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PROGRAMMABLE LOGIC CONTROLLERS

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This document provides an overview of programmable logic controllers (PLCs) and their use in manufacturing control systems. It discusses the history and purpose of PLCs, the components that PLCs interact with including input/output devices, switches, relays, timers, and counters. The document also covers PLC architecture, components, ladder logic programming, and provides an example of a ladder logic program for controlling the filling of a tank.

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PROGRAMMABLE LOGIC CONTROLLERSRichard A. Wysk IE450 - Manufacturing Systems
Agenda Review brief history of PLCs and manufacturing control systems Introduce the concepts of discrete control of manufacturing Review the various kinds of instrumentation used for control. Overview ladder logic programming
Readings Chapter 10 of Computer Aided Manufacturing, Chang, Chang, T.C. and Wysk, R. A. and Wang, H.P., 3rd Edition, 2006.
Exercise What are some common examples ofWhat are some common examples of control?control? Washing machine, sump pump, microwave,Washing machine, sump pump, microwave, .. Others?
Types of control Temporal -- control based in time State -- control based in state level Hybrid both temporal and state
Objectives To define the basic components of a PLC To apply PLC based control to a manufacturing system To be identify instrumentation required to implement a PLC control system To program a PLC To implement a PLC control program and hardware
PURPOSE OF Programmable Logic Controllers (PLCs) Initially designed to replace relay logic boards Sequence device actuation Coordinate activities Accepts input from a series of switches Sends output to devices or relays
FUNCTIONS OF CONTROLLERS 1) on-off control, 2) sequential control, 3) feedback control, and 4) motion control.
CONTROL DEVICES 1) mechanical control - cam, governor, etc., 2) pneumatic control - compressed air, valves, etc. 3) electromechanical control - switches, relays, a timer, counters, etc, 4) electronics control - similar to electromechanical control, except uses electronic switches. 5) computer control.
PLC CPU System User Ladder Diagram Working memory registers Input Flag Output Input Module Output Module
PLC Configuration
What devices does a PLC interact with? INPUT RELAYS-(contacts)These are connected to the outside world. They physically exist and receive signals from switches, sensors, etc. Typically they are not relays but rather they are transistors. INTERNAL UTILITY RELAYS-(contacts) These do not receive signals from the outside world nor do they physically exist. They are simulated relays and are what enables a PLC to eliminate external relays. There are also some special relays that are dedicated to performing only one task. Some are always on while some are always off. Some are on only once during power-on and are typically used for initializing data that was stored. COUNTERS-These again do not physically exist. They are simulated counters and they can be programmed to count pulses. Typically these counters can count up, down or both up and down. Since they are simulated they are limited in their counting speed. Some manufacturers also include high-speed counters that are hardware based. We can think of these as physically existing. Most times these counters can count up, down or up and down.
What devices does a PLC interact with? Continued TIMERS-These also do not physically exist. They come in many varieties and increments. The most common type is an on-delay type. Others include off-delay and both retentive and non-retentive types. Increments vary from 1ms through 1s. OUTPUT RELAYS-(coils)These are connected to the outside world. They physically exist and send on/off signals to solenoids, lights, etc. They can be transistors, relays, or triacs depending upon the model chosen. DATA STORAGE-Typically there are registers assigned to simply store data. They are usually used as temporary storage for math or data manipulation. They can also typically be used to store data when power is removed from the PLC. Upon power-up they will still have the same contents as before power was removed. Very convenient and necessary!!
SWITCHE S DPSTSPDT Non-locking Locking Normally Open Normally Closed Multiple Throw P1 P2 Multiple Pole Break-before-make Make-before-break
TERM SThrow - number of states Pole - number of connecting moving parts (number of individual circuits). SPDT DPST A serial switch box (A-B box) has two 25 pin serial ports to switch from. Input Output A B Knob How is this switch classified?
TYPES OF SWITCHES 1. Basic switch, operated by a mechanical level, 2. Push-button switch, 3. 際際滷 switch, 4. Thumbwheel switch, 5. Limit switch, 6. Proximity switch, and 7. Photoelectric switch. RATING: voltage, current
RELAY S A switch whose operation is activated by an electromagnet is called a "relay" contact coil input Relay coil Output contact
COUNTE RDigital counters output in the form of a relay contact when a preassigned count value is reached. Register Accumulator contact input reset output Input Reset Output Count 0 1 2 3 4 5 0 1 5
TIME RA timer consists of an internal clock, a count value register, and an accumulator. It is used for or some timing purpose. Clock Accumulator contact reset output Register Contact Time 5 seconds. Clock Reset Output Count 1 2 3 40 5
AN EXAMPLE OF RELAY LOGIC L1 LS1 PB1 LS2 R1 R1 R1 TIMER R2 PR=5 For process control, it is desired to have the process start (by turning on a motor) five seconds after a part touches a limit switch. The process is terminated automatically when the finished part touches a second limit switch. An emergency switch will stop the process any time when it is pushed. LS1 PB1 LS2 R1 TIMER 5 Motor R2
PLC ARCHITECTUREProgrammable controllers replace most of the relay panel wiring by software programming. Processor I/O Modules Memory Power Supply Program Loader Printer Cassette Loader EPROM Loader Switches Machines Peripherals External Devices PC A typical PLC
PLC COMPONENTS 1. Processor Microprocessor based, may allow arithmetic operations, logic operators, block memory moves, computer interface, local area network, functions, etc. 2. Memory Measured in words. ROM (Read Only Memory), RAM (Random Access Memory), PROM (Programmable Read Only Memory), EEPROM (Electronically Erasable Programmable ROM), EPROM (Erasable Programmable Read Only Memory), EAPROM (Electronically Alterable Programmable Read Only Memory), and Bubble Memory.
PLC COMPONENTS 3. I/O Modular plug-in periphery AC voltage input and output, DC voltage input and output, Low level analog input, High level analog input and output, Special purpose modules, e.g.., high speed timers, Stepping motor controllers, etc. PID, Motion 4. Power supply AC power 5. Peripheral Hand held programmer (loader), CRT programmer, Operator console, Printer, Simulator, EPROM loader, Cassette loader, Graphics processor, and Network communication interface. MAP, LAN
LADDER DIAGRAMA ladder diagram (also called contact symbology) is a means of graphically representing the logic required in a relay logic system. A R1 PB1 PB2 R1 R1 start emergency stop Rail Rung
Ladder Representation
PLC WIRING DIAGRAM 01 02 20 20 20 11 01 02 03 11 12 A PLCInput Output External switches Stored program
SCA N begin Input Output Resolve logic Idle A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to the bottom. Usually, all the outputs are updated based on the status of the internal registers. Then the input states are checked and the corresponding input registers are updated. Only after the I/Os have been resolved, is the program then executed. This process is run in a endless cycle. The time it takes to finish one cycle is called the scan time. Scan cycle
PLC INSTRUCTIONS1) Relay, 2) Timer and counter, 3) Program control, 4) Arithmetic, 5) Data manipulation, 6) Data transfer, and 7) Others, such as sequencers.
LOGIC STATESON : TRUE, contact closure, energize, etc. OFF: FALSE, contact open , de-energize, etc. (In the notes we use the symbol "~" to represent negation. AND and OR are logic operators. ) Do not confuse the internal relay and program with the external switch and relay. Internal symbols are used for programming. External devices provide actual interface.
AND and OR LOGICPB1 R1PB2 R2 R1 = PB1.AND.PB2 R2 = PB2.AND.~PB4 PB3 PB4 PB1 R1 PB2 R1 = PB1 .OR. PB2 AND OR
COMBINED AND & OR R1 = PB1 .OR. (PB2 .AND. PB3) PB1 R1 PB2 pb3
RELA Y A Relay consists of two parts, the coil and the contact(s). Contacts: a. Normally open -| |- b. Normally closed -|/|- c. Off-on transitional -||- d. On-off transitional -| |- Coil: a. Energize Coil -( )- b. De-energize -(/)- c. Latch -(L)- d. Unlatch -(U)- ( )
TIMERS AND COUNTERS Timers: a. Retentive on delay -(RTO)- b. Retentive off delay -(RTF)- c. Reset -(RST)- Counter: a. Counter up -(CTU)- b. Counter down -(CTD)- c. Counter reset -(CTR)- RTO counting stop counting resume RTF stop counting stop True False True Input RTO reach PR value, output ON RTF reach PR value, output OFF PR value in 0.1 second
SEQUENCE RSequencers are used with machines or processes involving repeating operating cycles which can be segmented into steps. Output Step A B C Dwell time 1 ON OFF OFF 5 sec. 2 ON ON OFF 10 sec. 3 OFF OFF ON 3 sec. 4 OFF ON OFF 9 sec.
Rockwell/ Allen Bradley PLCI/O points are numbered, they correspond to the I/O slot on the PLC. For A-B controller used in our lab I/O uses 1-32 Internal relays use 033 - 098 Internal timers/counters/sequencers use 901-932 Status 951-982
Programming a PLC Oil is consumed randomly. The tank needs to be refilled by turning on a pump. Two hydrostatic switches are used to detect a high and low level.
Ladder Logic for Tank
Logic for Ladder Solution
How does it work?
PROGRAMMING EXAMPLE 1Part microswitch Bar code reader Stopper Conveyor Machine Robot id description state explanation MSI microswitch 1 part arrive R1 output to bar code reader 1 scan the part C1 input from bar code reader 1 right part R2 output robot 1 loading cycle R3 output robot 1 unloading cycle C2 input from robot 1 robot busy R4 output to stopper 1 stopper up C3 input from machine 1 machine busy C4 input from machine 1 task complete
SOLUTIO N01 02 03 04 05 11 12 13 14 15 Input Output Programmable Controller PLC MS1 C1 C2 C3 C4 R1 R2 R3 R4 01 14 11 02 14 04 03 14 12 1305 03 Rung 1. If part arrives and no part is stopped, trigger the bar code reader. Rung 2. If it is a right part, activate the stopper. Rung 3. If the stopper is up, the machine is not busy and the robot is not busy, load the part onto the machine. Rung 4. If the task is completed and the robot is not busy, unload the machine.
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
EXAMPLE 2 TRAFFIC LIGHTS Cycle time Street Red Yellow Green Main 3 1 4 Jefferson 5 1 2 Main street Jefferson street
WIRING DIAGRAM 64 65 66 67 70 71 Programmable Controller input output Jefferson Red Jefferson Yellow Jefferson Green Main Green Main Yellow Main Red
PROGRAM (1)RUNG1 RUNG2 RUNG3 RUNG4 RUNG5 RUNG6 RUNG7 RUNG8 RUNG9 RUNG10 RUNG11 RUNG12 20 67 RTO 903 66 RTO 901 80 RTO 902 30 901 902 67 M. Red 901 903 66 J. Green 902 904 71 M. Green 904 905 70 M. Yellow RST RST 901 904 RTO 904 40 71 RST 901 903 RST 901 902 901 901
PROGRAM (2) RUNG13 64 RTO 907 50 65 RTO 906 10 70 RTO 905 10 903 906 65 J. Yellow 902 64 907 J. Red RST 901 907 RST 901 906 RST 901 905 RUNG14 RUNG15 RUNG16 RUNG17 RUNG18 RUNG19 RUNG 20

More Related Content

PROGRAMMABLE LOGIC CONTROLLERS

  • 2. Agenda Review brief history of PLCs and manufacturing control systems Introduce the concepts of discrete control of manufacturing Review the various kinds of instrumentation used for control. Overview ladder logic programming
  • 3. Readings Chapter 10 of Computer Aided Manufacturing, Chang, Chang, T.C. and Wysk, R. A. and Wang, H.P., 3rd Edition, 2006.
  • 4. Exercise What are some common examples ofWhat are some common examples of control?control? Washing machine, sump pump, microwave,Washing machine, sump pump, microwave, .. Others?
  • 5. Types of control Temporal -- control based in time State -- control based in state level Hybrid both temporal and state
  • 6. Objectives To define the basic components of a PLC To apply PLC based control to a manufacturing system To be identify instrumentation required to implement a PLC control system To program a PLC To implement a PLC control program and hardware
  • 7. PURPOSE OF Programmable Logic Controllers (PLCs) Initially designed to replace relay logic boards Sequence device actuation Coordinate activities Accepts input from a series of switches Sends output to devices or relays
  • 8. FUNCTIONS OF CONTROLLERS 1) on-off control, 2) sequential control, 3) feedback control, and 4) motion control.
  • 9. CONTROL DEVICES 1) mechanical control - cam, governor, etc., 2) pneumatic control - compressed air, valves, etc. 3) electromechanical control - switches, relays, a timer, counters, etc, 4) electronics control - similar to electromechanical control, except uses electronic switches. 5) computer control.
  • 12. What devices does a PLC interact with? INPUT RELAYS-(contacts)These are connected to the outside world. They physically exist and receive signals from switches, sensors, etc. Typically they are not relays but rather they are transistors. INTERNAL UTILITY RELAYS-(contacts) These do not receive signals from the outside world nor do they physically exist. They are simulated relays and are what enables a PLC to eliminate external relays. There are also some special relays that are dedicated to performing only one task. Some are always on while some are always off. Some are on only once during power-on and are typically used for initializing data that was stored. COUNTERS-These again do not physically exist. They are simulated counters and they can be programmed to count pulses. Typically these counters can count up, down or both up and down. Since they are simulated they are limited in their counting speed. Some manufacturers also include high-speed counters that are hardware based. We can think of these as physically existing. Most times these counters can count up, down or up and down.
  • 13. What devices does a PLC interact with? Continued TIMERS-These also do not physically exist. They come in many varieties and increments. The most common type is an on-delay type. Others include off-delay and both retentive and non-retentive types. Increments vary from 1ms through 1s. OUTPUT RELAYS-(coils)These are connected to the outside world. They physically exist and send on/off signals to solenoids, lights, etc. They can be transistors, relays, or triacs depending upon the model chosen. DATA STORAGE-Typically there are registers assigned to simply store data. They are usually used as temporary storage for math or data manipulation. They can also typically be used to store data when power is removed from the PLC. Upon power-up they will still have the same contents as before power was removed. Very convenient and necessary!!
  • 14. SWITCHE S DPSTSPDT Non-locking Locking Normally Open Normally Closed Multiple Throw P1 P2 Multiple Pole Break-before-make Make-before-break
  • 15. TERM SThrow - number of states Pole - number of connecting moving parts (number of individual circuits). SPDT DPST A serial switch box (A-B box) has two 25 pin serial ports to switch from. Input Output A B Knob How is this switch classified?
  • 16. TYPES OF SWITCHES 1. Basic switch, operated by a mechanical level, 2. Push-button switch, 3. 際際滷 switch, 4. Thumbwheel switch, 5. Limit switch, 6. Proximity switch, and 7. Photoelectric switch. RATING: voltage, current
  • 17. RELAY S A switch whose operation is activated by an electromagnet is called a "relay" contact coil input Relay coil Output contact
  • 18. COUNTE RDigital counters output in the form of a relay contact when a preassigned count value is reached. Register Accumulator contact input reset output Input Reset Output Count 0 1 2 3 4 5 0 1 5
  • 19. TIME RA timer consists of an internal clock, a count value register, and an accumulator. It is used for or some timing purpose. Clock Accumulator contact reset output Register Contact Time 5 seconds. Clock Reset Output Count 1 2 3 40 5
  • 20. AN EXAMPLE OF RELAY LOGIC L1 LS1 PB1 LS2 R1 R1 R1 TIMER R2 PR=5 For process control, it is desired to have the process start (by turning on a motor) five seconds after a part touches a limit switch. The process is terminated automatically when the finished part touches a second limit switch. An emergency switch will stop the process any time when it is pushed. LS1 PB1 LS2 R1 TIMER 5 Motor R2
  • 21. PLC ARCHITECTUREProgrammable controllers replace most of the relay panel wiring by software programming. Processor I/O Modules Memory Power Supply Program Loader Printer Cassette Loader EPROM Loader Switches Machines Peripherals External Devices PC A typical PLC
  • 22. PLC COMPONENTS 1. Processor Microprocessor based, may allow arithmetic operations, logic operators, block memory moves, computer interface, local area network, functions, etc. 2. Memory Measured in words. ROM (Read Only Memory), RAM (Random Access Memory), PROM (Programmable Read Only Memory), EEPROM (Electronically Erasable Programmable ROM), EPROM (Erasable Programmable Read Only Memory), EAPROM (Electronically Alterable Programmable Read Only Memory), and Bubble Memory.
  • 23. PLC COMPONENTS 3. I/O Modular plug-in periphery AC voltage input and output, DC voltage input and output, Low level analog input, High level analog input and output, Special purpose modules, e.g.., high speed timers, Stepping motor controllers, etc. PID, Motion 4. Power supply AC power 5. Peripheral Hand held programmer (loader), CRT programmer, Operator console, Printer, Simulator, EPROM loader, Cassette loader, Graphics processor, and Network communication interface. MAP, LAN
  • 24. LADDER DIAGRAMA ladder diagram (also called contact symbology) is a means of graphically representing the logic required in a relay logic system. A R1 PB1 PB2 R1 R1 start emergency stop Rail Rung
  • 26. PLC WIRING DIAGRAM 01 02 20 20 20 11 01 02 03 11 12 A PLCInput Output External switches Stored program
  • 27. SCA N begin Input Output Resolve logic Idle A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to the bottom. Usually, all the outputs are updated based on the status of the internal registers. Then the input states are checked and the corresponding input registers are updated. Only after the I/Os have been resolved, is the program then executed. This process is run in a endless cycle. The time it takes to finish one cycle is called the scan time. Scan cycle
  • 28. PLC INSTRUCTIONS1) Relay, 2) Timer and counter, 3) Program control, 4) Arithmetic, 5) Data manipulation, 6) Data transfer, and 7) Others, such as sequencers.
  • 29. LOGIC STATESON : TRUE, contact closure, energize, etc. OFF: FALSE, contact open , de-energize, etc. (In the notes we use the symbol "~" to represent negation. AND and OR are logic operators. ) Do not confuse the internal relay and program with the external switch and relay. Internal symbols are used for programming. External devices provide actual interface.
  • 30. AND and OR LOGICPB1 R1PB2 R2 R1 = PB1.AND.PB2 R2 = PB2.AND.~PB4 PB3 PB4 PB1 R1 PB2 R1 = PB1 .OR. PB2 AND OR
  • 31. COMBINED AND & OR R1 = PB1 .OR. (PB2 .AND. PB3) PB1 R1 PB2 pb3
  • 32. RELA Y A Relay consists of two parts, the coil and the contact(s). Contacts: a. Normally open -| |- b. Normally closed -|/|- c. Off-on transitional -||- d. On-off transitional -| |- Coil: a. Energize Coil -( )- b. De-energize -(/)- c. Latch -(L)- d. Unlatch -(U)- ( )
  • 33. TIMERS AND COUNTERS Timers: a. Retentive on delay -(RTO)- b. Retentive off delay -(RTF)- c. Reset -(RST)- Counter: a. Counter up -(CTU)- b. Counter down -(CTD)- c. Counter reset -(CTR)- RTO counting stop counting resume RTF stop counting stop True False True Input RTO reach PR value, output ON RTF reach PR value, output OFF PR value in 0.1 second
  • 34. SEQUENCE RSequencers are used with machines or processes involving repeating operating cycles which can be segmented into steps. Output Step A B C Dwell time 1 ON OFF OFF 5 sec. 2 ON ON OFF 10 sec. 3 OFF OFF ON 3 sec. 4 OFF ON OFF 9 sec.
  • 35. Rockwell/ Allen Bradley PLCI/O points are numbered, they correspond to the I/O slot on the PLC. For A-B controller used in our lab I/O uses 1-32 Internal relays use 033 - 098 Internal timers/counters/sequencers use 901-932 Status 951-982
  • 36. Programming a PLC Oil is consumed randomly. The tank needs to be refilled by turning on a pump. Two hydrostatic switches are used to detect a high and low level.
  • 38. Logic for Ladder Solution
  • 39. How does it work?
  • 40. PROGRAMMING EXAMPLE 1Part microswitch Bar code reader Stopper Conveyor Machine Robot id description state explanation MSI microswitch 1 part arrive R1 output to bar code reader 1 scan the part C1 input from bar code reader 1 right part R2 output robot 1 loading cycle R3 output robot 1 unloading cycle C2 input from robot 1 robot busy R4 output to stopper 1 stopper up C3 input from machine 1 machine busy C4 input from machine 1 task complete
  • 41. SOLUTIO N01 02 03 04 05 11 12 13 14 15 Input Output Programmable Controller PLC MS1 C1 C2 C3 C4 R1 R2 R3 R4 01 14 11 02 14 04 03 14 12 1305 03 Rung 1. If part arrives and no part is stopped, trigger the bar code reader. Rung 2. If it is a right part, activate the stopper. Rung 3. If the stopper is up, the machine is not busy and the robot is not busy, load the part onto the machine. Rung 4. If the task is completed and the robot is not busy, unload the machine.
  • 46. EXAMPLE 2 TRAFFIC LIGHTS Cycle time Street Red Yellow Green Main 3 1 4 Jefferson 5 1 2 Main street Jefferson street
  • 48. PROGRAM (1)RUNG1 RUNG2 RUNG3 RUNG4 RUNG5 RUNG6 RUNG7 RUNG8 RUNG9 RUNG10 RUNG11 RUNG12 20 67 RTO 903 66 RTO 901 80 RTO 902 30 901 902 67 M. Red 901 903 66 J. Green 902 904 71 M. Green 904 905 70 M. Yellow RST RST 901 904 RTO 904 40 71 RST 901 903 RST 901 902 901 901
  • 49. PROGRAM (2) RUNG13 64 RTO 907 50 65 RTO 906 10 70 RTO 905 10 903 906 65 J. Yellow 902 64 907 J. Red RST 901 907 RST 901 906 RST 901 905 RUNG14 RUNG15 RUNG16 RUNG17 RUNG18 RUNG19 RUNG 20

Editor's Notes

  • #2: This module provides an operational introduction to the use of Programmable Logic Controllers (PLCs) to manufacturing systems.
  • #3: The focus here is on the trends towards smaller lot sizes, more frequent change over and higher flexibility required today.
  • #4: There is no good reference here. The Computer Aided Manufacturing book provides a reasonable technical development of PLCs