plc ICS_PLC_Integration_Tools ICS_PLC_Integration_Tools.pptx

PLC application

1. Programmable logic controller

2. Leading Brands of PLC   AMERICAN EUROPEAN JAPANESE 1 ALLEN BRADLEY SIEMENS TOSHIBA 2 GOULD MODICON KLOCKNER & MOULLER OMRON 3 TEXAS INSTRUMENTS FESTO FANUC 4 GENERAL ELECTRIC TELEMECHANIQUE MITSUBISHI 5 WESTINGHOUSE     6 CUTTER HAMMER     7 SQUARE D    

3. PLC Programing Software’s Velocio Software Siemens Software Rockwell Automation (Allen-Bradley) Software Schneider Software Mitsubishi Software Modicon Software Panasonic Software Keyence Software Telemecanique Software Beckhoff Software GE Software Automation Direct Software IDEC Software Opto22 Software Omron Software Sirea Software VIPA Software Triangle Research International Software SPLAT Software Smart Software Solutions LSIS Software Control Microsystems Software Teco Software Unitronics Software ABB Software Horner APG Software Crouzet Software Xinje Software Entertron Software Delta Electronics Software

4. PLC Communications   Manufacturer Network 1 Allen-Bradley Data Highway 2 Gould Modicon Modbus 3 General Electric GE Net Factory LAN 4 Mitsubishi Melsec-NET 5 Square D SY/NET 6 Texas Instruments TIWAY

5. PLC Acronyms ASCII American Standard Code for Information Interchange BCD Binary Coded Decimal CSA Canadian Standards Association DIO Distributed I/O EIA Electronic Industries Association EMI ElectroMagnetic Interference HMI Human Machine Interface IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers I/O Input(s) and/or Output(s) ISO International Standards Organization LL Ladder Logic LSB Least Significant Bit MMI Man Machine Interface MODICON MOdular DIgital CONtoller MSB Most Significant Bit PID Proportional Integral Derivative (feedback control) RF Radio Frequency RIO Remote I/O RTU Remote Terminal Unit SCADA Supervisory Control And Data Acquisition

6. Definition of PLC According to NEMA standard ICS3-1978 A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process.

7. Areas of PLC Applications Annunciators Injection Molding Auto Insertion Assembly Bagging Motor Winding Baking Oil Fields Blending Painting Boring Palletizers Brewing Pipelines Calendaring Polishing Casting Reactors Chemical Drilling Robots Color Mixing Rolling Compressors Security Systems Conveyors Stretch Wrap Cranes Slitting Crushing Sorting Cutting Stackers Digesters Stitching Drilling Stack Precipitators Electronic Testing Threading Elevators Tire Building Engine Test Stands Traffic Control Extrusion Textile Machine Forging Turbines Generators Turning Gluing Weaving Grinding Web Handling Heat Treating Welding Manufacturing/ Machining Food / Beverage Metals Power Mining Petrochemical/Chemical

8. PLC in industry

9. PLC in traffic light

10. Relating the PLC Traditional system PLC system control function is modified by physically changing the wiring between the devices This is costly and time consuming endeavor Soft wiring control function is modified by just changing the control program inside the PLC These changes are easy and cheap

11. PLC and Computer A PLC and a computer both are electronic processor unit. The architecture of a PLC’s CPU is basically same as that of a general purpose computer; however, some important characteristics set them apart. Unlike computer, PLCs are specifically designed to survive the harsh conditions of the industrial environment. A well-designed PLC can be placed in an area with substantial amounts of electrical noise, electromagnetic interference, mechanical vibration, and noncondensing humidity.

12. Cont.… Distinction of PLCs is that their hardware and software are designed for easy use by plant electricians and technicians. The hardware interfaces for connecting field devices are actually part of the PLC itself and are easily connected. The modular and self-diagnosing interface circuits are able to pin point malfunctions and moreover, are easily removed and replaced.

13. Cont.… Software programming uses conventional relay ladder symbols, or other easily learned languages, which are familiar to plant personnel. A computer can execute a complex programming task and also multitasking. A standard PLC is designed to execute a single program in an orderly fashion. As PLCs are rapidly changing, modern PLCs have multitasking capabilities.

14. Why PLCs are so popular? Programmable logic controller have made it possible to precisely control large process machines and driven equipment with less physical wiring and wiring time than it requires with standard electro-mechanical relays, pneumatic system, timers, drum switches, and so on. The programmability allows for fast and easy changes in the relay ladder logic to meet the changing needs of the process or driven equipment without the need for expensive and time consuming rewiring process. Modem PLCs are "electrician friendly", PLC can be programmed and used by plant engineers and maintenance electricians without much electronic and computer programming background. They can programmed by using the existing ladder diagrams.

15. Advantage and disadvantage of PLC

16. Advantage of PLC   No Advantage Description   1 Flexibility Universal Controller Can replace various independent/ standalone controller.   2 Implementing Changes and Correcting Errors Do not have to rewiring relay panel. Change program using keyboard.   3 Large Quantity of Contact Large number of' Soft Contact' available   4 Lower Cost   Advancement in technology and open architecture of PLC will reduce the market price.   5 Pilot Running (Simulation Capability) A program can be simulated or run without actual input connection.   6 Visual Observation.   Can observe the opening and closing of contact switch on CRT. Operator message can be programmed for each possible malfunction.   7 Speed of Operation   Depends on scan time -millisecond. Asynchronous operation.  

17. 8 Ladder or Boolean Programming Method. Easy for 'Electrician ,   9 Reliability In general -very reliable   10 Simplicity of Ordering Control Sys. Components One package with Relay, Timers, Control Block, etc .   11 Documentation Printout of ladder logic can be printed easily   12 . Security Software lock on a program (Password)   13 Ease of Changes by Programming Ability to program and reprogram, loading and down loading   14 Highly versatile (universal applicability)     15 Simple troubleshooting Simple installation     16 Quick modification of the program (highly flexible )     17 Capable of task not possible with relays before as indicated by the following: Calculation, information exchange, text and graphic display, data processing, networking   18 Low space requirement     19 Low power consumption     20 High processing speed     21 No moving parts, hence no wearing parts  

18.   Disadvantages of PLC   No Disadvantages Description   1 New Technology Change from ladder and relay to PLC concept   2 Fixed program Application Not cost effective for single- function application   3 Environment Consideration Not adapted for very high temperature, high humidity level, high vibration, etc.   4 Fail-safe operation   Does not start automatically when power failure ( can be programmed into ) Not "Fail-safe" -Fail-shorted rather than OPEN   5 Fixed-circuit operation Fixed control system -less costly

19. What Is Inside A PLC?

20. Cont.… The Central Processing Unit, the CPU, contains an internal program that tells the PLC how to perform the following functions: Execute the Control Instructions contained in the User's Programs. This program is stored in "nonvolatile" memory, meaning that the program will not be lost if power is removed Communicate with other devices, which can include I/O Devices, Programming Devices, Networks, and even other PLCs. Perform Housekeeping activities such as Communications, Internal Diagnostics, etc.

21. How Does A PLC Operate? There are four basic steps in the operation of all PLCs; Input Scan, Program Scan, Output Scan, and Housekeeping. These steps continually take place in a repeating loop. 1. Input Scan Detects the state of all input devices that are connected to the PLC 2.Program Scan Executes the user created program logic 3. Output Scan Energizes or de-energize all output devices that are connected to the PLC. 4.Housekeeping This step includes communications with programming terminals, internal diagnostics, etc...

22. What Programming Language Is Used To Program A PLC? While Ladder Logic is the most commonly used PLC programming language, it is not the only one. The following lists of some of languages that are used to program a PLC. Ladder Diagram (LD) Traditional ladder logic is graphical programming language. Initially programmed with simple contacts that simulated the opening and closing of relays, Ladder Logic programming has been expanded to include such functions as counters, timers, shift registers, and math operations.

23. 2. Function Block Diagram (FBD) A graphical language for depicting signal and data flows through re-usable function blocks. FBD is very useful for expressing the interconnection of control system algorithms and logic.

24. 3. Structured Text (ST) A high level text language that encourages structured programming. It has a language structure (syntax) that strongly resembles PASCAL and supports a wide range of standard functions and operators. For example; If Speed1 > 100.0 then     Flow_Rate : = 50.0 + Offset_A1; Else     Flow_Rate : = 100.0; Steam: = ON End_If ;

25. 4. Instruction List (IL) A low level “assembler like” language that is based on similar instructions list languages found in a wide range of today’s PLCs. LD MPC LD ST RESET: ST   R1 RESET PRESS_1 MAX_PRESS LD    0 A_X43

26. 5. Sequential Function Chart (SFC) A method of programming complex control systems at a more highly structured level. A SFC program is an overview of the control system, in which the basic building blocks are entire program files. Each program file is created using one of the other types of programming languages. The SFC approach coordinates large, complicated programming tasks into smaller, more manageable tasks.

27. What Are Input/output Devices of PLC?

28. Input device Switches and Pushbuttons Sensing Devices Limit Switches Photoelectric Sensors Proximity Sensors 3. Condition Sensors 4. Encoders Pressure Switches Level Switches Temperature Switches Vacuum Switches Float Switches

29. OUTPUTS Valves Motor Starters Solenoids Actuators Horns and Alarms Stack lights Control Relays Counter/Totalizer Pumps Printers Fans