Module-V

ME-503 (Hydraulics & Pneumatic Controls)

 Programmable Logic Controllers (PLCs)
Electrohydraulic Servo Systems

Programmable Logic Controllers (PLCs)

• In recent years, programmable logic controllers (PLCs) have increasingly been
used in lieu of electromechanical relays to control fluid power systems.
• A PLC is a user friendly electronic computer designed to perform logic functions
such as AND, OR, and NOT for controlling the operation of industrial equipment
and processes.
• A PLC consists of solid-state digital logic elements for making logic decisions and
providing corresponding outputs.
• Unlike general-purpose computers, a PLC is designed to operate in industrial
environments where high ambient temperature and humidity levels may exist.
• PLCs offer a number of advantages over electromechanical relay control
systems.
• Unlike electromechanical relays, PLCs are not hard-wired to perform specific
functions. Thus, when system operation requirements change, a software
program is readily changed instead of having to physically rewire relays. In
addition, PLCs are more reliable, faster in operation, smaller in size, and can
be readily expanded.

• The relay is an electromechanical

switch used as a protecting device and
also as a controlling device for various
circuits, equipments, and electrical
networks in a power system.
• A PLC-based synchronous lift system used for precise lifting and lowering of high-
tonnage objects on construction jobs.
• Unlike complex and costly electronic lift systems, this hydraulic system has a
minimum number of parts and can be run effectively and efficiently by one
person. The PLC enables the operator to quickly and easily set the number of lift
points, stroke limit, system accuracy, and other operating parameters from a
single location.
• The PLC receives input signals from electronic sensors located at each lift point,
and in turn sends output signals to the solenoid valve that controls fluid flow to
each hydraulic cylinder to maintain the relative position and accuracy selected
by the operator.

Various types of relays are used in various

applications based on different criteria such as
rating of contacts, number & type of contacts,
the voltage rating of contacts, operating
lifetime, coil voltage & current, package, and
so on. Relays are frequently being used in
power system networks for controlling
purpose, automation purpose, and protection
purpose.
PROGRAMMABLE LOGIC CONTROLLERS (PLCs)

• A programmable logic controller (PLC) is a user-friendly electronic computer

designed to perform logic functions such as AND, OR, and NOT for controlling
the operation of industrial equipment and processes.

• PLCs, which are used in lieu of electromechanical, consist of solid-state digital

logic elements for making logic decisions and providing corresponding outputs.

• Unlike general-purpose computers, a PLC is designed to operate in industrial

environments where high ambient temperature and humidity levels may exist.

• In addition, PLCs are designed not to be affected by electrical noise commonly

found in industrial plants.

• A PLC designed for a wide variety of automation tasks.

• This PLC provides user-friendly service, from installation to troubleshooting

and maintenance. Its compact size permits the unit to be mounted directly
onto an installation panel.
PLCs provide the following advantages over electromechanical relay control
systems:
• Electromechanical relays have to be hard-wired to perform specific functions.
Thus, when system operation requirements change, the relays have to be
rewired.
• They are more reliable and faster in operation.
• They are smaller in size and can be more readily expanded.
• They require less electrical power and are less expensive for the same number
of control functions.

Major Units of a PLC

1. Central processing unit (CPU)

2. Programmer/monitor (PM)
3. Input/output module (I/O)
Central processing unit (CPU)
• This unit represents the “brains” of the PLC.
• It contains a microprocessor with a fixed memory and an alterable memory.
• The fixed memory contains the program set by the manufacturer. It is set into
integrated circuit (IC) chips called read only memory (ROM) and this memory
cannot be changed during operation or lost when electrical power to the CPU is
turned off.
• The alterable memory is stored on IC chips that can be programmed and
altered by the user. This memory is stored on random access memory (RAM)
chips and information stored on RAM chips is lost (volatile memory) when
electrical power is removed.
• In general, the CPU receives input data from various sensing devices such as
switches, executes the stored program, and delivers corresponding output
signals to various load control devices such as relay coils and solenoids.

• The PLC stores user programs in

nonvolatile flash memory for
safety. Thus, no battery is
needed to prevent loss of user
programs if electrical power is
lost.
Programmer/monitor (PM)
• This unit allows the user to enter the desired program into the RAM memory of
the CPU. The program, which is entered in relay ladder logic, determines the
sequence of operation of the fluid power system being controlled. The PM needs
to be connected to the CPU only when entering or monitoring the program.
Programming is accomplished by pressing keys on the PM’s keypad. The
programmer/monitor may be either a handheld device with a light-emitting
diode (LED) or a desktop device with a cathode-ray tube (CRT) display.
Input/output module (I/O)

• This module is the interface between the fluid power system input sensing
and output load devices and the CPU.
• The purpose of the I/O module is to transform the various signals received
from or sent to the fluid power interface devices such as push-button
switches, pressure switches, limit switches, motor relay coils, solenoid coils,
and indicator lights.
• These interface devices are hard-wired to terminals of the I/O module.

The PLC contains a powerful 16-bit, 20-MHz processor.

Multitasking of up to 64 programs allows the user to
divide the control task into manageable objects. This PLC
contains 12 inputs and 8 outputs, each of which are
monitored by light-emitting diodes. This PLC can be
programmed off-line in a ladder logic diagram using a
microcomputer. Capabilities include project creation,
program editing, loading, and documentation. The system
allows the user to monitor the controlled process during
operation and provides immediate information regarding
the status of timers, counters, inputs, and outputs.
Truth table
output
NOT gate
Rung
Latch
• The latching is used where the output must be
activated even after the entry ceases.

• A simple example of such a situation is a motor,

which is started by pressing a button switch.
Although the switch contacts do not remain
closed, it is required that the motor continue to
run until a stop button switch is pressed. The
latching used to stay the motor run until the push
button is pressed again.
Control of a hydraulic cylinder using a single limit switch
A PLC is a digital solid-state device and thus performs operations based on the
three fundamental logic functions: AND, OR, and NOT.

Limit switch
PLC ladder logic diagrams.
Inputs include switches, relay contacts, on/off
sensors (e.g., limit switches and
photodetectors), timers, and other binary
contact devices. Loads include motors, lamps,
solenoids, and alarms.
Fluid Logic Control Systems
• Fluid logic control systems use logic devices that switch a fluid, usually air, from
one outlet of the device to another outlet. Hence, an output of a fluid logic
device is either ON or OFF as it is rapidly switched from one state to the other by
the application of a control signal.
• Fluid logic control systems have several advantages over electrical logic control
systems. For example, fluid logic devices are not as adversely affected by
temperature extremes, vibration, and mechanical shock. In addition, fluid logic
systems are ideally suited for applications where electric arcing or sparks can
cause a fire or an explosion. Also, fluid logic devices do not generate electric
noise and therefore will not interfere with nearby electric equipment.
• Devices that use a fluid for control logic purposes are broadly classified as either
moving-part logic (MPL) devices or fluidic devices.
• Moving-part logic devices are miniature valve-type devices, which—by the
action of internal moving parts—perform switching operations in fluid logic
control circuits.
• MPL devices are typically available as spool, poppet, and diaphragm valves,
which can be actuated by means of mechanical displacement, electric voltage,
or fluid pressure. Moving-part logic circuits provide a variety of logic control
functions for controlling the operation of fluid power systems.
• Fluidic devices use a completely different technique for providing control logic
capability as compared to MPL devices. Fluidics is the technology that uses
fluid flow phenomena in components and circuits to perform a variety of
control functions such as sensing, logic, memory, and timing. The concepts of
fluidics are basically simple.
• They involve the effect of one fluid stream meeting another to change its
direction of flow and the effect of a fluid stream sticking to a wall.
• Since fluidic components have no moving parts, they virtually do not wear
out. However, component malfunction can occur due to clogging of critical
flow passageways if contaminants in the air supply are not eliminated by
proper filtration. Fluidics is rarely used in practical industrial applications and
thus is not covered in this book.
MOVING-PART LOGIC (MPL) CONTROL SYSTEMS
• Moving-part logic (MPL) control systems use miniature valve-type devices, each
small enough to fit in a person’s hand. Thus, an entire MPL control system can
be placed in a relatively small space due to miniaturization of the logic
components.
• Moving-part logic circuits use four major logic control functions: AND, OR, NOT,
and MEMORY
AND Function

• It requires two or more control signals in

order to obtain an output. The circuit
consists of three two-way, two-position,
pilot-actuated, spring-offset valves
connected in series. If control signals exist at
all three valves (A, B, and C), then output D
will exist. If any one of the pilot signals is
removed, output D will disappear.
• A second method of implementing uses a
single directional control valve and two
shuttle valves. Pilot lines A, B, and C must be
vented to shut off the output from S to P.
OR Function
An OR circuit is one in which a control signal at any one valve will produce an
output. Thus, all control signals must be off in order for the output not to exist. This
is accomplished in Figure, in which the three valves are now hooked in parallel. If
any one of the valves picks up an air pilot signal, it will produce an output at D.
NOT Function
In a NOT function, the output is ON only when the single input control signal A is
OFF, and vice versa. Figure shows that the output will not exist if the control signal A
is received. A second way to implement a NOT function is to use a three-way valve
shown in Figure.

MEMORY Function
MEMORY is the ability of a control system to retain information as to where a signal
it has received originated. Figure shows a MEMORY circuit, which operates as
follows: If control signal A is momentarily applied, output C will come on.
Conversely, if control signal B is momentarily applied, the output will exist at D.
Thus, an output at C means the signal was applied at A, and an output at D means
the signal was applied at B. The MEMORY circuit does not function if control signals
A and B are applied simultaneously because both ends of the output pilot valve
would be piloted at the same time.
MPL CONTROL OF FLUID POWER CIRCUITS
Sequence Control of Two Double-Acting Cylinders
BOOLEAN ALGEBRA

OR function
AND Function

NOT Function
NOR Function
The NOR function has its name derived from the following relationship:

The NOR function is an inverted OR function whose MPL valve system, truth table, and
general symbol are provided in Figure. The Boolean relationship is

The NOR function. (a) MPL components. (b) Truth table. (c) Symbol. (d) OR/NOT
combination = NOR.
NAND Function

The NAND function is an inverted AND function whose MPL valve system, truth
table, and general symbol are provided in Figure.

The NAND function. (a) MPL components. (b) Truth table. (c) Symbol.
(d) AND/NOT combination = NAND.
Filters
• A filter is a device whose primary function is to remove insoluble contaminants
from the fluid, by use of a porous medium.
• Filter cartridges have replaceable elements made of nylon cloth, paper, wire
cloth or fine mesh nylon cloth between layers of coarse wire.
• These materials remove unwanted particles, which collect on the entry side of
the filter element.
• When saturated, the element is replaced.
• The particles sizes removed by the filters are measured in microns.
• One micron is one-millionth of a meter or 0.000039 of an inch.
• Filters can remove particles as small as 1 μ. Studies have proved that particle
sizes as low as 1 μ can have a damaging effect on hydraulic systems and can also
accelerate oil deterioration.

Beta ratio:
It is a measure of a filter’s efficiency. It is defined as the number of particles
upstream from the filter that are larger than the micron rating of the filter, divided
by the number of particles downstream from the filter larger than the micron
rating of the filter.
It is seen that there are 200 particles
upstream from the filter which are larger
than 3 μm in size. A filter having a lower beta
ratio is less efficient because it allows more
particles through it. Again referring the
example above, it is seen that while the filter
at the top allows 100 particles through, only
1 particle is allowed to pass through the filter
at the bottom.
Filter location
The function of breathers in a hydraulic
system is to prevent entry of airborne
particles which are drawn into the
system due to changes in the fluid level
of the reservoir. They are usually
mounted on the reservoir. Components
such as servo valves which are located
immediately downstream of the filter
are protected from wear and silting-
related problems by pressure filters.
Strainers
• A strainer is a device made of wire mesh screens, which seek to remove large solid
particles from a fluid. As part of standard engineering practice, strainers are
installed on pipelines ahead of valves, pumps and regulators, in order to protect
them from the damaging effects of fluid and other system contaminants.
• A common strainer design uses two screens,
cylindrical in shape.
• One cylinder is inside the other and the two are
separated by a small space.
• The outer cylinder is a coarse mesh screen and
the inner one is a fine mesh screen.
• The fluid first passes through the coarse mesh
screen and filters the larger particles. It then
passes through the fine mesh screen, which
blocks the smaller particles.
• The bottom of the strainer serves as the sump (or pot) for the solids to collect.
• The strainer can be cleaned out easily at intervals, by two different procedures:
1. The cleanout plug can be removed and the pressure in the line can be used to blow
the fixture clean.
2. The large retaining nut at the bottom is to be removed for pulling the mesh out of the
strainer in order to clean it and putting it back in line.
RESERVOIRS
The proper design of a suitable
reservoir for a hydraulic system is
essential to the overall performance
and life of the individual
components. The reservoir serves
not only as a storage space for the
hydraulic fluid used by the system
but also as the principal location
where the fluid is conditioned. The
reservoir is where sludge, water, and
metal chips settle and where
entrained air picked up by the oil is
allowed to escape. The dissipation of
heat is also accomplished by a
properly designed reservoir.

This reservoir is constructed of welded steel plates. The inside surfaces are painted
with a sealer to prevent rust, which can occur due to condensed moisture.
Thank You