PLC (PROGRAMMABLE LOGIC CONTROLLER)

PLC is an industrial computer designed for multiple inputs and output arrangements. It is capable of storing the instructions to implement control functions such as sequencing, timing, counting, arithmetic, data manipulation and communication.

1. Presented By ( PROGRAMMABLE LOGIC CONTROLLER ) “ PLC ” Manoj K M.Tech (CIM) 1MS16MCM09

2. Contents What is PLC? History of PLC Major components of PLC Operational sequence of PLC Ladder logic Advantages Disadvantages Application 2 22 May 2017

3. What is PLC? PLC is an industrial computer designed for multiple inputs and output arrangements. It is capable of storing the instructions to implement control functions such as sequencing , timing , counting , arithmetic , data manipulation and communication . 3 22 May 2017

4. History of PLC PLC was introduced in late 1960’s First commercial & successful Programmable Logic Controllers was designed and developed by Modicon as a relay replacer for General Motors. Earlier, it was a machine with thousands of electronic parts. Later ,in late 1970’s,the microprocessor became reality & greatly enhanced the role of PLC permitting it to evolve form simply relay to the sophisticated system as it is today. 4 22 May 2017

5. PROCESSOR POWER SUPPLY I M N O P D U U T L E O M U O T D P U U L T E PROGRAMMING DEVICE From SENSORS Pushbuttons, contacts, limit switches, etc. To OUTPUT Solenoids, contactors, alarms etc. Major Components 5 22 May 2017

6. POWER SUPPLY Provides the voltage needed to run the primary PLC components I/O MODULES Provides signal conversion and isolation between the internal logic- level signals inside the PLC and the field’s high level signal . PROCESSOR Provides intelligence to command and govern the activities of the entire PLC systems. PROGRAMMING DEVICE Used to enter the desired program that will determine the sequence of operation and control of process equipment or driven machine. Major Components 6 22 May 2017

7. PLC operation sequence 1)Self test : Testing of its own hardware and software for faults. 2)Input scan : If there are no problems, PLC will copy all the inputs and copy their values into memory. 3)Logic solve/scan : Using inputs, the ladder logic program is solved once and outputs are updated. 4)Output scan : While solving logic the output values are updated only in memory when ladder scan is done, the outputs will be updated using temporary values in memory. Self test Input scan Logic scan Output scan 7 22 May 2017

8. Programming Languages of PLC Most common languages encountered in PLC programming are: 1) Ladder Logic 2) Functional Block Diagram 3) Sequential Function Chart 4) Boolean mnemonics 8 22 May 2017

9. Ladder logic is a programming language used to develop software for PLC used in industrial control applications. RUNGES RAIL RAIL Ladder Logic 22 May 2017 9

10. Ladder Logic language for PLC. It is well suited to express Combinational logic. The main ladder logic symbols represent the elements : M ake contact B reak contact R elay coil 10 22 May 2017

11. Ladder Logic For Basic gates A B Logic(Y) OFF OFF ON ON OFF ON OFF ON OFF OFF OFF ON A AND Gate A B Logic(Y) OFF OFF ON ON OFF ON OFF ON OFF ON ON ON R Gate OR Gate A OR Gate A A B B Y Y 11 22 May 2017

12. NOR Gate A B Y A B Logic(Y) OFF OFF ON ON OFF ON OFF ON ON ON ON OFF A B Logic(Y) OFF OFF ON ON OFF ON OFF ON ON OFF OFF OFF NAND Gate B Y A Ladder Logic For Basic gates 12 22 May 2017

13. Block diagram of a PLC Outputs LEDs Inputs 13 22 May 2017

14. Programming Example: Ladder Logic Program for Start/Stop of Motor : X1 Y1 Y1 X2 22 May 2017 14

15. Advantages of PLC s : Reliability. Flexibility in programming and reprogramming. Cost effective for controlling complex systems. Small physical size. High speed of operation . Ease of maintenance /troubleshooting. Reduced space. Energy saving. 15 22 May 2017

16. Disadvantages of PLCs PLC devices are proprietary it means that part or software of one manufacturer can’t be used in combination with parts of another manufacturer. Limited design and cost option. Fixed Circuit Operations. PLCs manufacturers offer only closed architectures. 16 22 May 2017

17. Applications: Wherever automation is desired the PLCs are best suited to meet the task. Few examples of industries where PLCs are used : 1) Robots manufacturing and control 2) Car park control 3) Train control station system 4) Food processing 5) Materials handling 6)Machine tools 7) Conveyer system etc. 17 22 May 2017

18. Case study-1 22 May 2017 18 Automation of Soda Ash Handling System using PLC and SCADA in Glass Production Line The glass production line all systems are controlled by DCS (Distributed Control System) but some sub systems are controlled by Electromechanical Relay System (Hard Wired Control System) . The relay control system looks toward many issues . To limit that issues the system change from relay control system to PLC (Programmable logic controller) control system. In this proposed system all parameters are controlled, processed and monitored with help of Allen Bradley PLC. Abstract

19. 22 May 2017 19 Schematic Diagram of Soda Ash Handling System

20. 22 May 2017 20 Flow Chart

21. 22 May 2017 21 Ladder Logic Program

22. 22 May 2017 22 Ladder Logic Program (cont…)

23. 22 May 2017 23 Ladder Logic Program (cont…)

24. 22 May 2017 24

25. 22 May 2017 25 This proposed system was implemented for overcome the drawbacks of existing system. This system gives high reliability, easy to trouble shoot, easy to modify the sequence without changing of wiring, it reduce the fault occurrence, it eliminated hardwiring, easy to monitoring, easy to find out the problem occur in the system. So the system improves the overall productivity and also it reduce system breakdown because of using programmable logic controller. Conclusion

26. Case study-2 22 May 2017 26 AUTOMATION OF CONVEYOR USING PLC Abstract - The development of programmable logic controller (PLC) makes it possible to do the required changes to the program without changing the electrical circuit connections. The Siemens s7-300 series programmable logic controller is used to mechanize the system and software for programming used is SIMATIC manager .

27. Case study-2(cont…) 22 May 2017 27 Siemens s7-300

28. Case study-2(cont…) 22 May 2017 28 FLOW CHART

29. Case study-2(cont…) 22 May 2017 29 Program in SIMATIC Manager software Here programming language used is functional block diagram . Here to make program faster and save memory function block used. Following pictures shows program to control conveyor motor in function block.

30. Case study-2(cont…) 22 May 2017 30 Conclusion Efficient monitoring and control of industrial automation. There will be immense control and monitoring of conveyor belt. Possible to do the required changes to the program without changing the electrical circuit connections.

31. Thank You!!! 31 22 May 2017