University of Baghdad
Al-Khwarizmi College of Engineering
Mechatronics Engineering Department
Programmable Logic Controllers
Asst. Lecturer: Oger Z. Amanuel
References:
• Book of programmable logic controllers by Frank Petruzella
• Book of programmable logic controllers by W. Bolton
Programmable Logic Controllers: an overview
Contents
• Programmable Logic Controller (PLC) definition
• History of the PLC
• PLC advantages and benefits
• Parts of PLC
• PLC types and applications
• PLC versus computers
History of PLC
The first PLC was introduced in the late 1960s.
A programmable logic controller is an industrial computer. It is designed to help in the control of
manufacturing processes.
The automobile sector was the first industry to deploy PLCs into its operations. Their aim was to replace
the hardwired relays and timers with programmable and flexible controllers.
Richard E. Morley, who worked for Bedford associates, designed a device known as the Modular Digital
Controller. Then, Bedford Associates changed its name to Modicon PLC. They began producing the
Modicon 084, the first PLC.
Morley’s genius idea was to incorporate ‘ladder logic’ into his system. Ladder Logic is essentially a
graphic representation of Boolean Logic that was by Irish Mathematician George Boole.
By the time the 70s were coming to a close, Allen-Bradley and other competitors had developed systems
that rivaled Modicon.
One of the most significant milestones in PLC history was the introduction of the International
Electrotechnical Commission (IEC) 61131-3 specification in 1982.
The 1990sThis is what led to the development of the programmable human-machine interface (HMI).
Introduction
A programmable logic controller (PLC) is an industrial grade computer that is capable of being
programmed to perform control functions. The programmable controller has eliminated much of the
hardwiring associated with conventional relay control circuits. Other benefits include easy programming
and installation, high control speed, network compatibility, troubleshooting and testing convenience, and
high reliability.
A PLC is an example of a real-time system since the output of the system controlled by the PLC depends
on the input conditions.
The programmable logic controller is, then, basically a digital computer designed for use in
machine control. Unlike a personal computer, it has been designed to operate in the industrial
environment and is equipped with special input/output interfaces and a control programming
language. The common abbreviation used in industry for these devices, PC, can be confusing
because it is also the abbreviation for “personal computer.” Therefore, most manufacturers
refer to their programmable controller as a PLC, which stands for “programmable logic
controller.”
Initially the PLC was used to replace relay logic, but its ever increasing range of functions
means that it is found in many and more complex applications. Because the structure of a
PLC is based on the same principles as those employed in computer architecture, it is capable
not only of performing relay switching tasks but also of performing other applications such as
timing, counting, calculating, comparing, and the processing of analog signals.
Programmable controllers offer several advantages over a conventional relay type of control. Relays
have to be hardwired to perform a specific function. When the system requirements change, the
relay wiring has to be changed or modified. In extreme cases, such as in the auto industry, complete
control panels had to be replaced since it was not economically feasible to rewire the old panels with
each model changeover. The programmable controller has eliminated much of the hardwiring
associated with conventional relay control circuits.
In addition to cost savings, PLCs provide many other benefits including:
• Increased Reliability.
• More Flexibility.
• Lower Cost.
more
explanation and
• Communications Capability.
clarification in
the reference
• Faster Response Time.
• Easier to Troubleshoot.
Parts of PLC
1. Input/ Output Modules
There are two ways in which I/Os (Inputs/Outputs) are incorporated into the PLC:
fixed and modular.
Input/ Output
section
Fixed Modular
Fixed I/O is typical of small PLCs that come in one package with no separate, removable units. The
processor and I/O are packaged together, and the I/O terminals will have a fixed number of connections
built in for inputs and outputs. The main advantage of this type of packaging is lower cost. The number of
available I/O points varies and usually can be expanded by buying additional units of fixed I/O. One
disadvantage of fixed I/O is its lack of flexibility; you are limited in what you can get in the quantities and
types dictated by the packaging. Also, for some models, if any part in the unit fails, the whole unit has to be
replaced.
Modular I/O is divided by compartments into which separate modules can be plugged. This feature greatly
increases your options and the unit’s flexibility. You can choose from the modules available from the
manufacturer and mix them any way you desire. The basic modular controller consists of a rack, power supply,
processor module (CPU), input/output (I/O modules), and an operator interface for programming and
monitoring. The modules plug into a rack. When a module is slid into the rack, it makes an electrical connection
with a series of contacts called the backplane, located at the rear of the rack. The PLC processor is also
connected to the backplane and can communicate with all the modules in the rack.
Input/ Output system connections
2. Power Supply
The power supply supplies DC power to other modules that plug into the rack. For large PLC systems, this
power supply does not normally supply power to the field devices. With larger systems, power to field
devices is provided by external alternating current (AC) or direct current (DC) supplies. For some small
micro PLC systems, the power supply may be used to power field devices.
3. CPU
The processor (CPU) is the “brain” of the PLC. A typical processor usually consists of a microprocessor
for implementing the logic and controlling the communications among the modules. The processor
requires memory for storing the results of the logical operations performed by the microprocessor.
Memory is also required for the program EPROM or EEPROM plus RAM. The CPU controls all PLC
activity and is designed so that the user can enter the desired program in relay ladder logic.
The PLC program is executed as part of a repetitive process referred to as a scan. A typical PLC scan
starts with the CPU reading the status of inputs. Then, the application program is executed. Once the
program execution is completed, the CPU performs internal diagnostic and communication tasks.
Next, the status of all outputs is updated. This process is repeated continuously as long as the PLC is
in the run mode.
scan cycle
PLC sizes and applications
The criteria used in categorizing PLCs include functionality, number of inputs and outputs, cost, and
physical size. Of these, the I/O count is the most important factor.
In general, the Nano is the smallest size with less than 15 I/O points.
This is followed by Micro types (15 to 128 I/O points).
Medium types (128 to 512 I/O points).
Large types (over 512 I/O points).
There are three major types of PLC application: single ended, multitask, and control management. A
single ended or stand-alone PLC application involves one PLC controlling one process. This would
be a stand-alone unit and would not be used for communicating with other computers or PLCs. The
size and sophistication of the process being controlled are obvious factors in determining which
PLC to select. The applications could dictate a large processor, but usually this category requires a
small PLC.
A multitask PLC application involves one PLC controlling several processes. Adequate I/O capacity
is a significant factor in this type of installation. In addition, if the PLC would be a subsystem of a
larger process and would have to communicate with a central PLC or computer, provisions for a
data communications network are also required.
A control management PLC application involves one PLC controlling several others.
This kind of application requires a large PLC processor designed to communicate with
other PLCs and possibly with a computer. The control management PLC supervises
several PLCs by downloading programs that tell the other PLCs what has to be done. It
must be capable of connection to all the PLCs so that by proper addressing it can
communicate with any one it wishes to.
There are five programming languages for PLC:
Two textual languages:
1. IL (Instruction List)
2. ST (Structured Text)
Three graphical languages:
3. LD (Ladder Diagram)
4. FBD (Function Block Diagram)
5. SFC (Sequential Function Chart)
Although Ladder logic is still the most commonly used language by many PLC programmers,
and for good reasons, because you can use LAD to program almost most of the logic you need
for your application, a small portion of your logic might need other languages like SFC or ST.
So for the small applications you can depend on LAD and it will almost always be enough, but
as your automation process gets larger and more complicated, you have to start considering
other options.
PLCs versus Computers
The architecture of a PLC is basically the same as that of a personal computer. A personal computer (PC) can be
made to operate as a programmable logic controller if you provide some way for the computer to receive
information from devices such as pushbuttons or switches. You also need a program to process the inputs and
decide the means of turning load devices off and on. However, some important characteristics distinguish PLCs
from personal computers.
First, unlike PCs, the PLC is designed to operate in the industrial environment with wide ranges of ambient
temperature and humidity. A well-designed industrial PLC installation, is not usually affected by the electrical
noise inherent in most industrial locations.
Unlike the personal computer, the PLC is programmed in relay ladder logic or other easily learned languages.
The PLC comes with its program language built into its memory and has no permanently attached keyboard,
CD drive, or monitor. Instead, PLCs come equipped with terminals for input and output field devices as well as
communication ports.
Computers are complex computing machines capable of executing several programs or tasks simultaneously
and in any order. Most PLCs, on the other hand, execute a single program in an orderly and sequential fashion
from first to last instruction.
PLC control systems have been designed to be easily installed and maintained. Troubleshooting is simplified by
the use of fault indicators and messaging displayed on the programmer screen. Input/output modules for
connecting the field devices are easily connected and replaced.
Software associated with a PLC but written and run on a personal computer falls into the following
two broad categories:
• PLC software that allows the user to program and document gives the user the tools to write a PLC
program—using ladder logic or another programming language and document or explain the program
in as much detail as is necessary.
• PLC software that allows the user to monitor and control the process is also called a human machine
interface (HMI). It enables the user to view a process or a graphical representation of a process on a
monitor, determine how the system is running, trend values, and receive alarm conditions.
Many operator interfaces do not use PLC software. PLCs can be integrated with HMIs but the same
software does not program both devices.
Most recently automation manufacturers have responded to the increased requirements of
industrial control systems by blending the advantages of PLC style control with that of PC-
based systems. Such a device has been termed a programmable automation controller, or
PAC. Programmable automation controllers combine PLC ruggedness with PC functionality.
Using PACs, you can build advanced systems incorporating software capabilities such as
advanced control, communication, data logging, and signal processing with rugged hardware
performing logic, motion, process control, and vision.
PAC
