CH 5 Weeks 12-15 PLC Mechatronics Pe 4030 Dec 21

General Objectives
To explain and understand the following PLC
Programmable logic controller;

Structure of PLC and system
components;
Programming Languages;
( LAD,STL,FBD)
Logic Gates application for PLC
Timers
Counter
Shift Register
Jump
Programming
Applications
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prof CHARLTON S. INAO
concept:
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Programmable Logic
Controllers
Defined by NEMA as a digital electronic
apparatus with a programmable memory for
storing instructions to implement specific
functions (logic, sequencing, timing, counting,
and arithmetic) to control machines and
processes.
Considered as the first industrial-based computer
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Basic Structure of PLC
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Advantages of Using PLC

Shorter Project
Implementation
Easier Modification
Without Cost Penalty
Project Cost Can be
Accurately Calculated
Shorter Training Time
Required
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Design Easily Change

Using Software
A Wide Range of
Control Operations
Easy
Maintenance
High
Reliability
Standardization of
Controller Hardware
Able to Withstand
Harsh Plant
Environment
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Functions of PLC
Conventional Relay Logic Replacer
Sequence Control
Timer and Counter Functions

Auto / Semi / Manual Control of
Machines and Processes
Arithmetic Operations
Sophisticated
Control
Analog Control (Temperature,

Pressure, etc.)
PID (Proportional Integral
Derivation)
Stepper / Servo Motor Control
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Functions of PLC
Process Monitoring and Alarm
Supervisory Control
Interfacing with Computers

Factory Automation network
Wide Area Network
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I and O
DEVICES
INPUT
LOGIC
- Pushbuttons
- Relays
- Motors
- Limit Switches
- Timers
- Solenoid valves
- Level Switches
- Counter
s
- Lamps
- Flow Switches
PLC
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OUTPUT
- Alarm/annunciato
r
- Relays/contactors
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Basic Control System

Closed Loop System
Controller
Error
Set value
Final Control
Element
Process
Variable
Temperature
Flow
_
Process
Variable
Transmitter
Primary
Element / Transducer
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TYPES
OF PLC
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Hardware Components
Central Processing Unit (CPU)
Micro PLC less than 100 I/Os
Small PLC 0 to 128 I/Os
Medium PLC 0 to 256 I/Os
Large PLC 0 to 512 I/Os
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Power Supply
100 240 Volts AC
100 / 110 Volts AC
200 / 220 Volts AC
24 Volts DC
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Inputs
DC 24 Volts
AC 110 / 220 Volts
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Outputs
Transistor type (24 Vdc )
Relay / Contact type (24Vdc / 220 Vac)
TRIAC type (110 / 220 Vac)
PNP-type Transistor
Input
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NPN-type Transistor
Input
Source
Sink
Generates power
Transmits power
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Relay
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PLC =replacement for relays
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Programming DEVICES
Peripheral Devices
Programming Console
CX-Programmer Software
Conversion Cables
Connecting Cables
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PLC Programming Format

1. Ladder Diagram Language a symbolic instruction type
language
2. Boolean Language- Basic level language that composed
of three (3) Boolean logic operation: AND, OR, NOT
Mnemonic Instruction written in abbreviated
form using 3 or 4 letters that generally imply
the the operation of the instruction
3. Functional Blocks Language high level instructions that
permit the user to program more complex functions
using the ladder diagram format
- Instruction set is composed of blocks that executes
or performs specific function
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4. English Statement Language considered derivative of

computer language such as BASIC.
-also known as Control Statements
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Structured Text
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Function Block Diagram (FBD)
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Sequential Function Chart (SFC)
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Programming Format
1)
Ladder diagram
2)Mnemonic List(STL)
3) Function Block
Diagram
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NOR,NAND,EX-OR
NOR
NAND
EX -OR
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Ladder Diagram
FBD
STL
NETWORK COMMENTS
//
LD I0.0
O
M1.0
O
I0.2
AN I0.1
AN M4.0
=
M1.0
NETWORK 2
LD I0.3
O
M2.0
A M1.0
=
M2.0
NETWORK 3
LD I0.5
O
M3.0
A M2.0
=
M3.0
NETWORK 4
LD I0.2
O
I0.4
A M3.0
=
M4.0
NETWORK 5
LD M1.0
AN M3.0
=
Q3.4
NETWORK 6
LD M2.0
AN M3.0
=
Q3.7
LAD
AND LOAD
STL
FBD
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OR LOAD
LD I0.1
A
I0.2
LD I0.3
A
I0.4
OLD
=
Q3.4
OR LOAD/AND LOAD
LD
A
LD
LD
O
ALD
OLD
=
I0.1
I0.2
I0.3
I0.4
I0.5
Q3.4
Conversion of Relay Ladder LOGIC

to PLC Format
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Ladder Diagram
Steps in PLC Programming

Draw the Schematic Diagram
Draw Control Diagram
Develop PLC Ladder Diagram
I/O Assignment
Convert to Mnemonic (Boolean)
PLC Layout
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Latching Relays(Or logic)
Two Input control;

Resetting a Latch
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Timer: On delay and Off

delay
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TIMER Instruction
ON DELAY TIMER- it delays the

turning on of a device by some
prescribed time.(bit logic from 0 to 1)
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OFF DELAY TIMER

OFF DELAY TIMER- it delays the
turning OFF of a device by some
prescribed time.(bit logic from 1 to 0)
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Timer Resolution Siemens
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Timer Resolution(Siemens)
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TIMER ADDRESS
RESOLUTION
T32, T96
T33-T36
1 ms
10 ms
T97-T100
10 ms
T37-T63
100ms
T101-T255
100ms
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Cascaded timer
Mitsubishi
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Siemens
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On-OFF Cycle Timer

Siemens
Mitsubishi
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COUNTERS
Counter UP
Counter Down
Counter Up/Down (Bi Directional
Counter)
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Counter
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Arithmetic Instruction/Data Manipulating

Instruction
Equal
Add
Not equal
Greater than or
equal
Less than or equal
Subtract
Multiply
Divide
Greater than
Less than
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Equal operation:
<Operand1>
<Operand2>
Description:
You can use the "Equal" instruction to determine if a first comparison value (<Operand1>) is equal to a
second comparison value (<Operand2>).
If the condition of the comparison is fulfilled, the instruction returns the result of logic operation (RLO)
"1". If the comparison condition is not fulfilled, the instruction returns RLO "0". The RLO of the
instruction is logically combined with the RLO of the entire current path as follows:
By AND, when the comparison instruction is connected in series.
By OR, when the comparison instruction is connected in parallel.
Specify the first comparison value (<Operand1>) in the operand placeholder above the instruction.
Specify the second comparison value (<Operand2>) in the operand placeholder below the instruction.
Greater Than >
The OR and AND functions are used to set the values of active and heater. The
TON timer uses the enable EN and delay PRE inputs to drive the accumulator ACC and DN
outputs.
The DN output drives fan2 while the ACC value is compared to the value of 5 to set the output
fan1.
Data flow diagrams can be very useful for doing a high-level design of a control system.
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Equal operation example

Q0.0 is set to 1 only when both conditions are satisfied:
I0.0 is 1; And MB0 equals 15.
%I0.0
MB0
INT
15
Memory Bit 0(MB0)
INT=integer
Q0.0
Greater than or Equal to/SET and RESET
SET=10,000
mV
RST= 20,000
mV
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Add
Description:
You can use the "Add" instruction to add the value at input IN1 and the value at input IN2 and query the sum at
output OUT (OUT = IN1+IN2).
In its initial state, the instruction box contains at least 2 inputs (IN1 and IN2). The number of inputs can be
extended. The inserted inputs are numbered in ascending order in the box. When the instruction is executed, the
values of all available input parameters are added. The sum is stored at the OUT output.
The instruction is only executed if the signal state is "1" at the EN enable input. If the instruction is executed
without errors, the ENO enable output also returns the signal state "1".
The ENO enable output has the signal state "0" if one of the following conditions is fulfilled:
Enable input EN has the signal state "0".
The result of the instruction is outside the range permitted for the data type specified at the OUT output.
A floating-point number has an invalid value.
Add example
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Subtract
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MOVE
Functions
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Move value
Description:
You use the "Move value" instruction to transfer the contents of the operand at the IN
input to the operand at the OUT1 output. The transfer is always made in the direction of
the ascending address.
Move value example:
SET/RESET Function
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Shift
Registers
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Shift and Rotate Operands
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Shift Left Word
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Shift Left Word

=>Illustration
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Shift Register Bit
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88
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89
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90
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Shift Register -Mitsubishi
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Shift Register
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M0.0 start output for internal

relay
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MC/MCR(Master Control Set/Reset)
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JUMP Instructions
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JUMP(JMP)
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Problem: Belt Sanding Machine
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Transfer Station
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Electric Relay Ladder Logic
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102
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103
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Liquid Level Sorter
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105
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106
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107
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Wiring Diagram(Siemens
LOGO)
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Liquid Level Sorter Electrical Ladder

Diagram
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Liquid level Sorting Machine PLC Ladder Ladder

Diagram
M2.0
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Artillery Cartridge Polishing Machine
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The designed and developed automated artillery cartridge polishing machine is intended for
defence application to recondition the 122mm and 130mm diameter cartridges. The machine
is intended to replace the traditional way of polishing the artillery cartridge with a modern
and automated machine for HOMICHO Ammunition Factory. The Artillery cartridge
polishing machine is a pneumatic type polishing machine which is basically used for
polishing the external and internal surfaces of 122mm and 130mm artillery cartridges. The
abrasive head can be moved to any point over the polishing area.
The longitudinal and traverse movements of the polishing head are controlled using a
programmable Language Control (PLC) integrated with pneumatically controlled cylinders.
The PLC program is written using a ladder logic programming method using software for
precise control of all the movements of the actuators in the two directions. Different
directional control valves with pressure relieve valves are mounted to perform different
functions.
Standard design approaches and manufacturing sequences are followed to design and
fabricate the polishing machine. The complete machine includes electric motor, pneumatic
cylinders, polishing abrasives and a pneumatic line. The overall dimension of the machine is
2585x705x470mm and its spindle is designed to hold firmly different caliber cartridges and
can be rotated at 800 RPM with a 5Kw spindle motor.
Since quality of the polishing machine is dependent on different polishing parameters like,
polishing abrasives used, depth of polishing, RPM of the spindle and the feed rate of the
polishing head, the surface quality of polished cartridges when it compared with previously
polished parts it can expected to be in the range of 0.2 and 0
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Cartridge polishing machine PLC Ladder diagram
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Material Sorter
Metal and Non-metal Sorting Machine
Using capacitive and inductive sensor
with material detector
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/NETWORK COMMENTS
//
LDN I0.0
LD I0.1
O
M1.0
ALD
A I1.1
AN M8.0
=
M1.0
NETWORK 2
LD M1.0
LD I0.3
O
M2.0
ALD
=
M2.0
NETWORK 3
LD M1.0
LD I0.4
O
M3.0
ALD
=
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M3.0
NETWORK 4
LD M1.0
LD M2.0
A M3.0
O
M4.0
ALD
=
M4.0
NETWORK 5
LD M1.0
LDN M2.0
A M3.0
O
M5.0
ALD
=
M5.0
NETWORK 6
LD M1.0
LD I0.5
O
M6.0
ALD
=
M6.0
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NETWORK 7
LD M1.0
LD I0.6
O M7.0
ALD
= M7.0
NETWORK 8
LD M1.0
LD I0.7
O I1.0
ALD
= M8.0
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NETWORK 9
LD M1.0
A M4.0
AN M6.0
= Q0.0
NETWORK 10
LD M1.0
A M5.0
AN M7.0
= Q0.1
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FBD
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MIXING TANK APPLICATION
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125
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TRAFFIC LIGHT
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Key Points to Know in Selecting or

Using PLC
I. Know the process to be controlled
II. Determine the type of control
Distributed control
Centralized control
Individual machine control
III. Determine I/O interface requirements

Estimate digital and analog I./Os
Check for I/O specifications
Determine if remote I/O is required
Allow for future expansion
IV. Define peripheral devices

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Plc Wiring
SOURCING AND SINKING CONCEPT
From PLC
negative to
positive
(Sinking)
From PLC
Positive to
Negative
(Sourcing)
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PNP
(sourcing)
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Sinking Sensor Wiring
(Sinking)
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PLC Wiring
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Advanced Capabilities
PLCs are often used in applications that go beyond basic logic solving. Some
advanced programming
and input/output (I/O) functions are listed below.
CalculationsThe ability to do basic scientific calculations. Lower end PLCs
only use integer math,
while higher end PLCs also provide floating point math.
Analog I/OContinuous voltage and current values can be input and
output.
Feedback controlProportional integral derivative (PID) controller
calculations are provided as function blocks and can be used with analog
I/O.
CommunicationsThe ability to transmit data as strings over serial ports or
to transfer parts of the PLC memory using proprietary protocols.
ASCII stringsFunctions to manipulate ASCII strings.
System Fault detection, status monitoring, interrupt routines, etc.
Fuzzy logicSome PLCs include fuzzy set functions for nonlinear control
problems.
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At a minimum PLCs use communications for programming. But in

many applications PLCs are used to communicate with other
devices. In the past, most communications were based on
proprietary, or closed, standards. More recently a few open
communication standards have been developed and are
supported by many vendors; these include Profibus,
DeviceNet, CanBus, and ModBus. There has also been a
trend to use more universal communication standards such as
RS-232, RS-422, RS-485, and Ethernet. An example of an
automation system is shown in Figure 18.14. An RS-232
connection is used
between a laptop computer (e.g., COM1) and PLC1 for
rogramming. DH+ is used to connect PLC1, PLC2, and the HMI; it
is a proprietary communication standard developed by AllenBradley. An operator can use the Human Machine Interface (HMI)
to display data and accept operator input and communicate
these values directly to both PLCs. Devicenet, an open
automation standard, is used to connect PLC2 to
a welding controller.
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PLC Analog Inputs and

Outputs
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Maintenance
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The End
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General Objectives

To explain and understand the following PLC

Programmable logic controller;

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

Basic Structure of PLC

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

Advantages of Using PLC

Design Easily Change

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

Timer and Counter Functions

Analog Control (Temperature,

prof CHARLTON S. INAO

Interfacing with Computers

prof CHARLTON S. INAO

prof CHARLTON S. INAO

Basic Control System

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

PLC =replacement for relays

prof CHARLTON S. INAO

PLC Programming Format

prof CHARLTON S. INAO

4. English Statement Language considered derivative of

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

Function Block Diagram (FBD)

prof CHARLTON S. INAO

Sequential Function Chart (SFC)

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

prof CHARLTON S. INAO

Conversion of Relay Ladder LOGIC

prof CHARLTON S. INAO

Steps in PLC Programming

prof CHARLTON S. INAO