WARM WELCOME
TO
ALL
ON BEHALF OF
PROLIFIC SYSTEMS AND
TECHNOLOGIES
ASIAS LARGEST INDUSTRIAL TRAINING PROVIDER
AN ISO-CERTIFIED COMPANY
NSDC APPROVED & FUNDED COMPANY
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GENERAL INFORMATION
Automatic
Process which run fully controlled by a
controlling device on its own , without any
human interrupt.
Semi automatic
Process that uses both combination of
machines and human control .
Manual
Process which is controlled over only by a
human.
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WHAT IS AUTOMATION ?
Automationorautomatic control, is the
use of control systems (PLC)for operating
equipments.
For controlling machinery, processes in
factories, boilers and heat treating ovens,
switching in telephone networks, steering and
stabilization of ships, aircraft and other
applications with minimal or reduced human
intervention.
Some processes have been completely
automated. Now days.
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BENEFITS
Biggest benefit
it saves labour
To save
energy
wastage of materials
To improve
quality
accuracy
precision.
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ARCHITECTURE OF AUTOMATION
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WORLD BEST AND FASTEST
AUTOMATIC
CONTROL SYSTEM
Field Inputs
Controller
Field Output
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MANUAL CONTROL
Water Inlet
Human has to
turn open
and close
these valves.
Water Outlet
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AUTOMATIC CONTROL
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PLCS
Allen Bradley
GE Fanuc
Siemens
ABB(Asian brown broweri)
Mitsubishi
Omron
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WHAT IS A PLC ?
PLC (Programmable Logic Controller)
A PLC works by looking at its Field inputs and
depending on their state, and the user entered
program, turns on/off Field outputs.
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BASIC PLC SCHEMA
CPU
Power Supply
Memory
Input Blocks
Output Blocks
Communication
s
Expansion
Connections
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OVERVIEW OF TECHNOLOGY
Modular
Integrated
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PLC CONFIGURATION
The process of mounting a plc based on its structure.
Rack Type
ShoeBox
Type
Mini Type
Micro Type
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PLC CONFIGURATION
RACK
SHOE BOXwww.prolifictraining.com
MINI
MICRO
SIZING OF PLC
Micro PLC
Small PLC
: I/O up to 32 points
: I/O up to 128 points
Medium PLC : I/O up to 1024 points
Large PLC
: I/O up to 4096 points
Very Large PLC : I/O up to 8192 points
*I/O Inputs and Outputs
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SELECTING A PLC
Criteria.
Number of logical inputs and
outputs.
Memory.
Number of special I/O modules.
Expansion Capabilities.
Scan Time.
Communication.
Software.
Support.
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Dollars.
SAMPLE PLC DIGITAL I/O
Digital Input
Digital Output
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SAMPLE PLC ANALOG I/O
Analog Input
Analog Output
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SCAN CYCLE
The Central Processing Unit (CPU) Module is the brain of the
PLC.
Primary role to read inputs, execute the control program,
update outputs.
The
CPU
consists
of
the
arithmetic
logic
unit
(ALU),
timing/control circuitry, accumulator, scratch pad memory,
program counter, address stack and instruction register.
A PLC works by continually scanning a program
Time taken for one scan is called scan time.
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SCAN CYCLE
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MEMORY
Data Types
Memorys Used In PLC
ROM (Read-Only Memory)
RAM (Random Access
Memory)
PROM (Programmable
Read-Only Memory)
EPROM (Erasable
Programmable Read-Only
Memory)
EEPROM (Electronically
Erasable Programmable
Read-Only Memory)
BINARY VALUE
1 BIT STORAGE
INTEGER
16 BIT VALUE(WORD)
FLOAT OR REAL
32BIT (DOUBLE
WORD)
DOUBLE INTEGER
32 BIT VALUE
(DOUBLEWORD)
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I/O MODULES
Input and output (I/O) modules
connect the PLC to sensors and
actuators.
Provide isolation for the lowvoltage, low-current signals that
the PLC uses internally from the
higher-power electrical circuits
required by most sensors and
actuators.
Wide range of I/O modules
available
including:
digital
(logical) I/O modules and analog
(continuous) I/O modules.
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INPUTS MODULES
The list below shows typical ranges for input
voltages.
5 Vdc
12 Vdc
24 Vdc
48 Vdc
12 Vac
24 Vac
120 Vac
240 Vac
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EXAMPLE OF INPUT CARD
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OUTPUTS MODULES
Output modules rarely supply any power, but instead act as
switches.
External power supplies are connected to the output card and the
card will switch the power on or off for each output.
A common choice when purchasing output cards is relays,
transistors or triacs.
Relay are the most flexible output devices. They are capable of
switching both AC and DC outputs. But, they are slower, cost more,
and they will wear out after millions of cycles.
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Outputs
Typical output voltages are listed below,
5 Vdc
12 Vdc
24 Vdc
48 Vdc
24 Vac
120 Vac
240 Vac
WARNING: Always check rated voltages and
currents for PLCs and never exceed.
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Example of Output Card
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Analogue Cards
Analogue Input signals
:
Analogue Output
signals :
Flow sensors
Humidity sensors
Load Cells
Potentiometers
Pressure sensors
Temperature sensors
Vibration
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Analogue Valves
Actuators
Chart Recorders
Variable Speed Drives
Analogue Meters
ANALOG IO PROCESS
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SCALING PROCESS
Field Input
Filed output
Analog
Transmitter
Speed of
the vehicle
Using Transducers
Converted into Electrical
Signals
Analog
Transmitt
er
Field Control device
PLC Output
Module
PLC Input
Module
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PLC
SCALING FORMULA
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ANALOG INPUTS/OUTPUTS
Analog input cards convert continuous signals
via a A/D converter into discrete values for the
PLC
Analog output cards convert digital values in
then PLC to continuous signals via a D/A
converter.
Resolution can be important in choosing an
applicable card
Example, for a temperature input of 0 to 100
degrees C
For 8 bit resolution the value in the PLC is 0 to 128
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For 12 bit resolution
the value in the PLC is 0 to 4095
SPECIAL MODULES
RF ID
Voice
Gas Flow Calculation
Weigh Cell
Hydraulic Servo
ASCII
Fuzzy Logic
Temperature Sensor
Temperature Control
Heat/Cool Control
Field Bus Cards
DeviceNet, Profibus
etc
Lonworks, BACNet
Fast Response
(Interrupt)
PID
Loop Controller
BASIC Cards
RS232 Comms
Modbus ASCII/RTU
Ethernet Comms
High Speed Counters
Position Control
Cards
Per to Per Comms
Controller Link
DH+
Modbus Plus
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PROTOCOLS
ASI
Devicenet
Interbus-S
Profibus
Interbus
Fieldbus
Ethernet I/P
Smart Distributed System
(SDS)
Seriplex
CANopen
Lonworks
BACNet
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REPRASENTATION IEC 61131-3
IL (Instruction List) or STL (Statement List)
Mnemonic programming
LD (Ladder Diagram)
Relay logic
ST (Structured Text)
A basic programming language
FBD(Functional Block Diagram)
Graphical dataflow programming language
SFC (Sequential Flow Chart)
Graphical method for structured programs
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IEC 61131-3 Examples
Instruction List
Sequential Flow Chart Function Block
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Ladder
Structured Text
LADDER LOGIC
PROGRAM
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NORMALLY OPEN IN FIELD
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PUSH BUTTON ACTUATED
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CLOSED STATE OF NO CONTACT
NORMALLY CLOSED INPROGRAM
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OPEN STATE OF NC CONTACT
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OPEN STATE OF NC CONTACT
PARALLEL CONNECTION
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START/STOP FUNCTION
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START/STOP FUNCTION
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START/STOP FUNCTION
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START/ STOP FUNCTION
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START/ STOP FUCNTION
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FIELD INPUT CONNECTION
IS IMPORTANT
FIELD INPUT
CONNECTED IN
NC
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USING OUTPUT AS INPUT
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USING OUTPUT AS INPUT
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ADVANTAGES
The advantages they offer are:
Cost effective for controlling complex systems
Flexible and can be reapplied to control other
systems quickly and easily
Computational abilities allow more sophisticated
control
Trouble shooting aids make programming easier
and reduce downtime
Reliable components ensure operation for years
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ADVANTAGES
Variety of I/O interfaces
Small size
Growing with technology, faster scan times,
capability etc
Quick I/O disconnects that aids in field
servicing
Modularity in hardware architecture
Modularity in software design (programmer
dependant)
Software Timers/Counter, Relays
Clean failure mode
On-line programming
Self inspecting for operation code during
execution
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BENEFITS
The benefits achieved with programmable
controllers will grow with the individual way
of using them.
The more you learn about PLCs, the more you
will be able
to solve other control problems.
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ANY QUESTIONS ?
Thank
You
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