Programmable Logic Controller

PLC
MT3B

Marya Andrea Martínez Carreón ​ ​ ​ 3533

Francisco Javier Marmolejo Vela ​ ​ ​ 3730

Alexis Naim Cortés Hernández ​ ​ ​ 3520

Kevin Ruben Martínez Muñoz​ ​ ​ 3676

Introduction

A Programmable Logic Controller or P.L.C. (Programmable Logic Controller) is a computer

specially designed for industrial automation, controlling a machine or process industrial.

Unlike a traditional computer, a PLC does not have a keyboard, screen or mouse, nor do
they have a hard drive or Windows. But internally if it is a computer, with its hardware:
processors, memory, communication ports, etc. and with its software: an operating system
(which they call Firmware), and a programming, specific for the application or the particular
case in which it is wearing.

The main difference between a PC and a PLC is that the PLC contains multiple channels to
measure different signals coming from sensors installed in the machine or process they
control. And also They have signal output channels that act on the device or process they
own.

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Figure 1. Parts of a PLC

A PLC allows control or protects an industrial process, also enabling the options of
monitoring and diagnosis of conditions (alarms), presenting them in an HMI
(Human-Machine Interface) or operating screen, or presenting them to a higher control
network.

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A PLC is an example of real-time control, as it automatically reacts to conditions and
variables you are monitoring.

A PLC can be part of a distributed control system (DCS). Or it can be part of a SCADA. Or it
may be part of the security system.

A DCS (Distributed Control System). It is a process control system (of an industrial plant)
formed by a network of controllers. A DCS is oriented to real-time control of the process. In
change, we speak of a SCADA, when it is network-oriented to the monitoring of distant
equipment (not real-time monitoring).

On the other hand, a security system, or SIS (Safety Instrumented System) is something
different from a system of control, it is the protection for when the process (or the
machine) goes out of control. Therefore: The same PLC that is used for process control
should NOT be used as part of the control system. safety (protection) of the process itself.
Well, the purpose of a security system is just to bring the process to a safe condition, when
its control goes out of bounds of security.

PLC

Among the latest automation innovations in the industrial market is the PLC and which is
defined as a Programmable Logic Controller; It is a computer whose main objective is the
automation of processes in a production line, so it is in charge of controlling the machine
systems.

This type of tool is considered an intelligent computer that works closely with automatic
engineering, which is why it can execute processes electromechanically; Depending on the
control needs of the company, the actions of a Programmable Logic Controller can be
programmed and provide multiple utilities.

Its acronym stands for Programmable Logic Controller (PLC). This equipment works like a
computer, where the main parts are the CPU, a memory and input/output module, the
power supply and the programming unit.

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For it to work, it is necessary to carry out programming prior to the function that it is going
to carry out. To carry out this programming, specific software adapted to the brand and the
programming language to be developed is needed.

Its function is to detect various types of process signals and develop and send actions
according to what has been programmed. In addition, it receives configurations from the
operators (programmers) and reports to them, accepting programming modifications when
necessary.

The Programmable Logic Controller receives information from connected sensors or input
devices, processes the data and triggers outputs based on pre-programmed parameters.

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Figure 2. PLC fiscally.

Depending on the inputs and outputs, it can monitor and record runtime data such as
machine productivity or operating temperature, automatically start and stop processes,
generate alarms if the machine malfunctions, and more. Programmable Logic Controllers
are a flexible and robust control solution, adaptable to almost any application.

There are a few key features that differentiate PLCs from industrial PCs, microcontrollers,
and other industrial control solutions:

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• I/O. The PLC's CPU stores and processes program data, but input and output modules
connect the PLC to the rest of the machine. These I/O modules are what provide
information to the CPU and trigger specific results.

• Communications. In addition to input and output devices, a PLC may also need to
interface with other types of systems; for example, users may want to export the
application data recorded by the PLC to a supervisory control and data acquisition (SCADA)
system, which monitors multiple connected devices.

• HMI. To interact with the Programmable Logic Controller in real-time, users need an HMI
or human-machine interface. These operator interfaces can be simple screens, with text
readout and a keyboard, or large touch panels more akin to consumer electronics, but
either way, they allow users to review and enter information in real-time.

PLC Architecture

When we talk about the architecture of the PLC we are referring to or mentioning the
components or hardware elements and the set of electronic circuits that make it up. It also
refers to the operating system of each of these circuits.

The architecture of the PLC is made up of 5 components or internal elements that are: 1)
The memory. 2) The CPU. 3) The input module. 4) Output module and 5) power supply.

Below is a general description of each of the internal components that make up the PLC
architecture:

●​ Memory: It is the place or place where instructions and data are stored or saved.
The memory of the PLC or programmable logic processor stores the user programs,
all input and output information, timer data and a large number of program control
constants.
●​ The CPU: Central process or processing unit, is the main part within the PLC
architecture, it is responsible for processing data that it receives continuously. It
makes logical decisions and coordinates various tasks by executing arithmetic and
logical calculations, among other functions.

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 ●​ The input module: Facilitates connection to various actuators and signals for specific
applications. These inputs are interconnected to several switches that will be
activated automatically by the machine or by the operator.
●​ Output module: They coordinate signal outputs that can be digital. PLCs activate or
initiate an output by applying a voltage to the element used in the circuit. The
outputs, as well as the inputs, show two kinds of values ​or electrical voltage
capacities; absent (inactive) and present (active).
●​ The power supply: Provides or provides all the necessary energy to the CPU and
other cards as the PLC has been configured. The power supply acts as a controller.

PLC architecture, external components.

Within the PLC architecture we find the following external components:

●​ Programming terminal: It is an apparently accessory element but very useful in the

activities or operations of a PLC. With this device you can access the instructions
that make up the user plan to execute industrial control activities.

Many PLCs have a programming device or artifact, which palpably has the form of a
calculator, on whose keyboard are all the necessary symbols to carry out projects or control
programs.

In addition, they have a small screen made of liquid crystal in which the representation of
the key that has been pressed is displayed graphically.

●​ Peripherals: These are artifacts or devices such as HMI interfaces, connections to

various types of printers, communication ports, etc. The super memory of a
programmable logic controller stores two types of data: process data and control
data.

PLC architecture, functions and design.

The PLC architecture has been designed to perform a variety of functions. Among those we
can find we have:

●​ Timer: Control connections and disconnections. It is vital in many industrial

automation processes.

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 ●​ Sequencer: Its two main functions are: Identify physical variables remotely
(humidity, temperature, etc.). According to pre-established criteria, activate remote
equipment (deactivate, activate).
●​ Relay: Electromechanical device directed by an electrical system or circuit in which
several contacts are actuated by means of an electromagnet, allowing independent
electrical circuits to open or close.
●​ Counter: Activates internal memories or outputs, when its count register matches
specifically defined values.
●​ Arithmetic / Logical: Performs arithmetic operations and calculations using word
mode operands, the result of the operations are transferred to another word. The
arithmetic operations are: addition, subtraction, multiplication, division and square
root.

I/O of a PLC

PLC I/O is the part of the PLC that connects the brain of the PLC, the CPU, to the outside
world, the machines. In a PLC system there will usually be dedicated modules for inputs
and dedicated modules for outputs. An input module detects the status of input signals
such as push-buttons, switches, temperature sensors, etc.. An output module controls
devices such as relays, motor starters, lights, etc.

Discrete I/O

The most common type of PLC I/O is discrete I/O. Sometimes discrete I/O is referred to as
digital I/O. The concept is simple, discrete I/O are signals that are either on or off. Some
examples of discrete input devices would be things like light switches, push-buttons and
proximity switches.

Some specific real-world examples of discrete inputs to a PLC would be open or closed
circuit breakers, running or stopped generators, a conveyor belt position sensor, or a water
tank level sensor. Some specific applications of discrete outputs would be closing or
opening circuit breakers, starting or stopping generators, opening or closing water valves,
or turning on and off alarm lights.

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Again, this concept is really simple so I won’t belabor it. Just think of discrete I/O as always
either on or off.There’s no in between. Because of this, discrete signals are simple to
process for a computer or PLC. Other ways you can describe a discrete signal are to say it is
either true or false, 1 or 0, open or closed.

NOTE: Many people have questions about sinking versus sourcing discrete I/O. Unfortunately this
topic causes a lot of confusion. However, the concept is fairly simple. Basic electrical theory says
that DC current must flow from DC+ through a load to DC-. You have to have a complete circuit
for current to flow, right? Sinking and sourcing just has to with which side of the circuit you are
completing to detect your input or activate your output. The sinking device is the device that’s
connected to the DC- and the sourcing device is the device that’s connected to the DC+ side of
the circuit. In the U.S., most PLC/PAC systems are designed with sinking input modules and
sourcing output modules. This seems intuitive to me; sinking in, sourcing out. If you want to read
more about this topic, check out this graphical lesson here.

Analog I/O

The other common form of PLC I/O is analog I/O. Analog I/O refers to signals that have a
range of values much greater than just 1 or 0. For instance, an analog signal could produce
a voltage anywhere in the range of 0 – 10 VDC. The signal could be 2 V, 3 V, 8.5 V, etc. In the
PLC world, analog input modules usually measure analog inputs in one of the following
forms: -10 to 10 VDC, 0 – 10 VDC, 1 to 5 VDC, 0 to 1 mA, or 4 – 20 mA. Basically the analog
input module either measures voltage or current from the input device. There are other
types of analog signals but these are definitely the most common. Similarly, the analog
output module can supply voltage or current signals in one of the ranges I mentioned
previously.

An analog signal that most of us are familiar with is the light dimmer. As you adjust the
dimmer knob or slider, the light will get either dimmer or brighter depending on the
direction of the adjustment. Similarly an analog input into the PLC can increase or decrease
in very small increments and the PLC can produce an analog output that acts the same
way.

Some real-world examples of analog inputs in an industrial environment would include

engine temperature sensors (RTDs, thermocouples, etc.), oil pressure sensors and weight

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scales. A temperature sensor might report a temperature range of -50 to 150 degrees C
corresponding to 4-20 mA. A weight scale might report a range of 0 to 1000 lb
corresponding to 0 to 10V. And so on and so forth. Analog outputs can be used to control
the power output on a generator, the position of a needle on an analog pressure meter,
and much more. A 0-3 VDC analog output might be used to drive a generator from 0 – 2000
kW or a 4-20 mA analog output could be used to drive a temperature gauge from -20 to 200
degrees F. As you can see there are many possibilities for applications of analog inputs and
outputs!

Industrial COMMUNICATIONS

Discrete and analog I/O make up the majority of I/O in most PLC systems. However, one
topic I want to discuss briefly is communications and the I/O data that can be transmitted
or received to/from other controllers and devices via industrial communication protocols.
This is a very broad topic, but I want to at least introduce it to you in this post.

There are many industrial communications protocols: Modbus, DNP, BACnet, ControlNet,
EtherNet/IP and many more. One of the oldest industrial communications protocols is
Modbus. Modbus is still widely used in many devices and PLCs because of its simplicity and
its widespread acceptance. It is a good protocol to learn when you’re getting started with
industrial communications.

Modbus is a master-slave type protocol where one device is the master and all other
devices on the Modbus network are slaves. The Modbus master can read from or write to
the device depending on the capabilities of the slave device.

So how does this relate to PLC I/O? Many devices such as PLCs, digital meters, SCADA
systems, VFDs and genset controllers have been designed with an internal data map of
input and output points. The device designer gets to decide how data is allocated. For
instance, in my work I commonly read Modbus data into my PLC/PAC system from power
meters so that I can know the kilowatts, voltage, amps, etc on a circuit or generator. In this
case the PLC acts as a Modbus master and the power meter is the Modbus slave device.
Each device manufacturer will order the data differently in their device’s Modbus map, but
the communications protocol remains the same.

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Master devices can also write data to slave devices. For example, a PLC may be set up as a
Modbus master that writes data to start, stop, or change the speed of a Variable Frequency
Drive (VFD). If you want to learn more about Modbus check out this video from John Rinaldi
at Real Time Automation: Modbus RTU Protocol. John keeps it interesting and fun.

Though all communications protocols work differently they are all designed to do basically
the same thing. Industrial communications devices read and write analog or discrete values
from and to other PLCs/devices without the need for hardwiring every single input and
output point between the PLCs/devices.

NOTE: Most Allen-Bradley PLCs/PACs must use a third-party module or gateway device to
communicate via Modbus. There are many of these devices available on the market from
companies like Prosoft Technology, Sierra Monitor and Real Time Automation.

As you can see, not only can you connect hard-wired inputs and outputs to your PLC, but
you can also read input data from and write output data to devices over Modbus and other
industrial communications protocols. This versatility allows most PLCs/PACs to interface
with almost any device in an industrial environment.

PLC Classification

A wide range of PLC products have different specifications and performance. For PLC, the
classification is generally based on the difference in structure, functions, and the number of
I/Os.

Classification by structure

According to the structure of PLC, it can be divided into two types: integral type and
modular type.

●​ Integral PLC: integrates the power supply, CPU, and I/O interfaces in a single chassis,
as shown in the figure. With compact structure, small size, low price features. Small
PLCs generally use this monolithic structure. The integral PLC consists of a basic unit
(also called a host) with different I/O points and an expansion unit. The basic unit
has a CPU, an I/O interface, an expansion port connected to the expansion I/O unit,
and a programmer or EPROM. The interface to which the router is connected, etc.;

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 the expansion unit only has I/O and power supply, and no CPU. Base units and
expansion units are usually connected by flat cables. Integral PLCs can also be
equipped with special function units, such as analog units, position control units,
etc., so that their functions can be expanded.
●​ Modular PLC: makes the various components of the PLC into separate modules,
such as CPU modules, I/O modules, power modules (some included in the CPU
module), and various function modules. The modular PLC consists of a frame or
base plate and various modules that are mounted on the base socket or frame as
shown. This modular PLC features flexible configuration, and can be equipped with
systems of different sizes according to needs, and is easy to assemble and easy to
expand and maintain. Large and medium-sized PLCs generally adopt a modular
structure.

There are also PLCs that combine the integral and modular features to form a so-called
stacked PLC. The stacked PLC CPU, power supply, I/O interface, etc. They are also separate
modules, but they are connected by cables, and each module can be stacked layer by layer.
In this way, not only can the system be configured flexibly, but it can also be made
compact.

Classification by function

According to the different functions of the PLC, it can be divided into three groups of low,
medium and high end.

●​ Low-end PLC: has basic functions such as logic operation, timing, counting, shifting,
self-diagnosis and monitoring. It can also have a small number of analog input /
output, arithmetic operation, data transmission, and comparison and
communication functions, etc. It is mainly used for logic control and sequencing.
Control or a small number of autonomous control systems of analog control.
●​ Midrange PLC: In addition to the functions of the low-end PLC, the mid-range PLC
also has a strong analog input / output, arithmetic operations, data transfer and
comparison, digital system conversion, remote I / O, subroutines, and
communication networks; some can also be added. Interrupt control, PID control
and other functions are applicable to complex control systems.

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 ●​ High-end PLC: In addition to the functions of the mid-range PLC, the high-end PLC
also adds arithmetic operations such as arithmetic operations, arrays, bit logic,
square root operations and other special functions, tabulation, and table transfer
functions. The high-quality PLC has a stronger communication network function,
which can be used for large-scale process control or constitute a distributed
network control system, allowing factory automation to be realized.

Sorting by I/O points

According to the number of PLC I/O points, it can be divided into small, medium and large
size types.

●​ Small size PLCs: have fewer than 256 I/O points, single-CPU, 8- or 16-bit processors,
and a user memory capacity of 4 KB or less. For example: Mitsubishi FX0S series.
●​ Medium sized PLCs: have I/O points between 256 and 2048. They have dual CPUs
and a user memory capacity of 2 to 8 KB.
●​ Large size PLCs: have more than 2,048 I/O points, multiple CPUs, 16-bit or 32-bit
processors, and 8 to 16 KB of memory capacity.

Conclusions:

Naim: In this project it was very easy to develop the sensors since they were not
complicated at all and apart we were able to investigate the sensors and it was easier for
us.

Francisco Javier Marmolejo Vela: I found it a very interesting practice to learn everything
we saw about these sensors, each sensor that we analyzed seemed very important to me,
since we could use them in the future, which is why we must know them very well, from
their specifications, their function, etc. We also analyze how to connect them to a PLC, and
it seems surprising to me what can be achieved thanks to these innovative devices, they are
undoubtedly of great help in the industry.

Kevin Ruben Martínez Muñoz: My conclusion is that the PLC revolutionized the world of
automation since it has many applications, mainly in the industry so as not to have to make

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more circuits, the PLC already has them integrated and it is easier to carry out the activities
through its programming indicated in the computer as well. It is very useful to simulate how
the programmed circuit works and thus not damage components.

Marya Andrea Martínez Carreón:

The PLC is an important tool in the industry to avoid the use of so many components. It is
easy to use and depends on the desired function is the amount of knowledge that you will
need to have. Its operation is based on digital language. It can be used in endless
applications due to its versatility and its easy programming, which would be a ladder.

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