Tugas

Programmable Logic Controllers

1. Apa keuntungan dan kerugian PLC?
2. Sebutkan alat apa saja yang termasuk dalam
Input PLC?
3. Sebutkan alat apa saja yang termasuk dalam
Output PLC?
4. Jelaskan prinsip kerja dari dua Simple Relay
Circuit berikut ini!

Struktur / Elemen Makatronika

Programmable Logic Controllers

( Definition according to NEMA standard ICS3-1978)
A digitally operating electronic apparatus which uses a programming memory for the internal
storage of instructions for implementing specific functions such as logic, sequencing, timing,
counting and arithmetic to control through digital or analog modules, various types of machines or
process.

Advantages and Disadvantages

1.
2.
3.
4.
5.
6.
7.

armored for severe conditions

(dust, moisture, heat, cold,
have the facility for extensive
input/output (I/O) arrangements
Cost effective for controlling
complex systems.
Flexible and can be reapplied to
control other systems quickly and
easily.
Computational abilities allow more
sophisticated control.
Trouble shooting aids make
programming easier and reduce
downtime.
Reliable components make these
likely to operate for years before
failure.

1.
2.
3.

Too much work required in

connecting wires.
Difficulty with changes or
replacements.
Difficulty in finding errors; requiring
skillful work force.

Leading Brands Of PLC

AMERICAN

EUROPEAN

JAPANESE

1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
1.
2.
3.
4.

Allen Bradley
Gould Modicon
Texas Instruments
General Electric
Westinghouse
Cutter Hammer
Square D
Siemens
Klockner & Mouller
Festo
Telemechanique
Toshiba
Omron
Fanuc
Mitsubishi
5

PLC
CPU

Input

Input
Module

Flag
System
Output
User Ladder
Diagram

Working
memory
registers

Output
Module

SWITCHES
Non-locking

Locking

Normally Open

Normally Closed

P1

P2
Multiple Throw

Multiple Pole

Break-before-make

Make-before-break

RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"

contact

coil

input

Relay coil

Output contact

COUNTER
Digital counters output in the form of a relay contact when a
preassigned count value is reached.
input
Register

Accumulator
reset
contact
output

Input
Reset
Output
Count

12

TIMER
A timer consists of an internal clock, a count value register, and
an accumulator. It is used for or some timing purpose.
Clock

Accumulator
reset
Register
Clock

contact
Contact
output

Reset
Output
Count

Time 5 seconds.

Relay Ladder Logic

Ladder logic is possibly the simplest
programming language.
The principle behind the language is illustrated
by a simple electrical relay. (Electrical relay
logic preceded PLCs as initially all logic was
implemented in hard wired panels using actual
relays, timer, Counters etc.)
18

Simple Relay Circuit

19

Circuit representation in Ladder Logic

The above circuit is represented in Ladder
logic as shown in figure below (only the low
voltage circuit is used in ladder logic
diagrams):

Eng. R. L. Nkumbwa @ CBU 2010

20

AN EXAMPLE OF RELAY LOGIC

AN EXAMPLE OF RELAY LOGIC

For process control, it is desired to have the process start (by turning on a motor)
five seconds after a part touches a limit switch. The process is terminated
automatically when the finished part touches a second limit switch. An emergency
switch will stop the process any time when it is pushed.
L1
LS1

PB1

LS2

R1

R1

R1

TIMER

R2

PB1
LS1

LS2

PR=5

TIMER
5

R1

Motor
R2

AN EXAMPLE OF RELAY LOGIC

Programming a PLC
Oil is consumed
randomly. The tank
needs to be refilled by
turning on a pump.
Two hydrostatic
switches are used to
detect a high and low
level.

AN EXAMPLE OF RELAY LOGIC

Ladder Logic for Tank

AN EXAMPLE OF RELAY LOGIC

Logic for Ladder Solution
#1
Initially the tank is empty.
Therefore, input 0000 is TRUE
and input 0001 is also TRUE

AN EXAMPLE OF RELAY LOGIC

Logic for Ladder Solution
#2
The internal relay is turned on as
the water level rises.

AN EXAMPLE OF RELAY LOGIC

Logic for Ladder Solution
#3
After scan 2 the oil level rises
above the low level sensor and it
becomes open. (i.e. FALSE)

AN EXAMPLE OF RELAY LOGIC

Logic for Ladder Solution
#4
After scan 4 the oil level rises
above the high level sensor at it
also becomes open (i.e. false)

AN EXAMPLE OF RELAY LOGIC

Logic for Ladder Solution
#5
Since there is no more true logic
path output 500 is no longer
energized (true) and therefore
the motor turns off.

AN EXAMPLE OF RELAY LOGIC

Logic for Ladder Solution
#6
After scan 6 the oil level falls
below the high level sensor and
it will become true again.

PROGRAMMING EXAMPLE 1
Bar code reader

microswitch

Stopper
Conveyor

Part

Robot

Machine

id
description
MSI
microswitch
R1
output to bar code reader
C1
input from bar code reader
R2
output robot
R3
output robot
C2 input from robot
R4
output to stopper
C3 input from machine
C4
input from machine

state
1
1
1
1
1
1
1
1
1

explanation
part arrive
scan the part
right part
loading cycle
unloading cycle
robot busy
stopper up
machine busy
task complete

SOLUTION
Input
MS1

Output

01
02

11
12

C3

03
04

13
14

C4

05

C1
C2

01

Programmable
Controller
PLC

11

14

14

02

14

04

05

03

03

12

13

R1
R2
R3
R4

15

Rung 1. If part arrives and no

part is stopped, trigger the
bar code reader.
Rung 2. If it is a right part,
activate the stopper.
Rung 3. If the stopper is up, the
machine is not busy and the
robot is not busy, load the
part onto the machine.
Rung 4. If the task is completed
and the robot is not busy,
unload the machine.