PLCs

The Heartbeat Of

Modern Automation,

Driving Efficiency

And Innovation
 REPORT OF UNDERGRADUATE STUDENT
Title: "PLC's Application In Industrial
Automation"

University: NCWU SIE department

Course: PLC

Major: MECHANICAL ENGINEERING

Name: MALLOUL BILAL

Student ID: 2021LXSB0076

Teacher’s Name: Teacher Lei

Introduction:
Automation is a leading factor that defines the current industrial
environment as well as the resources and items that surround us
daily. In a way it’s hard to describe the convenience of the modern
factory systems and supply chains that help make the imagined
world function. Central to this automation drive is the Programmable
Logic Controller; PLC which is at the helm of increased precision
control over various synchronous tactics within industries.

Introducing PLCs was in the late 1970s and early 1980s when China
was in the process of the industrial modernization led by Deng
Xiaoping. With China moving towards opening up its economy to
technology and investment from the overseas, PLCs stepped into
play an instrumental role in the inclusion of China in the modernized
map of the industrial revolution. This technology played a key role in
changing the nature of China’s industrial structure and improving
the conditions for organizing production. Today, PLCs remain
relevant in the development of automation all across the globe as
the industrial systems that support our complex world today.

Definition;
A Programmable Logic Controller (PLC) is conditioned as an industrial computer which operates
in a cyclic manner to acquire data from input devices and then decide on the program
developed to process these devices and command the output devices. In the beginning used to
supplant intricate relay-based systems, the PLCs offered flexibility and enhanced performance
to industrial automation. They are extensively applied to benches in industries such as
manufacturing to energy control and management.

Modicon invented the first PLC in 1969, and Dick Morley popularized it with the basic model,
the 084. Intended at the time to do away with rewiring in controllers, PLCs made changes
feasible by way of software, thereby enhancing control flexibility and utilization of less space.
The first of these units used for commercial application was the 184 PLC which was designed by
Michael Greenberg in 1973.

PLCs are built in a modular form and this implies that different types of inputs and output and
other related extra modules can be incorporated according to the need. This has made them
valuable especially in the automation and optimisation of many industrial processes they are
involved in managing inputs and outputs.

General information about PLC;

COMPONENTS OF PLC
A standard ‘Programmable Logic Controller also known as a PLC comprises of a number of parts
through which it operates in connection with the industrial processes. Mediating this is the
“CPU (Central Processing Unit)” that is frequently termed as the controller of the PLC and is
accountable to performing the control logic coded in the system while supervising all processes.
The “mounting rack” accommodates the elements of the PLC; It keeps the system as a modular
arrangement so that the components can be installed in various ways.

The I/O modules stand for Input/Output and are designed to mediate interaction with the
outside world. They implement information obtained from various sensor including
temperature or pressure switch and provide commands to devices like motors, actuators or
valves. Such modules can control buttons/digital signals, and voltages/analog signals apart from
the current flow on/off switch.
The aforementioned “power supply” changes the AC current into DC current to supply the
former to the CPU and the I/O elements. The programming device, normally PC or portable
device, serves the purpose of to loading and setting the control algorithm for PLC.
Present PLC systems emphasize more on their ability to communicate with outside devices and
networks it uses RS-232 or Ethernet for this purpose. Lastly, most PLCs are accompanied by
‘Human-Machine Interfaces (HMIs)’ through which operators receive live information about
and control over the processes which the PLC oversees. Thus with these components PLCs are
able to effectively control as well as automate most industrial process systems.

How it does work;

A Programmable Logic Controller (PLC) operates in a cycle that consists of three key stages:
program inputs, actual execution of program, and program outputs . Here involved,
the PLC is constantly gathering data from the connected machines and devices as well as its
input signals may come from sensors or directly from the Human Interface. The input data is
then filtered through the whole program and the logic given by the user in a language, to
decide the actions to be taken by the output devices. For example, a valves position sensor
would be configured as an input and the control of that valve would form an output. The valve
position would be first detected, second whether there is need for the valve position to be
changed and thirdly, the change would be effected in line with the output.
PLCs distinguish between digital (discrete) and analog input/output (I/O). Digital I/O
operates like a simple light switch with two states: on or off (1 or 0). Inputs of the digital type
can range from push buttons or switches while outputs are things like, switching on a light.
Analog I/O, however, is a different story, because his or her value may fall anywhere from 0 to
255, or 0 to 1023 if the system uses integers. Analog inputs can be received from such devices
as thermistors and barometers; analog outputs can refer to such things as controlling the rate
of a motor, the level of liquid in a container, and so on.

Input data for PLCs can come from two primary sources: Process inputs or Data inputs are
decision support data produced by the process or by other instruments such as temperatures
or switches and Operator inputs that are input which are provided by the operators via the
HMI or SCADA system by for example pressing a button, using touch screen etc.

The cycle of operation of a PLC is well defined and follow a flow chart pattern. First, the PLC
recognizes all activated input devices whether digital or analog ones connected to the system.
The next step is the PLC performs the action as per the logic which crafted about inputs and
decides what data they want to put out or change. Last of all, the PLC controls the output
devices; this may involve opening or closing a valve, increasing or decreasing a motor speed, or
sounding a signal that includes a light or other sound. Once all these tasks have been
accomplished, a housekeeping step for the internal diagnostics of the whole system is done by
the PLC. Switching between these states happens over and over, and in real time, it controlling
and automating industries.

WHAT-PROGRAMMING-LANGUAGE IS USED TO PROGRAM A PLC?

They also present many different languages for accomplishing PLC programming that can be
used based on the needs of the system being implemented. Pendants are associated
predominantly with the most popular type of language, Ladder Logic (LD) that was created
to imitate electrical relay logic. It features a graphical layout that looks more like a ladder,
where every step is a set of conditions and actions and, for this reason, easy to comprehend,
debug and apply particularly for technicians who are working with relay based systems. But
thanks to development Ladder Logic can be used for more advanced functionalities such as
timers, counters and even simple arithmetic operations.
Nevertheless, the PLC programming is not just restricted to using Ladder Logic. Function
Block Diagram (FBD) is another graphical alternative for describing plant processes through
function blocks used to present data flow as well as control algorithms. Applicable especially
where the control uses PID loops, safety logic and or analog control, FBD excels due to its
structured nature and reusability.

For more elaborate programming, Structured Text (ST), a textual programming language is
used most often. It has been considered that ST resembles such languages as PASCAL and C
most closely, and therefore it is the most appropriate for the problems which include
calculations, data manipulation and cycles. This language enable great control and optimization
of code, but it is more difficult to solve problems.

The last but not least method is the Sequential Function Chart (SFC) that breaks down
large, complicated control schemes into components applying steps and transitions. SFC is
useful for systems where a process can be divided into multiple states or where there are
conceived batches of activity.
 Last is the **Instruction List (IL)**, which is a low level textual language similar to assembly
language. Even though IL has mostly been replaced in more modern systems due to better
options, there are some systems out there that directly employ IL for low level manipulation of
hardware as well as for performance specifically.

In China today, Ladder Logic remains the most popular programming language in using
industrial automation as compared to ST, FBD, and SFC languages. Some of the reasons for its
usage are, Its ease of use and simplicity for engineers and technicians within manufacturing
industries. Ladder Logic was discovered to be the most suitable since China experienced rapid
industrialization that required proper automation. Due to the resemblance to electrical
schematics and relay control systems, for workers who have prior experience using
conventional methodologies, little training was needed to adapt to its usage. In addition,
Ladder Logic is highly visual enabling easy fault diagnosis, this is very important in industries
whose operations require minimal interruption.

All of these languages thou classified under the IEC 61131-3 standard have their own benefits
to be considered. SCL is the least used language due to its challenging programming ability,
however, the other languages come with more features compared to the Ladder Logic which is
easy to code, and troubleshoot. There is five kinds of programming Languages of PLC’s: LD,
FBD, ST, SFC, and IL As a matrix of these language a programmer can choose suitable
language for a control system application for better performance and easy to maintain.

General Uses of PLC

Most of the operations which occur in any given day and are often so fundamental that most
of us do not even give its management a second thought happens through a Programmable
Logic Controller (PLC). In homes, and offices we have automatic systems, a PLCS is important
for managing and enhancing the everyday performant that is so often overlooked yet present
in all facets of our lives starting from the gadgets in our homes via to the massive industrial
machines in industries and public facilities.
The following are broader applications of PLCs across various domains:

1. Manufacturing and Production:

- Assembly Line Control:
Communal PLCs play an unmatched role in automating sequential activities
within assembly lines. In the car manufacturing for instance, they supervise all the processes from body
welding to engine mounting right up to the final inspection to ensure that each fabricated part meets
certain standard.
- Machining Processes:
PLCs command CNC (Computer Numerical Control) machines that contain a
detailed working system such as cutting, drilling, as well as milling processes. The PLC inhibits erosion of
precision by controlling movements of the tools according to programs that are set in advance.
- Packaging Systems:
In the food and beverage industry, packaging machinery, like PLCs, can be used to
fill containers, seal packages, label items, and pack products for shipping, in the pharmaceuticals and
consumer goods industries as well.

2. Process Control:
- Chemical Processing:
In the chemical industries, PLCs control different factors, that is; temperature,
pressure, flow rate and chemical concentrations during production. They assist in sustaining constant
product quality and safety by tracking requisites conditions in accelerated tempo.
- Oil and Gas Industries:
In drilling operations, pumping, compression and distribution of natural gas
right down to the refinement of the final product, PLCs take charge. They facilitates effective, safe and
environmentally sustainable operations.
- Water Treatment Plants:
PLCs are used to regulate the operating conditions of Water Treatment
Plants in regard to filtration, chlorination and distribution giving assurance for a plausible purification
process that meets the Standard Set till date.
3. Infrastructure and Transportation:
- Automated Transportation Systems:
PLCs are applied to control the towed transport system present in
airports such as baggage conveyors, check-in counters and other security screening equipment. In
railway systems, the inputs and outputs in a PLC control signals and gates, as well as power switching for
trains.
- Smart Traffic Management:
Traffic lights and intelligent traffic signals rely on PLCs to control the
ongoing movement of automobiles and to regulate utilization of roads.

4. Energy Management:
- Renewable Energy Systems:
In renewable power segments like wind, solar and hydropower, the
authenticated PLCs intervene in commanding the manufacture of power and supply. For instance in the
wind farm, PLCs are used in the monitoring of the operations of turbines, where the amount of power
generated is determined with relation to the wind speed.
- Power Generation Plants
: PLCs in applied in power plants that include: nuclear power plant, thermal
power plant, hydroelectric power plant to manage the generation as well as distribution of power. They
observe equipment, control loads, and ration fuel in order to control the output of electrical power.

5. Building Automation:
- HVAC Systems:
PLCs find application in Heating, Ventilation and Air conditioning (HVAC) with respect
to the modulation of temperatures and air quality of rooms and other structures. They make the
systems to be energy efficient by varying its parameters due to change in environment and occupancy.
- Security Systems:
PLCs are used to manage surveillance cameras, access control systems and alarms.
They are synergistic and manage the security of people and assets, including responding automatically
to events, by locking doors or raising alarms.
- Lighting Automation:
In business premises, PLCs control lighting; by programming it to turn on and off
at specified times, or through occupancy sensors to guarantee maximum utilization of light and
comfortable atmosphere at the workplace.

6. Agriculture:
 - Precision Farming:
PLCs make modern farming possible and influence such subsystems as irrigation,
fertilization, and pest control. For example, in greenhouses, such as, a PLC controls the temperature,
humidity level, and the irrigation sequence to enhance plants’ yield.
- Livestock Farming:
In large-scale livestock farming, PLCs automate feeding systems, monitor water
supply, and control ventilation systems to maintain a healthy environment for animals.

Uses of PLC in the Automation Industry;

In the automation industry, PLCs are used to control industrial machines, automate
production and maintain product standard, quality and safety. The following are specific
ways PLCs are applied within automation:

1. Assembly Line Automation:

Automotive and electronics industries have adopted complicated array of these devices in newest
production lines. In each task, such as transferring of components on conveyors, synchronizing of robot
arms for welding, soldering, or fastening, a PLC is utilized. This enables the company to achieve high
speed, accuracy and minimum labour cost.

- PLCs offer free programmability, so it becomes really easier to alter the location of assembly lines in
order to meet new products or changed production volumes without much need for rewiring.

2. Robotic Systems and Automation:

The automotive, electronics and aerospace industries, paint, weld or sort parts, and transport
materials to and from assembly lines. PLCs are used to control these robotic systems; and they initiate
action according to programmed instructions and also receive data from the sensors that control the
system and automate the necessary correspondence changes in the robotic system.

For example, the PLCs are used in a car manufacturing plant where they control the robotic arms that
handle the welding tasks and synchronize the welding operations so that thousands of welds in a car are
correctly and simultaneously placed and welded.

3. Material Handling and Warehousing:

PLCs control the conveyance and distribution of all sorts of materials right from the warehouse to the
manufacturing plant or distribution center. They manage conveyor lines, robotic pickers and drivers, and
automated storage and retrieval systems (ASRS) that respond to product and shipping logistics, thereby
minimizing the amount of work done by hand.
 In technologically advanced stores, PLC’s collaborates with WMS to enhance the flow of products and
improved inventory retrieval without compromising on the quality.

4. CNC Machine Control:

In the manufacturing industries PLCs play a crucial role in controlling the CNC machines used in cutting,
drilling and milling operations. PLCs are responsible of handling the input from CAD (Computer-Aided
Design) and translates them into instructions that can be understood by the machines. This assures that
the cnc tools work within precise tolerance and execute activities such as, cutting of steel, shaping of
parts among others with least level of disparity.

PLCs are important in some sectors like the aerospace, automotive, and electronics industries among
others due to the need to place high accuracy on parts production.

5. Packaging Systems:

In the packaging industry such as the food and beverage, pharmaceutical and other types of packaging
industries, the PLCs are used to control systems that include filling, sealing, labeling, and palletizing.
PLCs helps guarantee the packaging of every product with strict adherence to quality without the
interference of the human hand.

For instance, in a bottling plant, there are Programmable Logic Controllers or PLCs that dictate the flow
of the filling machines to ensure that they dispense the right dosage of the liquid product into bottles
correctly and then seal, label, and pack these bottles for distribution.

6. Process Automation in Chemical, Oil & Gas Industries:

In the chemical industry, PLCs regulate often complicated processes including distillation, mixing or
chemical reactions to keep tiny factors including temperature, pressure and flow rates within tightly
controlled ranges. This enhances the synthesis of chemical products and deters accumulation, which
would have otherwise been hazardous.

In oil and gas sectors, PLCs enable the observation of pipelines and pressures, pumps, and even more,
the refining stages. From drilling crude oil to processing it into gasoline or any other product, they
handle it all.

7. Food-and-Beverage Processing:

Some of the functions of food and beverage industry which apply the concept of PLC are brewing,
baking, bottling, and packaging. PLCs are used to operate machinery which comes into contact with raw
materials, controls cooking or processing time and package the food safely and correctly.
 For instance in a brewery, smart automation through PLCs controls the fermentation process through
changing temperatures and regulation of valves in order to produce good beer all the time.

In what way is PLC used in the Automation Industry

1. Input/Output (I/O) Management:

- PLCs also operate as a central controller for input and output signals within automatically controlled
systems. Inputs are gathered from various instruments including; This category comprises of any devices
that record the status of the system for example temperature, pressure, proximity, among others) while
outputs enable control of other devices such as motors, valves, relays among others that are helpful in
the movement of the parts.

–These elements take inputs from PLCs, and the obtained data along with the instructions from the
programming source is processed and then relayed to the output devices of the plant. For example, in
an automated conveyor system, the Programmable Logic Controllers (PLCs) tally sensors to need an item
and instruct motors to power the conveyor system accordingly.

2. Sequential Control:
–PLCs are established to perform sequential logic to find that they can perform a task for another
depending on a certain set of conditions. This is especially helpful for procedures that need to go into
various stages before they are accomplished, in the right order.

- For example, in a bottling plant, the PLC controls a series of tasks: linking smelling an empty bottle,
pouring liquid into it, screwing the cap on, labelling it, and then moving it to packing section. All these
steps are carried out in a workflow manner to avoid interruption and to ensure the best production
results.

3. Real-time Monitoring and Control:

Again, one significant advantage of PLCs is in real-time observation of a system. They always read input
signals, perform control programs, and modify the functioning of machines and processes with
reference to the existing situation.

In time sensitive industries like the semiconductor manufacturing plant or even the pharmaceuticals,
the use of PLCs help maintain time and order in manufacturing, thus avoiding creation of substandard
products.

4. Error Detection and Handling:

 PLCs are very safe and very reliable as compared to other control systems. They can sense anomalies
on the machines, like excessive temperature, excessive load, or wear of the components and cause
safety features like shutdown.

For instance, in a factory with robotic arms, a sensor can develop a signal showed that the robotic arm
has deviated from its correct pattern; the PLC can halt the process to avoid any harm to the product or
the robotic arm itself.

5. Human-Machine Interface (HMI):

– PLCs may be linked with an HMI- Human-Machine Interface which lets the operators control the
process through graphics. From the HMI, operators are able to observe the status of a machine, make
changes to setpoints, or debug faults.

Real case studies of plc’s applications in industry

automation
Ford Motor Company – Automotive Manufacturing

Application:
Ford applies PLC controls on assembly lines of automobile manufacturing plants
especially during robotic welding, painting and parts fitting.

Problem:
Ford sought to automate and streamline the complex tasks of assembling vehicles so that
they would be done accurately and speedily without increased costs in labor.

Solution:
Some of these PLCs are used to control robotic systems such as welders, bolts, and painters
in the assembly lines. These PLCs control activities on conveyor belts, robotic hands, and even sensors to
help achieve accuracy in the workflow.

Outcome:
With the introduction of the PLC’s, Ford was able to improve on speed of production,
decrease mistakes made by human operators, and control standards of all the final products. It is also
easy to adapt on the various models of vehicles produced as opposed to conventional form of
programming w2hen retuning is done; this is because of fuel system models which reduce changeovers
time during the ramp-up periods.
Coca Cola Bottling Plant – Food and Beverage Industry

Application:
PLCs are used by Coca Cola in the automated processes of bottling and packaging
beverages.

Problem:
The challenge was to ensure sufficient volumes of output while achieving an even level of
quality in the operations of filling, capping, and labeling bottles.

Solution:
Use a PLC to automate and control the entire bottling process. From filling bottles to sealing,

labeling and filling, sensors and PLCs together adjust the machine to real-time conditions. To ensure
accuracy and consistency

Results:
The use of PLCs has resulted in significant increases in production efficiency and reduced

operating costs. Coca-Cola has improved product stability in factories around the world. Reduce human

error and achieve faster production cycles with a PLC-controlled control system. 3. Shanghai

Pudong International Airport - Automated Baggage Handling (China)

Application:
Shanghai Pudong International Airport uses PLC to automate its baggage handling

system. Helps ensure efficient sorting and transportation of baggage through multiple terminals...

Problem:
As one of the world's busiest airports, Shanghai Pudong needed to automate its

baggage handling system to handle millions of passengers and their luggage. Reduce delays and
errors...

Solution:
A PLC is used to control the baggage controls, scanners, sorting and loading systems.

These synchronize real-time data from PLC sensors and ensure that baggage is automatically
sorted according to flight and terminal information.
The result:
is a significant improvement in the efficiency of automation. Reduce cases of lost

baggage and guarantees faster baggage processing. The system's ability to handle high
passenger volumes and adapt to peak travel times makes the airport extremely efficient in
terms of baggage handling...

Trends for PLC-Based Automation, and Changes in Future

The role of PLCs in industrial automation is continuously evolving, and several trends are
shaping their future:

1. Aperture in Interaction with IoT and Industry 4.0

PLCs, which have been used in industrial production for a long time, are gradually connected to the IoT
as a part of the Industry 4.0 revolution. This integration facilitates real time data capturing, sophisticated
modelling and control as well as distant observation of industrial procedures. Advanced PLCs in an IoT
setting can also be connected allowing for conversations with other machines; Systems within a smart
factory can self-configure, self-diagnose for failure as well as manipulate changes to systems in real-
time.

2. Edge Computing

Edge computing is slowly being adopted in industrial automation to perform data analytics locally to the
context it is being generated from. This is because the specific intelligent device such as PLC in the
industrial chain can process data locally to avoid latency and achieve faster decision-making speed. This
proves most valuable for real-time applications like robotics and safety-critical application where timing
is critical.

3. Cybersecurity

When the industrial automation is done , the security concern comes into the light. Cyber attackers have
started focusing on attacking PLCs and this puts manufacturers under immense pressure of having to
add better security into these systems. Reflected in future PLCs are the advanced encryption, the
authentication mechanisms and the communication protocols to ensure against the risks.

4. AI and ML
They are also slowly starting to adopt AI and ML algorithms in the control processes and to be able to
predict the failures in the machines. Real-time data analytics of large amounts of data make the
implementation of AI in PLC possible to enhance industrial production, reduce maintenance cost and
sometimes offer automated decisions.

Conclusion & Personal Opinion

After looking at all the uses of PLC’s we can say that PLC’s are the
heart of today’s industrial automation. Its capability in controlling,
supervising, and enhancing the industrial processes has made
industries related to manufacturing, energy, motion control, and
predictive maintenance more efficient. PEC is thus guaranteed
through the flexibility of PLCs, given that they can funditinal for
meeting efficiency, precision, and safety in extremely complicated
operations.

In the field of industrial automation the use of Programmable Logic

Controllers, PLCs, is mandatory. For a and complex systems, their
real-time response capabilities make them suitable to maintain and
manage high-level industries as the industries progress to smart
manufacturing and Industry 4.0 systems. As AI, IoTs, and cloud
systems are adopted, PLCs also develop, and their role in the
modern production environment will only improve in both efficiency
and creativity.

From my point of view, it can be discussed that the role of PLCs is

critical to developing industrial efficiency and safety. The examples
of their application in the different fields allow indicating their
applicability and modernity. The overwhelming utilization of ladder
logic all over especially from countries like China; show how
simplicity, and reliability are some of the key success factors.
However, decreasing variability and increasing system complexity
demand using high-level programming languages like Structured
Text and Function Block Diagrams (FBD) more extensively. These
languages can readily handle the complexities of the present day
automation systems thereby providing more flexible and expandable
solutions.
Thus, PLCs are not only the necessary element of modern industrial
setups but can also expect the further advancement. Embedded with
the state of the art technologies and have been tested to deliver
their functionalities make them an essential component for the next
generation industrial revolution. Managing their use, as well as
researching the possibilities in current or more progressive
computer languages will be vital for engineers and designers
seeking to remain competitive in this quickly developing industry.