BDA 2811

MECHANICAL ENGINEERING PRACTICE IV

PROGRAMMABLE LOGIC
CONTROLLER (PLC)

Prepared by: Saliana binti Sanusi

DEPARTMENT OF MANUFACTURING & INDUSTRIAL ENGINEERING

FACULTY OF MECHANICAL & MANUFACTURING ENGINEERING
08/09/09 FACULTY OF TECHNOLOGY MANAGEMENT - PGD 2008 1
UNIVERSITI TUN HUSSEIN ONN MALAYSIA
 Learning Outcome
After finish this task, students are able to:
• Write PLC definition
• List PLC language and program
• Identify input/output address and device
classification
• Draw PLC configuration & structure
• Design simple program & assemble
input/output devices with single output
 What is PLC?
• Definition:
A programmable logic controller (PLC) is a
specialized computer used to control
machines and process
• It uses a programmable memory to store
instructions and specific functions that
include on/off control, timing, counting,
sequencing, arithmetic and data handling.
How does PLC look like?
PLC system
 PLC configuration (training kit)
OUTPUT TERMINALS POWER SWITCH

PLC

PERIPHERAL
INPUT/OUTPUT
PORT
CARD

RS 232 CABLE

INPUT TERMINALS EARTH TERMINAL V+ TERMINAL

Courtesy from OMRON PLC

 Processor (CPU)
• Is a ‘brain’ of the PLC
• Consists of microprocessor for
implementing the logic and controlling the
communications among the modules
• Designed so the desired circuit can be
entered in relay ladder logic form
• The processors accepts input data from
various sensing devices, executes the
stored user program and send appropriate
output commands to control devices
 Memory System
• The memory system stores both the
control and data from the equipment
connected to the PLC.
• For storage of programs, present PLC
use semiconductor memory devices
such as RAM or a programmable
read-only memory (ROM)
 PLC can process data
PLC can memory

But how we communicate with PLC?

Can PLC talks to us?
How can we tell PLC what we want?
 PLC Language
• It is a medium where we can write program
• To program means set command or to instruct
the PLC what to do
• There are several programming methods, such
as ‘Ladder Diagram’, ‘Statement List’,
‘Mnemonic Code’, ‘Functional Block’ and ‘Block
Diagram’
• Several software available in markets are such
as OMRON with CX-programmer, SIEMENS
with TISOFT, FESTO with FST and Allen-Bradley
with RSLogix
 Input/Output (I/O) Units
• I/O units form the interface between the PLC and
outside devices.
• This unit received any input signal, converts it
into low voltage signal and sent it to the
processor.
• The processor determines and interprets the
data due to the program.
• Then the processor sent the data to the output
unit.
• The output unit produce out the output signal and
sent it to the output device
• For easy assessment, every input/output has
their own adddress.
 PLC applications
Automatic Storage Process Control

Food & Beverages Wrapping & Packaging

 Quality Control

Machine System

Automotive Assembly
 Parking System

Automated
Material Handling
Advantages of PLC control system
• Eliminates much of the hard wiring that
was associated with conventional relay
control circuit
• More flexibility
• Increased reliability
• Communications capability
• Faster response time
• Easier to troubleshoot
• Lower costs
 Limitation
• PLC is not suitable for analogue
application
 PLC Language
• Concentrate on ‘ladder logic diagram’
• A ladder diagram is a means of graphically
representing the logic required in a relay
logic system.
 Ladder Logic Structure
24 V+ 0V, COMMON
RAIL

RUNG

BRANCH
INPUT OUTPUT
 Ladder Logic Symbols & IO Address
INPUT OUTPUT

Normally Open Normally Normally Normally

contact Close contact Open Close
contact contact
IP address: 0.00 to 0.15 IP address: 1.00 to 1.15
Timer &
Sensor Cylinder
Counter
Limit Switch Buzzer
Push button Solenoid
 Simple Application

0.04
1.07
Lamp 1
Switch
1.10
Lamp 2
1.15
Solenoid

The ladder logic program

 In actual……

Lamp 1 Lamp 2

Switch
DC supply

AC supply
Relay

Solenoid
 Hardwire Circuit
24+V

Lamp 1 Lamp 2 Solenoid

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

CPU
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Switch

0V, common
• Assignment 1 & lab report submit on/before
14 AUGUST 2009 to En Omar.
TIPS: assignment 1
• Host having reset button
• Using latching for each group of contestants
• Just a simple circuit
You may access the lab on any time (refer
to the schedule outside the room)
Print out your program (drawing using cx-
programmer) using printer in the lab.