AUTOMATION

Dr. Ibrahim Al-Naimi

Chapter five
Programmable Logic
Controller
(PLC)

Discrete/Continuous Control
System

Input
parameter
(set point )

Controller

Control element
/Actuator

Feedback
sensor

process

Output
variable

Digital Controllers
Traditional (Hardwired).
Digital Logic (Electronic).
Microcontroller.
Programmable Logic Controller (PLC).

Traditional Controller
(Hardwired)

Hard-wired Controller
Disadvantages
Very low reliability.
Inflexibility (very hard to expand and
modify).
No communication, data collection, and
data handling capabilities.
Very hard to troubleshoot.
Very large size.

Programmable Logic Controller

(PLC)
Definition:
Programmable logic controller (PLC) is a
specialized computer (microprocessor-based
controller) used to control machines and
processes. It uses a programmable memory to
store instructions and execute specific
functions that include: On/off control, timing,
counting, sequencing, arithmetic, signal
processing, and data handling.

PLC and Personal Computer

(PC)
Unlike the PC, the PLC has been
designed to operate in the industrial
environment and is equipped with
special input/output interfaces and
also a special control program
language.

PLC and Traditional

Controller
Initially, the PLC was used to replace relay
logic (hard-wired controller).
Many technological advances in the
programmable logic controller industry
continue today. Changes include both
hardware (physical components) and
software (control program) upgrades.
Therefore, PLC can be used in many and
more complex applications.

PLC and Traditional

Controller
Because the structure of PLC is based on
the same principles as those employed in
computer architecture, PLC is capable not
only to performing relay switching tasks
but also capable to perform other functions
such as counting, arithmetic, data
handling, comparing, analogue signal
processing, and so forth.

PLC Advantages
Relatively low cost.
High reliability: The program takes the
place of much of external wiring that would
normally be required for controlling the
process.
Flexibility/programmability: It is easier to
create and change a program in the PLC
than to wire and rewire a control circuit.

PLC Advantages
Communication capabilities: PLC can
communicate with other controllers,
computers, and/or equipments to perform
several functions.
Fast scan and response time.
Easier to troubleshoot: PLCs have
diagnostics and override functions that
allow users to easily track and correct
software and hardware problems.

PLC Advantages
Special interfaces have allowed certain
devices to be connected directly to the
controller, such as thermocouples and
strain gauges
Powerful instructions have been provided
and advanced functional block instructions
have been implemented

PLC Advantages

Expandability/modular
Ease of use in an industrial environment
Ease of installation
Used less space (small size)

PLC Applications

Automotive.
Chemical and Petrochemical.
Glass Processing.
Manufacturing and Machining.
Materials Handling.
Metals.
Power.
Rubber and Plastic.

PLC

Hardware components.
Principle of operation/scan cycle.
Response time.
Modes of operation.
Types and classifications.
Specifications.
Connections.
Programming languages.
Programming Instructions (logic functions, set/reset,
timers, and counters).
Examples/Applications.

PLC

PLC Programming Languages

Statement List (Instruction Set)

Functional Block Diagram (FBD)
Ladder Diagram (Ladder Logic)
Structured Text (ST)
Sequential Function Chart (SFC)

Ladder Diagram
A very commonly used method to program PLCs.
Ladder diagram is equivalent to drawing a control
circuit of traditional controller.
Ladder diagram consists of two vertical lines.
Circuit elements connected as horizontal lines.
Each rung on the ladder defines one operation in the
control process.
A ladder diagram is read from left to right, and from
top to bottom.
Each rung must start with an input(s) and must end
with at least one output.

Logic Gate Programming

Basic Logic Operation and Functions
Basic Rules of Boolean Algebra

Basic Logic Operation and Functions

Logic is the realm of human reasoning that tells you a
certain proposition is true or false.
Many situations and processes that you encounter in
your life can be expressed in the form of propositional
or logical functions.
These functions are true/false or yes/no statements.

Basic Logic Operation and Functions

The light is on only if the bulb is not
burned out and the switch is on
In this example, the first statement is true only if the
last two statements are true.
The first statement (The light is on) is then the basic
proposition, the other two statements are the
conditions on which the proposition depends, and the
(and) is the propositional/logical operation that
connect the two conditions.

Basic Logic Operation and Functions

The basic logic gates/elements are:
- NOT
- AND
- OR

Each logic gate has a symbol and perform a basic

logic operation.
The three basic logic elements can be combined to
form more complex logic functions/operations.
These logic operations can be described using:
-

Logic circuits
Logic equations (Boolean expressions)
Truth tables
Timing diagrams

Basic Rules of Boolean Algebra

Commutative Law.
Associative Law.
Distributive Law.
DeMorgans Theorem.
Basic Rules.

Logic Gate Programming

Example:
Write a PLC program that will turn on a light if one or
other of two switches is closed, and the light will be
turned off when a reset switch is closed. If both
switches are closed simultaneously, the light will be
turned off and an alarm light will operate which can
only by shut off by closing the reset switch.
Inputs

Outputs

Reset Switch (N.O): I0.0

Light: Q0.1

Switch 1 (N.O): I0.1

Alarm: Q0.2

Switch 2 (N.O): I0.2

Example:
A pump is to be used to fill two storage tanks. The
pump is manually started by the operator from a
start/stop station. When the first tank is full, the
control logic must be able to automatically stop flow
to the first tank and direct flow to the second tank
through the use of sensors and electric solenoid
valves. When the second tank is full, the pump must
shut down automatically. Indicator lamps are to be
included to signal when each tank is full. Prepare a
typical PLC program for this control process.

Inputs

Outputs

Stop PB (N.C): I0.0

Pump motor : Q0.0

Start PB (N.O): I0.3

Solenoid 1 (tank 1): Q0.1

Tank (1) full sensor (N.O): I0.1 Solenoid 2 (tank 2): Q0.2
Tank (2) full sensor (N.O): I0.2

Tank (1) full Lamp: Q0.3

Tank (2) full Lamp: Q0.4