram of an XOR gate.

3.7 XNOR Gate

Table 3-7 shows the truth table of an XNOR gate. It shows that the circuit will be ON only if the switches are both ON or both OFF. It is simply the inverse of XOR.

Table 3-7. Truth table of an XNOR gate. A 0 0 1 1 B 0 1 0 1 OUTPUT 1 0 0 1

Figure 3-8 shows the logic diagram circuit of an XNOR gate. Using this diagram, the students created the ladder diagram of an XNOR gate as shown in Figure 3-9. Two rungs connected in parallel with one rung consisting of two normally closed contacts in series and the other rung consisting of two normally open contacts in series. This connection indicates that the circuit will be ON if the two switches are both ON or both OFF.

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Figure 3-8. Logic diagram circuit of an XNOR gate.

Figure 3-9. Ladder diagram of an XNOR gate.

12 4. SUMMARY AND CONCLUSION

After performing the exercise, the students were able to familiarize themselves in using the Bosch CL150 simulator kit and the WinSPS 3.41 program. Also, the students learned the basics of a Programmable Logic Circuit (PLC) and ladder diagrams. The knowledge gained was then applied to construct ladder diagrams for the different logic gates. The students concluded that logic gates can be represented in a ladder diagram by using series and parallel combinations of normally open (NO) and normally closed (NC) contacts.

13 5. REFERENCES

ADVANCED MICRO CONTROLS. (2013). What is a programmable logic controller (plc)? Retrieved July 6, 2013 from http://www.amci.com/tutorials/tutorials-whatis-programmable-logic-controller.asp

HACKWORTH, J.R. & HCKWORTH JR, F.D. (n.d.). Programmable logic controller: programming methods and applications. n.p.

SUMALDE, A.A.M. (2013). Control diagrams (illustrations). [Powerpoint slides.]. DEE, CEAT, UPLB, College, Laguna.