Departemen Teknik Industri FTI-ITB

TI-3222: Otomasi Sistem Produksi

Programmable Logic Controller

Laboratorium Sistem Produksi

www.lspitb.org
©2004

Departemen Teknik Industri FTI-ITB

Hasil Pembelajaran
• Umum
ƒ Mahasiwa mampu untuk melakukan proses perancangan
sistem otomasi, sistem mesin NC, serta merancang dan
mengimplementasikan sistem kontrol logika.

• Khusus
ƒ Memahami fungsi PLC serta komponen-komponen PLC

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Departemen Teknik Industri FTI-ITB

PURPOSE OF Programmable
Logic Controllers (PLCs)

• Initially designed to replace relay logic boards

ƒ Sequence device actuation
ƒ Coordinate activities
• Accepts input from a series of switches
• Sends output to devices or relays

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Departemen Teknik Industri FTI-ITB

PURPOSE OF Programmable
Logic Controllers (PLCs)

• Initially designed to replace relay logic boards

ƒ Sequence device actuation
ƒ Coordinate activities
• Accepts input from a series of switches
• Sends output to devices or relays

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FUNCTIONS OF CONTROLLERS

• 1) on-off control,
• 2) sequential control,
• 3) feedback control, and
• 4) motion control.

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CONTROL DEVICES

1) mechanical control - cam, governor, etc.,

2) pneumatic control - compressed air, valves,
etc.
3) electromechanical control - switches, relays,
a timer, counters, etc,
4) electronics control - similar to
electromechanical control, except uses
electronic switches.
5) computer control.

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PROGRAMMABLE LOGIC
CONTROLLER
Invented in 1968 as a substitute for hardwired relay panels.

"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 analog input/output modules, various
types of machines or processes. The digital computer which
is used to perform the functions of a programmable
controller is considered to be within this scope. Excluded
are drum and other similar mechanical sequencing
controllers."
National Electrical Manufacturing Association (NEMA)

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Departemen Teknik Industri FTI-ITB

VENDORS
• Rockwell
• GE/Fanuc
• Schnieder
• MODICOM - GOULD
• ALLEN-BRADLEY
• Honeywell
• SQUARE-D
etc.

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PLC

Input
CPU Input
Module
Flag
System
Output
Output Module
User Ladder
Diagram

Working
memory
registers

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PLC Configuration

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What devices does a PLC interact with?

• INPUT RELAYS-(contacts)These are connected to the outside
world. They physically exist and receive signals from switches,
sensors, etc. Typically they are not relays but rather they are
transistors.
• INTERNAL UTILITY RELAYS-(contacts) These do not receive
signals from the outside world nor do they physically exist.
They are simulated relays and are what enables a PLC to
eliminate external relays. There are also some special relays
that are dedicated to performing only one task. Some are
always on while some are always off. Some are on only once
during power-on and are typically used for initializing data
that was stored.
• COUNTERS-These again do not physically exist. They are
simulated counters and they can be programmed to count
pulses. Typically these counters can count up, down or both
up and down. Since they are simulated they are limited in
their counting speed. Some manufacturers also include high-
speed counters that are hardware based. We can think of
these as physically existing. Most times these counters can
count up, down or up and down.
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What devices does a PLC interact with?

Continued

• TIMERS-These also do not physically exist. They come in many

varieties and increments. The most common type is an on-delay
type. Others include off-delay and both retentive and non-
retentive types. Increments vary from 1ms through 1s.
• OUTPUT RELAYS-(coils)These are connected to the outside world.
They physically exist and send on/off signals to solenoids, lights,
etc. They can be transistors, relays, or triacs depending upon the
model chosen.
• DATA STORAGE-Typically there are registers assigned to simply
store data. They are usually used as temporary storage for math
or data manipulation. They can also typically be used to store
data when power is removed from the PLC. Upon power-up they
will still have the same contents as before power was removed.
Very convenient and necessary!!

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SWITCHES

Non-locking Locking

Normally Open Normally Closed

P1
SPDT DPST
P2

Multiple Throw Multiple Pole

Break-before-make Make-before-break

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TERMS
Throw - number of states
Pole - number of connecting moving parts (number of
individual circuits).

A serial switch box (A-B box) has

two 25 pin serial ports to switch from.
SPDT
A B

Output
Input
DPST

Knob
How is this switch classified?

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TYPES OF SWITCHES

1. Basic switch, operated by a mechanical level,

2. Push-button switch,
3. Slide switch,
4. Thumbwheel switch,
5. Limit switch,
6. Proximity switch, and
7. Photoelectric switch.

RATING: voltage, current

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RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"

contact

coil

input

Relay coil Output contact

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COUNTER
Digital counters output in the form of a relay contact when a
preassigned count value is reached.

input
Register 5

Accumulator
reset

contact

output

Input

Reset

Output

Count 0 12 3 4 5 0 1
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TIMER
A timer consists of an internal clock, a count value register, and an
accumulator. It is used for or some timing purpose.

Clock

Accumulator
reset

Register

Clock
contact
Contact
Reset
output

Output

Count 0 1 2 3 4 5

Time 5 seconds.
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AN EXAMPLE OF RELAY LOGIC

For process control, it is desired to have the process start (by turning on a
motor) five seconds after a part touches a limit switch. The process is
terminated automatically when the finished part touches a second limit
switch. An emergency switch will stop the process any time when it is
pushed.
L1
LS1 PB1 LS2 R1

R1

TIMER
R1 R2
PB1
LS1 LS2

PR=5

TIMER

5
Motor
R2

R1
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Departemen Teknik Industri FTI-ITB

PLC ARCHITECTURE
Programmable controllers replace most of the relay panel wiring by
software programming.

PC
Program
Loader
Switches

Printer
I/O
Processor
Modules Machines
Cassette
Loader
Power
EPROM Memory Supply
Loader

Peripherals External Devices

A typical PLC
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PLC COMPONENTS
1. Processor Microprocessor based, may allow arithmetic
operations, logic operators, block memory moves,
computer interface, local area network, functions, etc.

2. Memory Measured in words.

ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electronically Erasable Programmable
ROM),
EPROM (Erasable Programmable Read Only Memory),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.

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PLC COMPONENTS
3. I/O Modular plug-in periphery
AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g.., high speed timers,
Stepping motor controllers, etc. PID, Motion
4. Power supply AC power
5. Peripheral Hand held programmer (loader),
CRT programmer,
Operator console,
Printer,
Simulator,
EPROM loader,
Cassette loader,
Graphics processor, and
Network communication interface. MAP, LAN

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LADDER DIAGRAM
A ladder diagram (also called contact symbology) is a means of
graphically representing the logic required in a relay logic
system.

Rail
start emergency stop
PB1 PB2
R1

Rung R1

R1

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Ladder Representation

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PLC WIRING DIAGRAM

Input PLC Output

01 01 02 20 11 A
12
02
20
03
20 11

External
switches

Stored program

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SCAN
A PLC resolves the logic of a ladder diagram (program) rung by rung, from
the top to the bottom. Usually, all the outputs are updated based on the
status of the internal registers. Then the input states are checked and the
corresponding input registers are updated. Only after the I/Os have been
resolved, is the program then executed. This process is run in a endless
cycle. The time it takes to finish one cycle is called the scan time.
Output
Input
begin

Idle

Scan cycle

Resolve
logic

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PLC INSTRUCTIONS
1) Relay,
2) Timer and counter,
3) Program control,
4) Arithmetic,
5) Data manipulation,
6) Data transfer, and
7) Others, such as sequencers.

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LOGIC STATES

ON : TRUE, contact closure, energize, etc.

OFF: FALSE, contact open , de-energize, etc.

Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.

(In the notes we use the symbol "~" to represent

negation. AND and OR are logic operators. )

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AND and OR LOGIC

PB1 PB2 R1

R1 = PB1.AND.PB2

AND PB3 PB4

R2
R2 = PB2.AND.~PB4

PB1 R1

R1 = PB1 .OR. PB2

OR PB2

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Departemen Teknik Industri FTI-ITB

COMBINED AND & OR

R1 = PB1 .OR. (PB2 .AND. PB3)

PB1 R1

PB2 pb3

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Relay diagram symbols

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Relay diagram symbols

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RELAY
A Relay consists of two parts, the coil and the contact(s).

Contacts:

a. Normally open -| |-
b. Normally closed -|/|-
c. Off-on transitional -|↑|-
d. On-off transitional -|↓ |-

Coil:

a. Energize Coil -( )-
()
b. De-energize -(/)-
c. Latch -(L)-
d. Unlatch -(U)-

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TIMERS AND COUNTERS

Input
Timers: True False True
counting
RTO counting stop
a. Retentive on delay -(RTO)- resume

b. Retentive off delay -(RTF)- RTF stop counting stop

c. Reset -(RST)-
RTO reach PR value, output ON
RTF reach PR value, output OFF
Counter:
PR value in 0.1 second
a. Counter up -(CTU)-
b. Counter down -(CTD)-
c. Counter reset -(CTR)-

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SEQUENCER

Sequencers are used with machines or processes involving

repeating operating cycles which can be segmented into
steps.

Output

Step A B C Dwell time

1 ON OFF OFF 5 sec

2 ON ON OFF 10 sec

3 OFF OFF ON 3 sec

4 OFF ON OFF 9 sec

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A-B PLC

I/O points are numbered, they correspond to the I/O slot on

the PLC.

For A-B controller used in our lab

I/O uses 1-32
Internal relays use 033 - 098
Internal timers/counters/sequencers use 901-932
Status 951-982

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Programming a PLC

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Ladder Logic for Tank

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Logic for Ladder Solution

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Departemen Teknik Industri FTI-ITB

How does it work?

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PROGRAMMING EXAMPLE 1
Bar code reader
microswitch Stopper

Part Conveyor

Robot
Machine

id Description State Explanation

MSI micro switch 1 part arrive
R1 output to bar code reader 1 scan the part
C1 input from bar code reader 1 right part
R2 output robot 1 loading cycle
R3 output robot 1 unloading cycle
C2 input from robot 1 robot busy
R4 output to stopper 1 stopper up
C3 input from machine 1 machine busy
C4 input from machine 1 task complete

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Input
SOLUTION
Output
MS1
01 11 R1 • Rung 1. If part
C1 02 12
R2
R3
arrives and no part is
C2
C3
03 13
R4 stopped, trigger the
04 14
C4 05
Programmable
15
bar code reader.
•
Controller
PLC Rung 2. If it is a
right part, activate the
stopper.
• Rung 3. If the
01 14 11 stopper is up, the
machine is not busy
02 14 and the robot is not
busy, load the part
12
onto the machine.
14 04 03
• Rung 4. If the task is
05 03 13 completed and the
robot is not busy,
unload the machine.

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EXAMPLE 2 TRAFFIC LIGHTS

Jefferson street
Main street

Cycle time
Street Red Yellow Green
Main 3 1 4
Jefferson 5 1 2

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WIRING DIAGRAM

input output

64 Jefferson Red

65 Jefferson Yellow
Programmable
Controller
66 Jefferson Green

67 Main Red

70 Main Yellow

71 Main Green

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PROGRAM (1)
901
RUNG1 RTO
80
901 901
RUNG2 RST
901 902
RUNG3 67 M. Red

902
RUNG4 67
RTO
30
RUNG5 901 902
RST
901 903
RUNG6 66 J. Green

903
RUNG7 66
RTO
901 903 20
RUNG8 RST
902 904 M. Green
RUNG9 71

904
71
RUNG10 RTO
901 904 40
RUNG11 RST
904 905
RUNG12 70 M. Yellow

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PROGRAM (2)
905
70
RUNG13 RTO
901 905 10
RUNG14 RST
903 906
RUNG15 65 J. Yellow

906
65
RUNG16 RTO
901 906 10
RUNG17 RST
902 907
RUNG18 64 J. Red

907
RUNG19 64
RTO
901 907 50
RUNG 20 RST

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