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KARMAVEER
BHAURAO PATIL
POLYTECHNIC,
SATARA
PLC
Fundamentals
Department Of Electronics And
Telecommunication Engineering
Control System and
PLC
EJ5G Subject Code: 17536
Third Year Entc
Amit Nevase
Lecturer,
Department of Electronics & Telecommunication
Engineering,
Karmaveer Bhaurao Patil Polytechnic, Satara
Objectives
The student will be able to:
criteria.
parts of PLC.
PAPER
TH TU PR TH PR OR TW TOTAL
HRS
3/12/17 Nevase A M 4
Module I Introduction to Control
System
Introduction to Control systems
(4 Marks)
Control System Definition and Practical Examples
Classification of Control System : Open Loop and Closed Loop
Systems Definitions, Block diagrams, practical examples, and
Comparison, Linear and Non-linear Control System, Time
Varying and Time In-varying Systems
Servo System : Definition, Block Diagram, Classification (AC and
DC Servo System), Block diagram of DC Servo System.
Laplace Transform and Transfer Function
(4 Marks)
Laplace Transform : Signifiance in Control System
Transfer Function : Definition, Derivation of transfer functions
for Closed loop Control System and Open Loop Control System,
Differential Equations and transfer functions of RC and RLC
Circuit
Block
3/12/17 Diagram Algebra
Nevase A M 5
Module II Time Response
Analysis
Time Domain Analysis
(4 Marks)
Transient and Steady State Response
Standard Test Inputs : Step, Ramp, Parabolic and Impulse, Need,
Significance and corresponding Laplace Representation
Poles and Zeros : Definition, S-plane representation
First and Second order Control System
(8 Marks)
First Order Control System : Analysis for step Input, Concept of
Time Constant
Second Order Control System : Analysis for step input, Concept,
Definition and effect of damping
Time Response Specifications
(8 Marks)
Time Response Specifications ( no derivations )
Tp, Ts, Tr, Td, Mp, ess
3/12/17 NevaseA M problems on time response
6
specifications
Module III Stability
Introduction to Stability
(4 Marks)
Definition of Stability, Analysis of stable, unstable,
critically stable and conditionally stable
Relative Stability
Root locations in S-plane for stable and unstable
system
Control Actions
(8 Marks)
Discontinuous Mode : On-Off Controller, Equation,
Neutral Zone
Continuous modes: Proportional Controller (offset,
proportional band), Integral Controllers, Derivative
Controllers output equations, corresponding
Laplace transforms, Response
3/12/17 Nevase A M
of P, I, D controllers8
Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
9
Module VI PLC Hardware and
Programming
PLC Hardware
(8 Marks)
Discrete Input Modules Block diagram, typical wiring details,
Specifications of AC input modules and DC input modules.
Sinking and sourcing concept in DC input modules
Discrete Output Modules Block diagram, typical wiring details,
Specifications of AC output modules and DC output modules.
Analog Input and output modules : Block diagram, typical wiring
details and specifications
PLC Programming
(16 Marks)
I/O Addressing in PLC
PLC Instruction Set : Relay instructions, timer instructions,
counter instructions, data handling instructions, logical and
comparison instructions
PLC programming examples based on above instruction using
Ladder programming
3/12/17 Nevase A M 10
Module-V
PLC Fundamentals
Specific Objectives
Explain the basics of PLC.
3/12/17 Nevase A M 12
Examples of PLCs
Wood Industry
Color Mixing
3/12/17 Nevase A M 13
Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
14
What is a Programmable Logic
Controller?
A programmable logic controller (PLC)
is a digital computer used for
automation of electromechanical
processes, such as control of
machinery on factory assembly lines,
amusement rides, or lighting fixtures.
PLCs are used in many industries and
machines.
3/12/17 Nevase A M 15
Advantages of PLCs
Less wiring.
Wiring between devices and relay contacts
are done in the PLC program.
Easier and faster to make changes.
Trouble shooting aids make programming
easier and reduce downtime.
Reliable components make these likely to
operate for years before failure.
3/12/17 Nevase A M 16
Advantages of PLCs
Eliminates much of the hard wiring that was
associated with conventional relay control
circuits.
3/12/17 Nevase A M 17
Advantages of PLCs
Increased Reliability: Once a program has
been written and tested it can be
downloaded to other PLCs.
Generally, if an application
requires more than about
6 control relays, it will
usually be less expensive
to install a PLC.
3/12/17 Nevase A M 20
Advantages of PLCs
Communications Capability: A PLC can
communicate with other controllers or
computer equipment.
3/12/17 Nevase A M 21
Advantages of PLCs
Faster Response Time: PLCs operate in real-
time which means that an event taking
place in the field will result in an operation
or output taking place.
Machines that process
thousands of items per
second and objects that
spend only a fraction of
a second in front of a
sensor require the PLCs
quick response capability.
3/12/17 Nevase A M 22
Advantages of PLCs
Easier To Troubleshoot: PLCs have resident
diagnostic and override functions that
allows users to easily trace and correct
software and hardware problems.
3/12/17 Nevase A M 23
Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and
benefits of PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
24
Origin of PLCs
3/12/17 Nevase A M 25
Evolution of PLCs
1968 Programmable Concept Developed
1969 Hardware CPU Controller with logic
instructions, 1K of memory and 128
I/O points
1974 Use of several (multi) processors
within a PLC, timers and counters,
arithmetic operations, 12K of memory
and 1024 I/O points
1976 Remote Input/output system
introduced
1977 Microprocessor based PLC introduced
3/12/17 Nevase A M 26
Evolution of PLCs
1980 Intelligent I/O modules developed,
Enhanced communication facilities,
Enhanced software features, (e.g.
documentation), Use of personal
microcomputers as programming aids
3/12/17 Nevase A M 27
Definition of PLC
(Definition according to NEMA standard ICS3-1978)
or process.
3/12/17 Nevase A M 28
Leading Brands of PLC
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D
EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
3/12/17 Nevase A M 29
Leading Brands of PLC
JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi
3/12/17 Nevase A M 30
Areas of Applications of PLC
Manufacturing/Machining
Food/Beverage
Metals
Power
Mining
Petrochemical/Chemical
3/12/17 Nevase A M 31
Role of PLC in Automation
In an automated system, PLC is commonly
regarded as the heart of control system.
With a control application program stored within
the memory of PLC in execution, PLC constantly
monitors the state of the system.
PLC provides easy and economical solution for
many automation tasks such as logic/sequence
control, PID control & computing, co-ordination and
communication, operator control and monitoring.
3/12/17 Nevase A M 32
Role of PLC in Automation
Any manufacturing application, which involves
repetitive or discreet operation for that application
PLC, can be used.
3/12/17 Nevase A M 35
Block Diagram of PLC
3/12/17 Nevase A M 36
Power Supply
3/12/17 Nevase A M 39
I/O Section
Input Module
Forms the
interface by which
output field
devices are
connected
PLCs employ to the
an
controller.
optical isolator
which uses light
to electrically
isolate the
internal
components from
the
3/12/17 input and
Nevase A M 41
Programming Device
PC with appropriate
software
3/12/17 Nevase A M 44
PLC Scan Cycle
3/12/17 Nevase A M 45
PLC Size
Sr. Size Description
No.
1 Small - It covers units with up to 128 I/Os and
memories
up to 2 Kbytes.
- These PLCs are capable of providing
simple to
advance levels or machine controls.
2 Medium - It have up to 2048 I/Os and memories
up to 32
Kbytes.
3 Large - the most sophisticated units of the PLC
family.
- They have up to 8192 I/Os and
3/12/17
memories
Nevase A M
up to 750 Kbytes.
46
-
Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules function,
3/12/17 Nevase A M different output devices
47
Types of PLC
Fixed PLC:
A Fixed PLC has all of its components-the
input section, CPU and associated memory,
power supply, and output section-built into
one self-contained unit.
Modular I/O
divided by compartments
nto which separate modules
an be plugged.
Modular I/O
3/12/17 Nevase A M 56
Input Module Connections
3/12/17 Nevase A M 57
Input Devices
Mechanical Switches:
Thermocouple):
3/12/17 Nevase A M 62
Input Devices
Position/Displacement Sensors:
(Rotary/Linear Potentiometer)
The term position sensor is used for a sensor
that gives a measure of the distance
between a reference point and the current
location of the target, while a displacement
sensor gives a measure of the distance
between the present position of the target
and the previously recorded position.
3/12/17 Nevase A M 63
Module V PLC Fundamentals
Introduction
(4 Marks)
Evolution of PLC in automation, need and benefits of
PLC in automation
Block Diagram of PLC
(12 Marks)
Block diagram and description of different parts of
PLC -
CPU Function, Scanning cycle, speed of execution,
Power supply function,
Memory function , organization of ROM and RAM
Input modules function, different input devices
used with PLC and their uses
Output modules Nevase
3/12/17 function,
AM different output
64
Output Modules
Output modules serve as the link between the PLCs
microprocessor and hardware field devices.
Each output module has a terminal block for
attaching output wiring to go to each individual
field output device.
Typical output modules have either 8, 16 or 32
output terminals.
The output signal once received from the CPU, must
be stored before being sent to each output
modules output screw terminals.
3/12/17 Nevase A M 65
The storage area for output signals is called the
Output Module Connections
Same output field
device is used and
wired to the output Triac
module.
3/12/17 Nevase A M 68
Output Devices
Motors
Stepper Motors
3/12/17 Nevase A M 69
References
Programmable Logic
Controllers F. D. Petruzella
Introduction to
Programmable Logic
Controllers Gary Dunning
Programmable Logic
Controllers Jhon
Hackworth, Federic
Hackworth
3/12/17 Nevase A M 70
Thank
You
Amit Nevase
3/12/17 Nevase A M 71