Introduction to Programmable Logic Controllers ( PLC )

Name Course Group Field

: R.A.S.C. Ranathunga : IESL :G4 : Electrical

Date of performance: 17/03/2012

ASSIGNMENT:
I. I0.0 IN A +100 PT T 37 TON

T 37

Q 0.0

B1 II. I 0.1 IN B +200 T38 Q 0.1 PT T38 TOF

B2

III. CO I 0.2 C I 0.3 R D +5 CO PV Q 0.2 CU CTU

B3

IV. A

I 0.0

I 0.1

Q 0.3

B B4 I 0.2

2. I 0.0 M 0.0

I 0.0

T38 IN

T37 TON

200 T37

PT T38 IN TON

+100

PT

T37

M 0.0

Q 0.0

T38

3. I 0.0

Q 0.1

I 0.5

M 0.0 T38

M0.0 M 0.0 T38 IN +30 PT T37 TON

T37

Q 0.2

T37 IN +10 PT

T38 TON

Where: Q0.1 motor contactor output Q0.2- pneumatic cylinder I0.0 motor start toggle switch I0.5 - Inductive Proximity sensor

DISCUSSION :
A programmable logic controller is a solid-state industrialized computer system designed to perform the logic functions previously accomplished by components such as electromechanical relays, drum switches, mechanical times/counters, etc., for the control and operation of manufacturing process equipment and machinery. PLC can defines as a "digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions, such as logic , sequencing, timing, counting, and arithmetic to control through digital or analogue I/O modules various types of machines or processes. Programmable controllers have grown throughout industrial control applications because of the ease they bring to creating a controller: ease of programming, ease of wiring, ease of installation, and ease of changing. PLCs span a wide range of sizes, but all contain six basic components:

1. processor or central processing unit (CPU); 2. input assembly; 3. output assembly; 4. power supply; 5. programming unit, device, or PC/software The processor, central processing unit, or CPU is the "brain" of the PLC. The size and type of CPU will determine things like: the programming functions available, size of the application logic available, amount of memory available, and processing speed. Understanding the CPU can be a complex subject and we will tackle that in other articles The power supply provides power for the PLC system. The power supply provides internal DC current to operate the processor logic circuitry and input/output assemblies. Common power levels used are 24V DC or 120 VAC & 240VAC. Inputs carry signals from the process into the controller, they can be input switches, pressure sensors, operator inputs, etc. These are like the senses and sensors of the PLC. Outputs are the devices that the PLC uses to send changes out to the world. These are the actuator the PLC can change to adjust or control the process - motors, lights, relays, pumps, etc. Many types of inputs and outputs can be connected to a PLC, and they can all be divided into two large groups - analog and digital. Digital inputs and outputs are those that operate due to a discrete or binary change - on/off, yes/no. Analog inputs and outputs change continuously over a variable range - pressure, temperature, potentiometer The term I/O refers to Input / Output. I/O is information representing the data that is received from sensing devices and the commands that are sent to actuating and indicating devices. The I/O System is the collection of physical elements of the control system that either provide or use I/O data. There are two major types of I/O: 1. Digital - binary devices which must be in one of only two states: on or off. 2. Analog - continues devices - sense and respond to a range of values. Digital input devices may be either on or off; they may not hold any other values. For example, digital position sensors do not sense how close an object is, they only tell if the object is within a range of positions. Common digital field input devices include pushbuttons, limit switches, and photo eyes. Common digital output devices include relays, motor starters, and solenoid valves.

Analog input devices sense continuous parameters. The information that they provide is given as a continuous range of values, not just an on or off indicator. Common analog inputs are pressure, temperature, speed, etc. Analog output devices respond to a range of output values from the controller. Common analog output signals include motor speed, valve position, air pressure, etc. The PLC is programmed using a specialty programmer or software on a computer that can load and change the logic inside. Most modern PLCs are programmed using software on a PC or laptop computer. Older systems used a custom programming device called as console. The process of reading inputs, executing logic, and writing outputs is called the PLC Scan or Sweep. Once the program is in the CPU - the PLC is then set to "run", and the PLC executes the application program repeatedly. In addition to executing the program, the CPU regularly reads the status of the input devices, and sends data to the output devices. The Input system senses the status of the real world inputs (a switch, a level, etc.), translates them to values that can be used by the CPU, and writes those values to the Input table. The application program is executed, and writes values to the Output table. The Output system then converts the output value to a real world change (motor turns on, valve opens, etc.)