A PLC system: CPU module (left) and an I/O rack (right) (Allen Bradley PLC-5)

(Courtesy of Allen-Bradley)

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A small PLC (Allen Bradley MicroLogix 1000)
(Courtesy of Allen-Bradley).

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 Definition of PLC
PLC is a digitally operating electronic
apparatus which uses a programmable
memory for the internal storage of
instructions by implementing specific
functions such as logic sequencing, timing,
counting, and arithmetic to control, through
digital or analog input/output modules,
various types of machines or processes.

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 Inputs and outputs of PLC
• Inputs of PLC
– Discrete signal from switch, approximate sensor,
push buttons
– Analog signal from thermal couple, voltmeters,
etc.
• Outputs of PLC
– Most often is the control signal to motor, valves,
etc.

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 Types of switches

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 A Relay

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 A counter

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Counter timing diagram (the count
value is 5)

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 A timer

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Timer timing diagram (the timing
value is 5)

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Ladder diagram for the circuit

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 Wiring diagram

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Programmable logic controller system structure

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 Memory
• ROM
• RAM
• PROM
• EPROM
• etc

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I/O modules (Courtesy of Allen-Bradley)

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 Input/output module
• Analog inputs
– Flow sensors
– Humidity sensors
– Potentiometers
– Pressure sensors
– Temperature sensors
• Analog outputs
– Analog meters
– Analog valves and actuators
– DC and AC motor drives
• Digital input/output
– Bar code, encoder
– Display
• Special purpose I/O
– PID controller
– Fast input
– Network module

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Power input connections: (a) AC, (b) DC, and
(c) TTL

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Power output connections: (a) AC, (b) DC, and (c) TTL

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 Peripherals
• Operator console
• Printer
• Simulator
• EPROM loader
• Network communication
• PC based programming software

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 Human interface terminal
(Courtesy of Allen-Bradley)

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PC-based programming software

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A ladder diagram (also called contact
symbology) is a means of graphically
representing the logic required in a relay
logic system.

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Some relay diagram symbols

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 A ladder diagram

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 PLC wiring diagram

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 PLC scan

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 Functions of PLC
• Relay
• Timer and counter
• Program control
• Arithmetic
• Data manipulation
• Data transfer
• Others, such as sequencers

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 Basic logic

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 And logic

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 OR logic

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 Combine AND and OR logic

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 Example
A robot is used to load/unload parts to a
machine from a conveyor. A part comes
along the conveyor. When it touches a micro
switch, it is scanned by a bar-code reader to
identify it. If the part is the desired one, a
stopper is activated to stop it. A robot picks
up the part and loads it onto the machine if it
is idle. Otherwise, the robot waits to unload
the machine.

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 Cell layout

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 Example

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 Program

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 Wiring diagram

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 EXPLANATION OF THE PROGRAM

Rung 1. If a part arrives and no part is stopped, trigger the

barcode 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.

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 Procedure for developing automation system using PLC

1. Define the process to be controlled.

2. Make a sketch of the process operation.
3. Create a written step sequence listing for the process.
4. Add sensors on the sketch as needed to carry out the control
sequence.
5. Add manual controls as needed for process setup or
operational checking.
6. Consider the safety of the operating personnel and make
additions and adjustments as needed.
7. Add master stop switches as required for safe shutdown.
8. Create the ladder logic diagram that will be used as a basis for
the PLC program.
9. Consider the "what if's" where the process sequence may go
astray.

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 1. Define the problem
We wish to set up a system for spray-painting
parts. A part is to be placed on a mandrel. (A
mandrel is a shaft or bar whose end is
inserted into a workpiece to hold it during an
operation.) When the part is in place, two
pushbuttons are pressed and the mandrel
rises. After the part rises to the top and is in
the hood, it is to have spray paint applied for
a period of 6 seconds. At the end of the 6
seconds, the mandrel returns to the original
position. The painted part is then removed
from the mandrel by hand.

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 2. Process sketch

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 3. List of operation sequence
1. Turn on the paint pump and pneumatic air supply.
2. Turn the system on. This requires pushbuttons other than the system buttons.
3. Put the part on the mandrel. A sensor indicates that the part is in place.
4. Push the Master Start button and the two system start buttons. Having to push two
system start buttons (with both hands) reduces the possibility of the operator's hands
being injured by the rising mandrel.
5. The mandrel is raised by a pneumatic cylinder energized by the opening of an
electrically actuated air valve when the system start buttons are pressed. (The mandrel
will return by gravity and downward spring action when the valve is reopened.) When
the mandrel rises, the part-in-place sensor at the bottom becomes de-energized. (Note:
The part-in-place sensor does not rise with the mandrel.)
6. When the part reaches the top and is under the hood, it is held against a stop by air
pressure. A sensor has indicated that the part has reached the top.
7. A timer starts and runs for 6 seconds.
8. During the timing period of 6 seconds, paint is applied by the sprayer.
9. At the end of 6 seconds, painting stops and the mandrel, with the part on it, lowers.
10. The up sensor is de-energized when the mandrel with the part on it descends.
11. The part arrives at the bottom, reenergizing the part-in-place sensor.
12. The part is removed from the mandrel.
13. The system resets so that we may start at step 3 again.

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 4. Add sensors

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 5. Add manual control
We may need a manual pushbutton to raise the
mandrel to the top for setup purposes. The
manual up position is needed when we set the
spray-gun pressure for optimum paint coverage.
We include pushbutton up (PBU) on our ladder
diagram to accomplish this manual control.

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 6. Consider safety
One basic way to keep hands out of a process is
to have two start buttons. Then both hands must
be away from the work to depress both buttons
(which works until the operator figures out how
to use one knee and one hand). Other
considerations, which we do not cover in detail
here, might be operating a fan to disperse fumes
during spraying, or perhaps a photocell
proximity-personnel-system-stop device.

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 7. Add emergency stop
Add emergency and master stop switches as
needed for operator safety. This may seem to be
part of step 6 because both steps deal with
operator safety. It is a continuation of the safety
issue, but emergency stop switches are so
important that they need special consideration
as an additional step.

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 Create Ladder Diagram

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 9. Determine what-ifs
• All possible situations and emergencies should
be listed. In this example, some of them might
be:
– What if no part is in place when the start buttons are
pushed?
– What if the power fails during the cycle when the part
is rising, during painting, or at any other time?
– What if the sprayer runs out of paint?
– What if the same part is left in for a double coat?
– What if the master stop button is pushed? Does the
stop button really stop the entire process, or can the
mandrel move and create a safety problem after the
stop button is depressed (it can)?

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 System I/O

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 Truth table

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Ladder diagram for a three-switch system

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Ladder diagram for Example 10.2

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State diagram for a two-state and transition system

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Ladder diagram for Example 10.3

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 Ladder diagram for
the state diagram in Figure 10.27

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State diagram for Example 10.4

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State diagram for Example 10.5

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State diagram for Example 10.6

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• New demo

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• Why PLC?
• PLCs have been gaining popularity on the factory
floor and will probably remain predominant for some
time to come. Most of this is because of the
advantages they offer.
• 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 make these likely to operate
for years before failure.
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 A Simple Relay Controller

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A PLC Illustrated With Relays

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A Simple Ladder Logic Diagram

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Fig: JIC Schematic Symbols

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 Continued

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To standardize electrical schematics, the Joint International Committee
(JIC) symbols

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