Fall

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Programmable Logic Controllers

Jessica MacDonald

Table of Contents

Introduction. Page 1 Task 1. .. Pages 3-4 Task 2. . Pages 5-8 Task 3. . Pages -10 Task 4. Pages 11-13 Conclusion. .. Page 13

Programmable Logic Controllers

Programmable logic Controller P!C"s are essential for t#e $orld $e li%e in toda&' a lot of t#e ti(e $e don"t e%en t#ink about t#eir e)istence. T#e& co%er a #uge %arit& of tasks and t#e& can be c#ea* or e)*ensi%e de*ending on t#eir *articular role in life. T#is assign(ent is going to look a little bit dee*er in to $#at t#e& do. Task 1: Three major programmable logic devices. T#ree t&*es of *rogra((able logic de%ices are+ ,nitar&' -odular and .ack (ounted. Unitary:

T#e unitar& P!C"s *ictured abo%e $ork as a si(*le control s&ste( in a little bo)' usuall& attac#ed to t#e unit being controlled' t#e& *refor( basic functions suc# as o*erating doors or s(all #oists. T#e& can"t be e)*anded and #a%e a li(ited nu(ber of in/out*uts MODULAR:

-odular P!C"s are slig#tl& (ore co(*le) t#an unitar& P!C"s. T#e& can be *rogra(ed to do (ulti*le tasks. 0ar&ing in/out*ut de%ices can be connected to t#e(. T#e& can be e)*anded and (odified.

Rack Mounted:

In *rinci*le rack (ounted P!C"s are ada*ted unitar& and (odular P!C"s t#e& are all *ut in to a cabinet 1or rack2 as *ictured abo%e. T#is arrange(ent is %er& useful as t#e rack can be as large or s(all as necessar& according to t#e re3uire(ents of t#e s&ste(.

4bo%e is a basic co(*arison gra*# to %isuali5e t#e differences bet$een t#e t#ree t&*es of P!C s&ste(. 6ac# #as it"s o$n ad%antages and disad%antages. 7#ile rack (ounted s&ste(s offer great fle)ibilit& and can co*e $it# large and (ulti*le *rocesses t#e& are 3uite e)*ensi%e. -odular s&ste(s are a #alf $a& *oint bet$een unitar& and rack (ounted s&ste(s' t#e& are c#ea*er t#an a rack (ounted s&ste( but can co*e $it# e)*ansion and (odification unlike t#e unitar& s&ste(. ,nitar& s&ste(s are C#ea* and basic t#e& #a%e t#e ad%antage of being eas& to *rogra(' but t#is is because t#e& onl& do one task t#e& can not be e)*anded and onl& #a%e a li(ited nu(ber of in/out*uts. Task 2: Input & Output devices

8or a P!C to be useful in an& $a& it needs to be connected to in*ut and out*ut de%ices. In*uts and out*uts are basicall& t#e connection bet$een t#e P!C and t#e real $orld. T#e P!C takes t#e infor(ation gi%en b& t#e in*ut and uses t#is infor(ation to control or dis*la& an out*ut. Possible In*uts and out*uts co%er a #uge %ariet& of *ossibilities' eac# in*ut and out*ut de%ice #as calculations as to $#ic# de%ice is t#e correct one to use' and co(*anies dedicated to t#e researc# and de%elo*(ent of eac# *articular sensor' s$itc# and (otor etc. 9elo$ are so(e e)a(*les of in*uts and out*uts.

Pressure s itc!es" can be used to detect le%els of air' gas or fluid. 4 t&*ical (ec#anical sensor #as t#ree functional blocks. T#is diagra( fro( sensor (ag gi%es a clear i(age of #o$ t#is $orks:

T#e sensor needs a (ec#anical ele(ent 1;ee diagra( abo%e2. T#is (ec#anical ele(ent turns t#e *ressure into a *#&sical (o%e(ent. T#e *#&sical (o%e(ent is t#e transduced to *roduce an electrical out*ut. T#e electrical out*ut is conditioned to gi%e 5

a clear signal' $#ic# can t#en be fed as an in*ut to t#e P!C. Limit # itc!es" 4re (ec#anical s$itc#es t#at according to t#e sensors #andbook are t#e oldest and si(*lest of *osition sensing de%ices. T#e& #a%e a $ide %ariet& of a**lications fro( furnaces to robotic control to do(estic a**liances. T#e& are c#ea* reliable and eas& to (aintain. T#e& can dissi*ate energ& s*ikes and are not affected b& electro(agnetic interference 16-I2.

;tandard li(it s$itc#

.otar& li(it s$itc#

$eat sensors" 4re a t&*e of transducer and are used in (an& a**lications fro( furnaces to do(estic irons. <eat sensors co(e in a #uge arra& of s#a*es and si5es. T#e& are (ade in different (aterials de*endent on a**lication. Please see belo$ for so(e e)a(*les courtes& of o(ega.

%iber o&tic !eat sensors" are digital sensors =sra( 1and I"( sure ot#er co(*anies too2 *roduce fibre-o*tic #eat sensors connected to a >

7i-8i base $#ic# is t#en *ossible to easil& connect to t#e P!C controller t#at can be *ositioned a$a& fro( t#e #eat source. T#is is good as P!Cs can be sensiti%e to #eat. Pro'imity #ensors" 7ork using four basic ele(ents. 1. Coil and ferrous core. 2. =scillator circuit. 3. ?etector circuit and 4. ;olid-state out*ut. T#e oscillator generates an electro(agnetic field $#ic#' t#en centers around t#e ferrite core. 7#en a (etal ob@ect enters t#at field' edd& currents are induced onto t#e surface of t#e ob@ect' $#ic# t#en loads into t#e oscillator circuit reducing its a(*litude. T#is infor(ation is gi%en to t#e P!C' $#ic# t#en e)ecutes an instruction for t#e out*ut de*ending on its *rogra(.

(Sensors hand book second edition, Sabrie Soloman)

T#ere are bot# s#ielded and non-s#ielded sensors. Aon-s#ielded sensors can detect bot# on t#e side and to t#e front of t#e sensor $#ere as t#e s#ielded sensor detects onl& to t#e front. T#ese sensors are s#ock and %ibration resistant. 4s t#ere are no (o%ing *arts $ear doesn"t *ose a *roble( $it# t#e(. 4s t#e $ork using electro(agnetis( t#e& can be used in *laces t#at are dirt& or #a%e sunlig#t. T#e o*erating te(* range is fro( -20 to BC0oC' t#e& can also detect t#e *resence of an ob@ect send a signal and reset $it# in 50 s 1in ?C (odels2 $eater" 4re used in a %ariet& of a**lications fro( industrial furnaces to #air straig#teners. In bot# t#e furnace and t#e #air straig#teners' case t#e control is b& P!C using a rela& to enable t#e #eater to co(e on and off.

0arious industrial #eaters Motors" =ne of t#e (ost co((on for(s of out*ut. T#e P!C uses a contactor rela& to start t#e (otor $#en t#e in*ut sensor gi%es t#e signal to do so. -otors are used in a $ide %erit& of a**lications $orld$ide. T#e range of (otors and #o$ t#e& $ork and can be controlled is a to*ic b& itself.

6)a(*le of (otors $it# rela&s connected.

(ndicators" Include a range of la(*s and !6?s and s*eakers. Indicators are %er& i(*ortant. T#e& can alert an o*erator to a *otential *roble( or indicate t#at e3ui*(ent is o*erating nor(all&.

T#e range of sensors' s$itc#es and out*uts is #uge' in fact a $#ole assign(ent could be $ritten on t#e(. T#e& are all %er& interesting and #a%e t#eir o$n calculations for selection co(*arati%e to t#e& re3uired a**lication. T#e& all #a%e *ro"s and con"s' unfortunatel& it is be&ond t#e sco*e of t#is assign(ent so ti(e can"t be allocated to e)tensi%el& researc# and include t#e(

Task ): Ty&es o* communication link Co((unication links for P!C"s are %ital t#e& carr& infor(ation fro( one *art of t#e net$ork to anot#er. 7it# out t#e( a net$ork $ouldn"t e)ist. T#ree co((on links are in cable for( eac# $it# t#eir o$n ad%antage and disad%antages t#ese are: t$isted *air' co-a)ial and fiber o*tic cables. T isted Pair:

T$isted *air cables co(e in t$o %ersions ;#ielded t$isted *air 1;TP2 and ,ns#ielded t$isted *air 1,TP2. T#is cable is used for bot# tele*#one and 6t#ernet. T$isting *re%ents Dcross-talkE as t#e t$isting creates a s(all (agnetic field cancelling out ot#er interference or Fnoise". T#e addition of t#e s#ielding #el*s to eli(inate un$anted interference. TP uses an .G45 1*rett& *ink t#ing abo%e2 connector to trans(it data. TP #as se%eral uses: Cat 1: Tele*#one co((unication. 1Aot suitable for trans(itting data2 Cat 2: Ca*able of trans(itting data at s*eeds u* to4 -b*s Cat 3: 10 94;6 - T net$orks' data trans(ission 10-b*s Cat 4: Token ring net$orks trans(its data 1> -b*s Cat 5: ?ata trans(ission 1000-b*s 11Hb*s2 Cat >: 8ast ?ata trans(ission <ig#er band$idt# t#an Cat 5 1fro( 100 -<5 to 250 -<52 Co+a'ial Cable:

4lt#oug# it is a bit difficult to install co-a)ial cable because of it"s s#ielding is %er& resistant to interference. -aking it good for a**lications $#ere t#ere are florescent lig#ts' (otors and (an& co(*uters. It can su**ort longer runs t#an t#e t$isted *air cable (entioned abo%e. Co-a)ial cable #as t$o t&*es to c#oose fro(' t#in and t#ick. Called t#in net and t#ick net res*ecti%el&. 9ot# t&*es are used for 6t#ernet signals. T#e t#icker co-a) #as t#e ad%antage of being (ore (oisture resistant and good for longer lengt#s but $it# t#at co(es t#e disad%antage of being able to bend it easil&. %ibre O&tic Cable:

8ibre o*tic cabling is *robabl& t#e 3uickest $a& of trans(itting data. It trans(its lig#t not electronic signals so it doesn"t #a%e t#e *roble( of electronic interference. It"s i((une to t#e effects of (oisture and lig#ting. It does #o$e%er #a%e a *roble( $#en it co(es to bends as lig#t doesn"t tra%el around corners too easil&' also ter(ination of t#is cable is difficult $#en co(*are to t#e t$isted *air abo%e -edia ,TP
-a) seg(ent lengt# 100(

;*eed
10-b*s1000-b*s 10-b*s100-b*s 10-b*s100100-b*s100Hb*s 100-b*s. 2Hb*s

Cost
!east e)*ensi%e -ore t#an ,TP Ine)*ensi%e but cost (ore t#an ,TP b*s 6)*ensi%e

4d%antages
6as& to install $idel& a%ailable .educed cross talk (ore resistant to 6-I !ess susce*tible to 6-I ;ecure' no 6-I' #ig# data rate' can be used in #a5ardous areas $it# no danger of arc#ing or s*arking

?isad%antages
;usce*tible to interference and #as li(ited distance ?ifficult to $ork $it#' can onl& be used o%er s(all distances ?ifficult to $ork $it# #as s#ort run lengt#s' li(ited band$idt# ?ifficult to ter(inate. ?ifficult to install around bends

;TP

100(

C=4)ial 8ibre=*tic

500(1T#icknet2 185(1T#innet2 10I( and furt#er in single (ode 2I( and furt#er in (ulti (ode

T#e table abo%e s#o$s t#e differences bet$een t#e different t&*es of cable a%ailable. ,TP and 8ibre o*tic cables bot# #a%e %er& strong ad%antages in (& e)*erience I #a%e co(e across ,TP and 8ibre o*tic cables a lot (ore t#an ;TP and Co J4)ial. T#ere is one (ore net$ork o*tion $#ic# s#ould be considered' it #as %er& recentl& is beco(e (ore and (ore *o*ular t#at is 7ireless net$orking

Task ,: Architecture & Operational characteristics of a CPU T#e CP, is a (icro*rocessor it"s detailed belo$:

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Ti(er ;tatus Inde) )

4 d d r e s s

Inde) K ;tack *ointer 4.!.,. 4ccu(ulator

Prog counter < Prog counter !

? e c o d e r

In*ut ?ata ?ata 9uffer Instruction .egister

-e(or&

In*ut/ =ut*ut

A CPU generall& s*eaking' selects instructions fro( t#e a**ro*riate (e(or& out *utting t#e code onto t#e address bus. ?ecodes t#e stored instructions' generates t#e re3uired ti(ing for signals bot# internal and e)ternal for t#e .4- and .=-. It *erfor(s arit#(etic and logic functions $#en re3uired and (akes decisions based on t#e results t#at occur fro( t#ese o*erations T!e ALU or Arit!metic Logic Unit is one of t#e (ost i(*ortant *arts of t#e CP,. It *erfor(s (at#e(atical o*erations. T#e 4!, *erfor(s D9ITE $ise (at#e(atical o*erations like add and subtract as $ell as t#e logic functions 4A?' =.' 6L-=. etc. It can also rotate' clear and look after branc#ing instructions. 11

Memory is in t$o for(s .4- and .=-. .=- is read onl& (e(or&. It $ill re(e(ber data e%en $#en t#ere is no *o$er connected to it. It is used to binar& t#at &ou $ant to be constantl& t#ere like binar& looku* tables' o*erating and debugging *rogra(s' basicall& an& infor(ation t#at isn"t going to c#ange. .4- - .ando( access (e(or& or *referabl& called .ead and $rite (e(or& is a te(*orar& (e(or& s*ace for code t#at is going to be fre3uentl& altered. T#e (icro*rocessor reads t#e data (odifies it and t#en *uts it back t#ere to store until anot#er ti(e. -./ Registers can be used as a te(*orar& store but are generall& used for inde)ing and counting. Data 0u**er is a register to store t#e data t#at is about to be o*erated u*on b& t#e contents of t#e accu(ulator in t#e 4!,. (nstruction register <olds *art of t#e instruction during its *rocess of being carried out. T#e decoder t#en translates t#is infor(ation and uses it to generate control signals to t#e .4- data fro( t#e (e(or& s&ste(s and *eri*#eral de%ices. %lags t#ere are si) t&*es of flag' 1. Carr& flag 1cf2 used for addition or as a borro$ for subtraction' 2. Parit& 8lag 1*f2 dis*la&ed as a 1 for e%en $ord o*erations *f ot#er$ise 0' 3. 4u)iliar& flag 1af2 t#is flag is set if t#ere is an o%erflo$ fro( t#e carr& flag' 4. Mero flag 15f2 ;ets if t#ere is a 5ero o*eration result in t#e 4!, or if a certain register is 5ero after an incre(ent or decre(ent o*eration' 5. ;ign register 1sr2 if t#is flag is set t#e o*eration of a set of logic is negati%e' >. =%erflo$ flag 1=82 t#is flag is set $#en a result of an o*eration is out of range. #!i*t register can (o%e data to t#e left or rig#t. T#is can be a %er& useful o*eration for (ulti*lication and di%ision. #torage de1ices are an e)ternal (eans of storing data' at first t#is $as done b& cassette ta*e and flo**& disk' no$ as tec#nolog& de%elo*s it is done b& (eans of ,;9 (e(or& stick or e)ternal #ard dri%e. O&to 2 (solators3 $#en controlling 220% and 440% circuits t#e (icro*rocessor needs so(e *rotection. T#is can be done b& rela&s but rela&s can #a%e arc#ing *roble(s t#erefore o*to-isolators are a good alternati%e as t#e s$itc#ing *rocess is done b& lig#t trans(ission. T#e CP, is constantl& c#ecking it"s in*uts and *erfor(ing logic o*erations and gi%ing out *uts and continuousl& u*dating. 8or an e)a(*le' *lease see flo$ c#art on t#e ne)t *age of an i(age u*date.

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I(age u*date

;can in*ut In*ut i(age register

;can *rogra(

,*date out*ut

;elf test

Conclusion T#is assign(ent co%ers a $ide range of to*ics in regard to P!C"s. It co%ers t#e in*uts and out*uts' #o$ t#e& can be net$orked toget#er also #o$ t#e brains of t#e o*eration t#e CP, $orks. I found researc#ing %er& interesting but also %er& distracting as I got carried a$a& looking at t#e different t&*es of sensor and cables and #o$ &ou calculate $#ic# one s#ould be used for $#ic# a**lication. T#is caused (e to (is(anage (& ti(e and to not s*end as (uc# ti(e as I $ould #a%e like on task 4. 4lso I #a%e (ade (& *ro@ect %er& colourful forgetting t#at it $ill be *rinted on a black and $#ite *rinter. T#ese t#ings I #o*e to re(e(ber on follo$ing *ro@ects.

0ibliogra&!y
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0ooks
%undamentals o* Logic Design 9& Charles Roth, Jr. Introduction To Microprocessor By D.A.Godse A.P.Godse Microprocessor By A.P.Godse, D.A.Godse 4et orking 0ible By Barrie Sosinsky Programmable logic controllers: t#e co(*lete guide to t#e tec#nolog&
b& Clarence T. Jones

Programmable logic controllers it! controllogi' 9& Jon Stenerson

5ebsites #tt*://$$$.@etter.de/en/industrial-auto(ation.#t(l #tt*://$$$.lu(el.co(.*l/ #tt*://$$$.san&odenki.eu/ #tt*://$$$.*anasonic-electric-$orks.co( #tt*://$$$.(itsubis#i-auto(ation.co(/ #tt*://$$$.directindustr&.co( #tt*://net$orkcable-tester.co( #tt*://$$$.dcdi.co.uk #tt*://$$$.cat>.co( #tt*://searc#net$orking.tec#target.co( #tt*://$$$.broadbandsu**liers.co.uk #tt*://$$$-(d*.eng.ca(.ac.uk #tt*://auto(odifiedesign.co( #tt*://fcit.usf.edu/net$ork/c#a*4/c#a*4.#t(

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