The PLC in automation technology Introduction: The first Programmable Logic Controller (PLC) was

developed by a group of engineers at General Motors in 1968, when the companies were looking for an alternative to replace complex relay control systems. The new control system had to meet the following requirements: Simple programming Program changes without system intervention (no internal rewiring) Smaller, cheaper and more reliable than corresponding relay control systems Simple, low cost maintenance Subsequent development resulted in a system, which enabled the simple connection of binary signals. The requirements as to how these signals were to be connected were specified in the control program. With the new systems it became possible for the first time to plot signals on a screen and to file these in electronic memories. Since then, three decades have passed, during which the enormous progress made in the development of

microelectronics did not stop short of programmable logic controllers. For instance, even if program optimization and thus a reduction of required memory capacity initially still represented an important key task for the programmer, nowadays this is hardly of any significance. Moreover, the range of functions has grown considerably. 15 years ago, process visualization, analogue processing or even the use of a PLC as a controller, were considered as Utopian. Nowadays, the support of these functions forms an integral part of many PLCs. The following pages in this introductory chapter outline the basic design of a PLC together with the currently most important tasks and applications. Areas of application of a PLC : Every system or machine has a controller. Depending on the type of technology used, controllers can be divided into pneumatic, hydraulic, electrical and electronic controllers. a combination of different technologies is

used. Furthermore, differentiation is made between hardwired programmable (e.g. wiring of electro-mechanical or electronic components) and programmable logic controllers. The first is used primarily in cases, where any

reprogramming by the user is out of the question and the job size warrants the development of a special controller. Typical applications for such controllers can be found in automatic washing machines, video cameras, and cars. However, if the job size does not warrant the development of a special controller or if the user is to have the facility of making simple or independent program changes, or of setting timers and counters, then the use of a universal controller, where the program is written to an electronic memory, is the preferred option. The PLC represents such a universal controller. It can be used for different applications and, via the program installed in its memory, provides the user with a simple means of changing, extending and optimizing control processes.

Example of a PLC application:

The original task of a PLC involved the interconnection of input signals according to a specified program and, if "true", to switch the corresponding output. Boolean

algebra forms the mathematical basis for this operation, which recognizes precisely two defined statuses of one variable: "0" and "1". Accordingly, an output can only assume these two statuses. For instance, a connected motor could therefore be either switched on or off, i.e. controlled. This function has coined the name PLC: logic controller, i.e. the input/output Programmable

behavior is similar to that of an electromagnetic relay or pneumatic switching valve controller; the program is stored in an electronic memory. However, the tasks of a PLC have rapidly multiplied: Timer and counter functions, memory setting and resetting, mathematical computing operations all represent functions, which can be executed by practically any of todays PLCs. The demand to be met by PLCs continued to grow in line with their rapidly spreading usage and the development in automation technology. Visualization, i.e. the representation of machine statuses such as the control program being executed, via display or monitor. Also controlling, i.e. the facility to intervene in control processes or, alternatively, to make such intervention by unauthorized persons impossible. Very soon, it also became necessary to interconnect and harmonize

individual systems controlled via PLC by means of automation technology. Hence a master computer facilitates the means to issue higher-level commands for program processing to several PLC systems the networking of several PLCs as well as that of a PLC and master computer is affected via special communication interfaces. To this effect, many of the more recent PLCs are compatible with open, standardized bus systems. Thanks to the enormously increased performance capacity of advanced PLCs, these can even directly assume the function of a master computer. At the end of the seventies, binary inputs and outputs were finally expanded with the addition of analogue inputs and outputs, since many of todays technical applications require analogue processing (force measurement, speed setting, servopneumatic positioning systems). At the same time, the acquisition or output of analogue signals permits an actual/set point value comparison and as a result the realization of automatic control engineering functions, a task, which widely exceeds the scope suggested by the name (programmable logic controller). The PLCs currently on offer in the market place have been adapted to customer requirements to such an extent that it has

become possible to purchase an eminently suitable PLC for virtually any application. As such, miniature PLCs is now available with a minimum number of inputs/outputs starting from just a few hundred Pounds. Also available are larger PLCs with 28 or 256 inputs/outputs. Many PLCs can be expanded by means and of additional input/output, modules. analogue, positioning communication

Special PLCs are available for safety technology, shipping or mining tasks. Yet further PLCs are able to process several programs simultaneously (multitasking). Finally, PLCs are coupled with other automation components, thus creating considerably wider areas of application.

Fig.2. Example of a PLC: Festo IPC PS1 Professional

Basic design of a PLC:

The term programmable logic controller is defined as follows by EN 61131-1 (IEC 61131-1): A digitally operating electronic system, designed for use in an industrial environment, which uses a programmable

memory

for

the

internal

storage

of

user-oriented

instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic, to control, through digital or analogue inputs and outputs, various types of machines or processes. Both the PC and its associated peripherals are designed so that they can be easily integrated into an industrial control system and easily used in all their intended functions." A programmable logic controller is therefore nothing more than a computer, tailored specifically for certain control tasks.

Fig.3. System components of a PLC

The function of an input module is to convert incoming signals into signals, which can be processed by the PLC, and to pass these to the central control unit. The reverse task is performed by an output module. This converts the PLC signal into signals suitable for the actuators. The actual processing of the signals is effected in the central control unit in accordance with the program stored in the memory. The program of a PLC can be created in various ways: via assembler type commands in statement list, in higher-level, problem-oriented languages such as structured text or in the form of a flow chart such as represented by a sequential function chart. In Europe, the use of function block diagrams based on function charts with graphic symbols for logic gates is widely used. In America, the ladder diagram is the preferred language by users. Depending on how the central control unit is to the input and output modules, connected

differentiation can be made between compact PLCs (input module, central control unit and output module in one housing) or modular PLCs.

FEC Standard controller Modular PLCs may be configured individually. The modules required for the practical application apart from digital input/output modules, which can, for instance, include analogue, positioning and communication modules are inserted in a rack, where individual modules are linked via a bus system. This type of design is also known as series technology. Two examples of modular PLCs are shown in fig. These represent the modular system IPC PS1 Professional by Festo and the new S7-300 series by Siemens. A wide range of variants exists, particularly in the case of more recent PLCs. These include both modular as well as compact characteristics and important features such as spacing saving, flexibility and scope for expansion. The card format PLC is a special type of modular PLC, developed during the last few years. With this type, individual or a number of printed circuit board modules are in a standardized housing. The hardware design for a programmable logic controller is such that it is able to withstand typical industrial environments as regard signal levels, heat, humidity, and fluctuations in current supply and mechanical impact.

DELTA PLC INTRODUCTION TO PLC Programmable Logic Controllers (PLCs), also referred to as programmable controllers, are in the computer family. They are used in commercial and industrial applications. It was called Sequence Controller before It was named Programmable Logic Controller (PLC) by NEMA (National Electrical Manufacture Association) in 1978 and defined as electronic equipment. The operation of PLC is in the following: Step 1. Read the external input signal, such as the status of keypad, sensor, switch and pulse. Step 2. Using microprocessor to execute the calculations of logic, sequence, timer, counter and formula according to the status and the value of the input signal read in the step 1 and pre-write programs saved inner to get the Corresponding output signal, such as open or close of relay, operation of controlled machine or procedure to control automatic machine or procedure of manufacture.

PLC also can be used to maintain and adjust of production program by editing or modifying the peripheral equipments (personal Computer/handheld programming panel). The common program language of PLC is ladder diagram. There are stronger functions in PLC with the development and application requirements of electronic technology, such as position control, network and etc. Output/Input signals are DI (Digital Input), AI (Analog Input), PI (Pulse Input), DO (Digital Output), AO (Analog Output) and PO (Pulse Output). Thus PLC plays an important role in the feature industry. BASIC PLC OPERATION PLC consists of input modules or points, a central processing unit(CPU) and output points

PARTS OF PLC CPU The central processing unit (CPU) is a microprocessor system which contains the system memory and is the PLCs decision making unit. The CPU monitors the inputs and makes decisions based on instructions held in the program memory. The CPU performs relay, counting, timing, data comparison, and sequential operations

THE WORKING PRINCIPLE OF LADDER DIAGRAM: Ladder diagram is an automatic control diagram language that developed during World War II. At first, it just has basic components, such as A contact (normally open), B contact (normally close), output coil, timer, counter and

etc. (The power panel is made up of these basic components) It has more functions, differential contact, latched coil and the application commands, add, minus, multiply and divide calculation, that traditional power panel cant make since PLC is developed. The working principles of the traditional Ladder Diagram and the PLC Ladder Diagram are similar to each other; the only difference is that the symbols for the traditional ladder diagram are expressed in the format that are close to its original substance, while those for the PLC ladder diagram employ the symbols that are more explicit when being used in computers or data sheets. In the Ladder Diagram Logics, it could be divided into the Combination Logics and the Sequential Logics, and is described as follows: Combination Logics: The following example is the combination logics that show in traditional diagram and PLC ladder diagram separately.

Fig8.Traditional ladder diagram

Sequential logics: The sequential logics are a type of circuit that possesses the Draw-Back structure, which is to draw back the circuits output result and has it serve as the input condition. Thus, under the same input condition, different output results will be generated in accordance with previous conditions and motions with different orders. The following example is the sequential logics that show in traditional diagram and PLC ladder diagram separately.

Current sensor:
A current sensor is a device that detects electrical current (AC or DC) in a wire, and generates a signal proportional to it.The generated signal could be analog voltage or current or even digital output.It can be then utilized to display the measured current in an ammeter or can be stored for further analysis in a data acquisition system or can be utilized for control purpose.

The sensed current and the output signal can be:

AC current input,
o

analog output, which duplicates the wave shape of the sensed current bipolar output, which duplicates the wave shape of the sensed current unipolar output, which is proportional to the average or RMS value of the sensed current

DC current input,
o

unipolar, with a unipolar output, which duplicates the wave shape of the sensed current digital output, which switches when the sensed current exceeds a certain threshold

Potential transformer:
A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductorsthe transformer's coils. A varying current in the first or primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a

varying electromotive force (EMF), or "voltage", in the secondary winding. This effect is called inductive coupling. If a load is connected to the secondary, current will flow in the secondary winding, and electrical energy will be transferred from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (Vs) is in proportion to the primary voltage (Vp) and is given by the ratio of the number of turns in the secondary (Ns) to the number of turns in the primary (Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus enables an alternating current (AC) voltage to be "stepped up" by making Ns greater than Np, or "stepped down" by making Ns less than Np. In the vast majority of transformers, the windings are coils wound around a ferromagnetic core, air-core transformers being a notable exception. Transformers range in size from a thumbnail-sized coupling transformer hidden inside a stage microphone to huge units weighing hundreds of tons used to interconnect portions of power grids. All operate on the same basic principles, although the range of designs is wide. While new technologies have eliminated the need for transformers in some electronic circuits, transformers are still found in nearly all electronic devices

designed for household ("mains") voltage. Transformers are essential for high-voltage electric power transmission, which makes long-distance transmission economically practical.

Temperatur sensor:
An analog temperature sensor is pretty easy to explain, its a chip that tells you what the ambient temperature is! These sensors use a solid-state technique to determine the temperature. That is to say, they dont use mercury (like old thermometers), bimetalic strips (like in some home thermometers or stoves), nor do they use thermistors (temperature sensitive resistors). Instead, they use the fact as temperature increases, the votage across a diode increases at a known rate. (Technically, this is actually the voltage drop between the base and emitter - the Vbe - of a transistor. By precisely amplifying the voltage change, it is easy to genereate an analog signal that is directly proportional to temperature. There have been some improvements on the technique but, essentially that is how temperature is measured. Because these sensors have no moving parts, they are precise, never wear out, don't need calibration, work under many environmental conditions, and are consistant between sensors and readings. Moreover they are very inexpensive and quite easy to use

Circuit breaker:
A circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by interrupting continuity, to immediately discontinue electrical flow. Unlike a fuse, which operates once and then has to be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation. Circuit breakers are made in varying sizes, from small devices that protect an individual household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city. All circuit breakers have common features in their operation, although details vary substantially depending on the voltage class, current rating and type of the circuit breaker. The circuit breaker must detect a fault condition; in low-voltage circuit breakers this is usually done within the breaker enclosure. Circuit breakers for large currents or high voltages are usually arranged with pilot devices to sense a fault current and to operate the trip opening mechanism. The trip solenoid that releases the latch is usually energized by a separate battery, although some high-voltage circuit breakers are self-contained

with current transformers, protection relays, and an internal control power source. Once a fault is detected, contacts within the circuit breaker must open to interrupt the circuit; some mechanically-stored energy (using something such as springs or compressed air) contained within the breaker is used to separate the contacts, although some of the energy required may be obtained from the fault current itself. Small circuit breakers may be manually operated; larger units have solenoids to trip the mechanism, and electric motors to restore energy to the springs. The circuit breaker contacts must carry the load current without excessive heating, and must also withstand the heat of the arc produced when interrupting (opening) the circuit. Contacts are made of copper or copper alloys, silver alloys, and other highly conductive materials. Service life of the contacts is limited by the erosion of contact material due to arcing while interrupting the current. Miniature and molded case circuit breakers are usually discarded when the contacts have worn, but power circuit breakers and high-voltage circuit breakers have replaceable contacts. When a current is interrupted, an arc is generated. This arc must be contained, cooled, and extinguished in a controlled way, so that the gap between the contacts can again withstand the voltage in the circuit. Different circuit breakers use vacuum, air, insulating gas, or oil as the

medium in which the arc forms. Different techniques are used to extinguish the arc including:

Lengthening / deflection of the arc Intensive cooling (in jet chambers) Division into partial arcs Zero point quenching (Contacts open at the zero current time crossing of the AC waveform, effectively breaking no load current at the time of opening. The zero crossing occurs at twice the line frequency i.e. 100 times per second for 50 Hz and 120 times per second for 60 Hz AC) Connecting capacitors in parallel with contacts in DC circuits

Finally, once the fault condition has been cleared, the contacts must again be closed to restore power to the interrupted circuit.