AUTOMATION USING PLC

INTRODUCTION:
There is a constant need for process control systems in the manufacturing industries to
produce a better quality product more efficiently at a low cost. This leads to the evolution of
automated systems.

HARD WIRE CONTROL:

In early days, the automated machines were controlled by electromagnetic relays. This is
known as hard wire control. In this relays were permanently connected together inside the control
panel. Every connection in the relay logic was rigidly connected and the entire control panel
looked bulky.
A hard wire control panel could be used for only one process control for which it was
fabricated. It cannot be changed immediately into a new system. A hardwire control circuit is not
flexible to accept new control jobs.

PROGRAMMABLE LOGIC CONTROLLERS (PLC):

The above limitations of hard wire control have led to the use of programmable logic
controllers (PLC).

NEMA, the National Electrical Manufacturers Association, defines a programmable logic

controller (PLC) as:
A programmable logic controller (PLC) is a digitally operating electronic apparatus which
uses a programmable 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 input/output, various types of machines or process.

Initially, programmable logic controllers were used to replace traditional hard-wired relay
logic; however, with its ever increasing functionality it is found in many more complex
applications. PLCs are used in any industrial application where operating requirements are
complex, are constantly changing, or where high reliability is necessary.

BASIC PLC COMPONENTS:

Programmable controllers have grown throughout industrial control applications because of
the ease they bring to creating a controller: ease of programming, ease of wiring, ease of
installation, and ease of changing.

PLCs span a wide range of sizes, but all contain six basic components:
 Processor or central processing unit (CPU),
 Rack or mounting,
 Input assembly,
 Output assembly,
 Power supply,
 Programming unit, device, or PC/software.

We will start with explaining the physical components

you see when looking at a PLC system - and then
explore what goes on inside each part, and how the components relate to each other.

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RACK ASSEMBLY:
Most medium to large PLC systems are assembled such that the individual components -
CPU, Input/Output, Power Supply - are modules that are held together within a rack.
In smaller PLC systems - all of these components may be contained in a single housing or "brick" -
these smaller systems are sometimes referred to as "bricks" or "shoebox" PLCs.

POWER SUPPLY:
The power supply provides power for the PLC system. The power supply provides internal
DC current to operate the processor logic circuitry and input/output assemblies. Common power
levels used are 24V DC or 120 VAC.

PROCESSOR (CPU):
The processor, central processing unit, or CPU is the "brain" of the PLC. The size and type
of CPU will determine things like: the programming functions available, size of the application
logic available, amount of memory available, and processing speed. Understanding the CPU can be
a complex subject and we will tackle that in other articles.

INPUT/OUTPUT ASSEMBLY:
Inputs carry signals from the process into the controller; they can be input switches, pressure
sensors, operator inputs, etc. These are like the senses and sensors of the PLC. Outputs are the
devices that the PLC uses to send changes out to the world. These are the actuator the PLC can
change to adjust or control the process - motors, lights, relays, pumps, etc.

Many types of inputs and outputs can be connected to a PLC, and they can all be divided
into two large groups - analog and digital. Digital inputs and outputs are those that operate due to a
discrete or binary change - on/off, yes/no. Analog inputs and outputs change continuously over a
variable range - pressure, temperature, and potentiometer.

PROGRAMMING DEVICE:
The PLC is programmed using a specialty programmer or software on a computer that can
load and change the logic inside. Most modern PLCs are programmed using software on a PC or
laptop computer. Older systems used a custom programming device.

BASIC OPERATION OF A PLC SYSTEM:

The operation of the PLC system is simple and straightforward. The Process or CPU
completes three processes: (1) scans, or reads, from the input devices (2) executes or "solves" the
program logic, and (3) updates, or writes, to the output devices.

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PLC PROGRAM:
For the PLC to be useful, it must first have a Program or Logic for the CPU to execute. A
system engineer or PLC programmer will first create the program logic in a programming device
(these days it is usually software running on a personal computer). This logic can be written in
Ladder Logic, Instruction List, Sequential Function Charts, or any of the IEC languages.

The programmer will then download the program to the PLC. This is usually done by
temporarily connecting the programmer to the PLC. Once the program is installed or downloaded to
the CPU - it is usually not necessary for the PC to remain connected.

BASIC SCAN:
Once the program is in the CPU - the PLC is then set to "run", and the PLC executes the
application program repeatedly. In addition to executing the program,
the CPU regularly reads the status of the input devices, and sends data to
the output devices. The Input system senses the status of the real world
inputs (a switch, a level, etc.), translates them to values that can be
used by the CPU, and writes those values to the Input table. The
application program is executed, and writes values to the Output table.
The Output system then converts the output value to a real world
change (motor turns on, valve opens, etc.)
This process of reading inputs, executing logic, and writing outputs is
called the PLC Scan or Sweep.
The CPU continuously Reads Inputs, Solves Logic, and Writes to
the outputs (there are other tasks the CPU does - which will be
discussed later). It is important to understand the scan because it may dictate how a programmer
structures logic.

MEMORY:
The control program or application program is stored in memory. As the PLC executes
logic, it may also read and store values to memory. The values may also be used and referenced by
the application program..

PLC INPUT AND OUTPUT DEVICES:

The term I/O refers to Input/Output. I/O is information representing the data that is received
from sensing devices and the commands that are sent to actuating and indicating devices. The I/O
System is the collection of physical elements of the control system that either provide or use I/O
data.
There are two major types of I/O:
Digital - Binary devices which must be in one of only two states: on or off.
Analog - Continuous devices - sense and respond to a range of values.

DIGITAL I/O:
Digital input devices may be either on or off; they may not hold any other values. For
example, digital position sensors do not sense how close an object is, they only tell if the object is
within a range of positions. Common digital field input devices include pushbuttons, limit
switches and photo eyes. Common digital output devices include relays, motor starters, and
solenoid valves.

ANALOG I/O:
Analog input devices sense continuous parameters. The information that they provide is
given as a continuous range of values, not just an on or off indicator. Common analog inputs
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are pressure, temperature, speed, etc. Analog output devices respond to a range of output values
from the controller. Common analog output signals include motor speed, valve position, air
pressure, etc.
I/O modules connect "real world" field devices to the controller. They convert the electrical
signals used in the field devices into electronic signals that can be used by the control system, and
translate real world values to IO table values.

I/O modules communicate with PLC CPU in one of three ways:

Backplane - The I/O modules can be located in the same rack or station. Communications then
takes place within the rack or across the backplane.
Backplane extension - backplane extension modules allow I/O modules to be located in racks or
stations which are separated from the controller.
Device network - modules can communicate with a controller over a network. Industrial networks
are used to interconnect field level devices with controllers. Common IO networks are FieldBus,
Profibus, and DeviceNet.

"Point Count" and the Size of the PLC System:

The number of I/O devices used within a control system is called its “point count”. Analog
device data requires significantly more manipulation and processing than digital device data.
Digital and analog point counts are typically considered separately. The total number of digital and
analog points is used to give an indication of the size of a control system.

PROGRAMMING LANGUAGE:
The Automotive Industry was a major early adopter of programmable logic controllers
(PLC). They wanted a programming method that could be easily understood by their existing
controls engineers and technicians. The result of this desire was a programming language called
Relay Ladder Logic (or "ladder logic").
The layout of Ladder Logic is very similar to reading the diagrams for hard wired relay
controls. Ladder Logic is still one of the most popular "language" for programming PLCs, but many
others have developed over the years.

Except ladder logic method we have two other methods for programming PLC. They are,

Function Block Diagram Method:

Function Block Diagrams (FBD) is one of the languages supported by IEC 1131. FBD is a
graphical language that allows the user to program elements in "blocks". The blocks can then be
wired together like electrical circuits.
Statement Listing Method:
A statement list provides another set of instructions for PLC programming. In this method,
the function to be executed is represented in the form of a string of statements.

SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA):

SCADA is the acronym for Supervisory Control And Data Acquisition. The term SCADA usually
refers to centralized systems which monitor and control entire sites, or complexes of systems spread
out over large areas (on the scale of kilometers or miles). Most site control is performed
automatically by programmable logic controllers ("PLCs").

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 Host control functions are usually restricted to basic site overriding or supervisory level
intervention.For example, a PLC may control the flow of cooling water through part of an industrial
process, but the SCADA system may allow operators to change the set points for the flow, and
enable alarm conditions, such as loss of flow
and high temperature, to be displayed and
recorded. The feedback control loop passes
through the PLC, while the SCADA system
monitors the overall performance of the loop.
Data acquisition begins at the PLC level
and includes meter readings and equipment
status reports that are communicated to SCADA
as required. Data is then compiled and
formatted in such a way that a control room
operator using the HMI can make supervisory
decisions to adjust or override normal PLC
controls. Data may also be fed to a Historian,
often built on a commodity Database
Management System, to allow trending and
other analytical auditing.

CONCLUSION:

PLC join hands with SCADA communication, makes the industrial automation as a high
reliable one and monitoring and controlling of industries are easily done from remote places.
Recent news in industrial automation is about 65 industries are automated through internet using
SCADA communication which shows the improvement in automation systems.

SUBMITTED BY
A.BALAKUMAR,
G.DINESH,
II YEAR, DEEE,
GPT, TRICHY-22.