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PLC and Its Application

The document discusses programmable logic controllers (PLCs) and their application in discrete state process control systems. PLCs are suitable for processes that involve sequential logic states rather than continuous variables. They can replace relay-based controllers by implementing the same logic functions through software. This makes PLC systems easier to program and modify. PLCs scan inputs, execute a ladder logic program to determine outputs, and update outputs on each scan cycle. They have made industrial control more flexible and reliable compared to hardwired relay panels.

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Aasshimaa Taneja
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240 views

PLC and Its Application

The document discusses programmable logic controllers (PLCs) and their application in discrete state process control systems. PLCs are suitable for processes that involve sequential logic states rather than continuous variables. They can replace relay-based controllers by implementing the same logic functions through software. This makes PLC systems easier to program and modify. PLCs scan inputs, execute a ladder logic program to determine outputs, and update outputs on each scan cycle. They have made industrial control more flexible and reliable compared to hardwired relay panels.

Uploaded by

Aasshimaa Taneja
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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PLC AND ITS APPLICATION

BY

SOUVIK GANGULI
ASSISTANT PROFESSOR, EIED
THAPAR UNIVERSITY, PATIALA
PLC (Programmable Logic Controller)

It is basically a
controller

Not continuous but logic state


i.e. on-off controller

Sequence of logic states are programmable

All operations are to control a process


FOR WHAT TYPE OF PROCESSES PLC IS SUITABLE ?

Automatic bottle filling system

An example of discrete
state process control
Example of Discrete State Process Control

Liquid Level Monitoring


Discrete State Process Control and PLC

• In majority of industrial process control, simply a


controlled variable is regulated , but there are many
processes where not a variable is controlled but sequence
of events are to be controlled These are called discrete
state process control.
• So discrete state process control system works on the basis
of sequence of events.
• These sequence of events are programmed and controlled
by Programmable Logic Controller (PLC).
Relay and Switch

• Relay as primary control element of


Discrete State Process Control

Use of relay and switch to start a motor Use of relay for a latch
When entire control system is implemented using relays , the system
is called relay sequencer.
LADDER DIAGRAM

• A special schematic representation of the hardware and its connection has


been developed that makes combination of hardware and event sequence
description clear. This schematic is called ladder diagram.

• An industrial control system typically involves electric motors, solenoids,


heaters etc. which are operated from the a.c. power line. e.g. when a conveyor
motor is turned on it may mean starting of a 50 H.P. motor. This will not be
done by single toggle switch but a small switch may be used to energize a
relay with contact ratings that can handle a heavy load as shown in previous
fig.
• When a relay panel is wired
to implement a ladder diagram ,
we say that it has been programmed
to satisfy the ladder diagram.
Advantages of Computer Based Controller or
Programmable Logic Controller (PLC) over Relay Logic
Controller

• After wiring of relay panel if the event sequence is to be


changed , it is necessary to rewire all or part of the panel.
• It may even be necessary to add more relays to the system
than the previous. This is quite trouble some.
• The I/O variables of discrete state process control systems
are binary in nature just as with computer.
• Many of the control relays of the ladder diagram can be
replaced by software which means less hardwire failure.
• It is easy to make change in programmed sequence of
events when it is only a change in software.
Advantages of Computer Based Controller or
Programmable Logic Controller (PLC) over Relay Logic
Controller

• Special functions such as time delay actions and counters


are easy to form in software.
• Solid state devices such as SCRs , TRIACs are available
that can control high power ac/dc in response to low level
commands from a computer.
BASIC BLOCK DIAGRAM OF PLC

• Processor executes a program to perform operations such


as arithmetic or logical operations on input variables.
• The processor is usually able to accommodate a number of
I/P s called channels.
INPUT AND OUTPUT MODULE OF PLC

• I/P module examines the state of physical switches and other I/P
devices and put their states into a form suitable for the processor.
• O/P module supplies a.c power to external devices such as motors,
lights, solenoids etc.
• Internally O/P module accepts 1 or 0 I/P from the processor and use
this to turn on/off an a.c. power control device such as triac.

I/P module O/P module


PLC details

• PLC can actually be considered to be a box full of


hundreds or thousands of separate relays, counters, timers
and data storage locations .
• These counters timers etc. don’t really exist but rather they
are simulated and can be considered software counters,
timers etc.
• I/P relays and O/P relays are connected to the outside
world , they physically exist .
• There are some internal internal utility relays (contacts ) .
They don’t receive signals from the outside world or not
physically exist. They are simulated relays.
PLC OPERATION
(I/O SCAN MODE AND EXECUTION MODE)
• The operation of the PLC can be
considered in two modes,
I/O Scan Mode & Execution Mode CHECK I/P STATUS

In I/O Scan mode the processor


EXECUTE PROGRAM
updates all outputs and inputs,
the state of all inputs one channel
at a time. The time required for this
depends on the speed of the UPDATE O/P STATUS
processor.
PLC EXECUTION MODE

• During this mode the processor evaluates each rung of the


ladder diagram program that is being executed sequentially,
starting from the first rung and proceeding to the last rung.
• As a rung is evaluated the last known state of each switch
and relay contact in the rung is considered and if any true
path to the o/p device is detected , then the o/p is indicated
to be energized, I.e. set on.
• At the end of the ladder diagram the I/O mode is entered
again and all O/P devices are provided with on or off state
determined from execution of the ladder diagram program.
• All I/P s are sampled and execution mode is entered again.
PLC SCAN TIME

• An important characteristics of the PLC is how mach time


is required for one complete cycle of I/O scan and
execution .
• This depends on how many I/P and O/P channels are
involved and on the length of the ladder diagram program.
• The speed of the controller is dependent on the clock
frequency of the processor. The higher the clock frequency
the greater is the speed and faster is the scan and execution
time.
SYMBOLS FOR CONTROL ,TIMER RELAYS, etc
TYPICAL EXAMPLE OF PLC LADDER
DIAGRAM
LADDER DIAGRAM DURING START AND STOP OF
THE ELEVATOR SYSTEM

DURING START DURING STOP


FULL LADDER LIAGRAM FOR THE ELEVATOR SYSTEM

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