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PLC & ITS APPLICATION IN DRIVE CONTROL

CONTENTS
Introduction History of PLC Block diagram Components Operation Response time Replacing relays

Programmable Logic Conrollers

Introduction
Device that was invented to replace the necessary sequential relay circuits for machine control. The PLC works by looking at its inputs and depending upon their state, turning on/off its outputs. The user enters a program, usually via software, that gives the desired results.

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History of PLC
First design 1968 Implemented 1969 Goals Eliminate high cost associated with frequent replacement of relay based system Reduce production downtime Provide expandability

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Block diagram
Inputs Outputs

I/O SYSTEM

POWER SUPPLY

PROCESSOR

PROGRAMMING DEVICE

MEMORY UNIT

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Cont..

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In PLC

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Input relays :
Connected to the outside world They physically exist and receive signals from switches, sensors, etc.

Internal utility relays :

These do not receive signals from the outside world nor do they physically exist.
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Counters :
Do not physically exist They are simulated counters and they can be programmed to count pulses

Timers :
do not physically exist on-delay type and off-delay type retentive and non-retentive types

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Output relays :
These are connected to the outside world They physically exist and send on/off signals to solenoids, lights, etc can be transistors, relays, or triacs depending upon the model chosen

Data storage :
Assigned to store data Volatile or non volatile

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PLC Operation
A PLC works by continually scanning a program Consisting of 3 important steps

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Check input status :


PLC takes a look at each input to determine if it is on or off It records the data into its memory to be used during the next step

Execute program :
PLC executes the program one instruction at a time It will store the execution results for use later during the next step
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Update output status :


It updates the outputs based on which inputs were on during the first step and the results of executing your program during the second step

One scan time is defined as the time it takes to execute the 3 steps listed above.

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Response time :
PLC takes a certain amount of time to react to changes Total response time = (Input response time + Program execution time + Output response time )

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Cont

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Pulse stretch function :

Extends the length of of the input signal until the plc looks at the inputs during next scan.

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Interrupt function :
interrupts the scan to process a special routine As soon as the input turns on, regardless of where the scan currently is, the plc immediately stops what its doing and executes an interrupt routine. Goes back to the point it left off at and continues on with the normal scan process.

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Cont

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Programming languages

Program is a set of instructions that are arranged in a logical sequence to control the actions of process or machine

Most common PLC language is Ladder logic

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Ladder diagram

ladder logic diagram

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Relays :
A relay is an electrically operated switch Many relays use an electromagnet to operate a switching mechanism

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Cont
Relay (electromagnetic switch)

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Replacing relays

Contact Coil

Ladder logic

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Basic instructions
Load presence of input signal is needed to turn an o/p on Laodbar absence of referenced signal is needed Out if path has logic continuity, the referenced o/p is energized Outbar if path of false instructions preceding Latch coil for an output to remain energized Unlatch coil reset a latched output

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Cont

Load Loadbar

Out
Outbar

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Level application

We are controlling lubricating oil being dispensed from a tank. This is possible by using two sensors. We put one near the bottom and one near the top, as shown in the picture
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Cont
Both of our inputs will be NC (normally closed) fiber-optic level sensors We are using an internal utility relay

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Scanning

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Advantages
Reduces the size of system Less expensive Easy maintenance Easy to modify

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References
Programmable controllers (2nd edition) by Thomas A Hughes www.plcs.net www.mech.co.uk

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THANK YOU

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