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1 1-Basics

A Programmable Logic Controller (PLC) is a computerized industrial controller that automates processes by performing logic operations in an industrial environment. It consists of hardware and software components, including input/output modules, a CPU, and a memory system, enabling precise control of machinery and systems. PLCs are essential in various industries for their efficiency in monitoring and controlling production processes.

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11 views7 pages

1 1-Basics

A Programmable Logic Controller (PLC) is a computerized industrial controller that automates processes by performing logic operations in an industrial environment. It consists of hardware and software components, including input/output modules, a CPU, and a memory system, enabling precise control of machinery and systems. PLCs are essential in various industries for their efficiency in monitoring and controlling production processes.

Uploaded by

ryancantago42
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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What is PLC? and why is it so important?

Programmable Logic Controller is a short abbreviation of PLC. PLC is


basically known as ‘Primary Controller‘ or ‘Programmable Controller’.
In the enhancing mode and development of new technologies, the trend of
PLC is evolving. It has become an integral part of the control system in an
industrial environment.

PLC is a solid-state control device or computerized industrial controller that


performs discrete or sequential logic in the factory or automation
environment.
Basically, PLC is a combination of software and hardware. It acts as the
brain of the machine or system for automation control systems.
Technical Definition of PLC:
The programmable logic controller is defined by ‘National Electrical
Manufacture Associations [NEMA]’ as,
The digital electronic device that uses programmable memory to store
instructions and implement specific function such as programming logic,
sequence, timing, counting and arithmetic operations to control electronic
machines and technical process.
This is how the Mini PLC looks like.
The PLC controller devices can be executed or
operated by automatically and manually. For its
operation, it consumes additional manpower,
time, utility, and accurate operation in the
system.
The most benefit of PLC:
It performs precise operations within very less
time. And it consists of many components for
controlling devices.
Basic Block Diagram of PLC System
The block diagram of PLC consists of different components. Each
component has associated specific functions and operations in the PLC.
The list of basic components are:
• Input and Output Modules
• Power Supply
• Control Processing Unit (CPU)
• Memory System
• Communication Protocols
• Programming

1. Input and Output (I/O) Modules


The input/output modules in PLC are of two types. It can be either digital or
analog.
Just like any other device or machine, we have to provide input to the PLC
controller. It yields output.

For example, when the user presses a button, the motor starts. Here the
switch button is input. The motor is an output device.
In PLC, to take the input and to return the output, there are an I/O
module.
The input modules are used for providing an interface for input devices like
different types of switches (push button switch, selector switch, limited
switch), sensors, etc.
The output modules are used for providing an interface for output devices
like motor, fan, relay, light, lamp, electric heater, solenoid valve, buzzer, etc.
2. Power Supply
There is no science to make the electrical device works without providing a
power supply.
Every device operates around you need power whether if its electrical or
mechanical or any other power supply.
For PLC, we need an electrical power supply.
The power supply provides power to all other components to operates. It
provides power to the input/output modules, memory system, and
processor.
The function of the power supply is to provide the DC or AC power to
operate the PLC.
How much power does it require to operate PLC?
Most of the PLCs work at 220VAC or 24VDC.
3. Central Processing Unit (CPU)
Central Processing Unit is the heart of the PLC system. The function of the
CPU is to store and run the PLC software programs.
It helps to perform the basic arithmetic, logic, controlling, and input/output
operations specified by the instructions. It consists of the three subparts as
memory, processor and power supply.
4. Memory System
A memory system is responsible for storing and retrieving data and
information. It consist of different type of memory such as RAM, ROM,
EEPROM and Flash memory.
Overall memory is classified into four sections based on the types of data it
stores.
• Input/Output Image Memory
• Data Memory
• User Memory
• Executive Memory
5. Communication Protocols
The communication protocols are useful for exchanging the information or
data between connected devices through a network.
6. PLC Programming
You need PLC programming instructions and programming to live the
communication between different circuits of the PLC.
The useful information or data are communicated by the specific
communication protocols.
Most of the PLC programmer works on the ladder diagram programming
language. It is pretty easy as compared to other PLC programming
languages.
How does Programmable Logic Controller Work?
The most important working principle is- the PLC is operated by
continuously scanning programs. Scanning happens every time per
millisecond. So, it is called as the Scan Cycle.
For this scan cycle, PLC required a little amount of time in the range of
milliseconds or ms.
What are the basic PLC Scan Cycle?
The scan cycle consists of the following three basic main steps.
1. Read the inputs
2. Execute the program by the CPU
3. Update the output
Step 1: Read / Sense the input
Firstly, PLC reads the on/off status of the external input signals. After
scanning the input, it gets stored in the input memory. This input included
switches, pushbuttons, proximity sensors, limit switches, pressure
switches, etc.
Step 2: Execute the logic by the processor
This scanned input gets transferred to the CPU for processing from input
memory. The processor executes the programming instructions based on
the input. After the execution, the result (on/off) will be stored in the device
memory.
Step 3: Update / write the output:
When the program executes the last instruction, it will send the on/off
status to the output device memory. The outputs include solenoids, valves,
motors, actuators, and pumps.
All three steps get completed under the scan time.
What is Scan Time?
The amount of time is taken by the processor to read/sense the first input
and execute the last output called the Scan time.
PLC is so fast as it can easily scan and execute the program in few
milliseconds i.e. 10-15 milliseconds.
What are the Types of Programmable Logic Controller (PLC)?
Two types of PLCs are used for commercial or industrial purposes.
1. Compact PLC
2. Modular PLC
Knowing these two types is the part of PLC basics knowledge.
What is a Compact PLC?
It is also called as
Integrated PLC or
Fixed PLC.
The compact PLC
has a fixed number
of input/output
modules along with
power supply and
CPU.
What is a Modular PLC?
It consists of a variable number of inputs and outputs. Inputs and outputs
can be added to the modular PLC systems by the user.
If you look at the below PLC designing structure, it looks more like a rack.
So, it is also called as Rack-Mounted PLC.

What are the Most Popular PLC Programming Languages?


Based on the International Electrotechnical Commission (IEC) standard,
PLC programming languages are classified into five main standards.
1. Ladder diagram (LD)
2. Instruction List (IL)
3. Structured Text (ST)
4. Function Block Diagram (FBD)
5. Sequential Function Charts (SFC)
These are the topmost 5 different type of PLC programming languages.
According to the study and operations, ladder diagram (LD) is the widely
PLC language for writing easily understandable programming logic. This
programming logic based on the logic gates.
LD has a graphical user interface. It comes with many features that give an
edge over other programming languages.
What is the most popular PLC brand used?
In the automation environment, more companies are manufacturing and
working on the control system by using PLC and SCADA.
Today, there are multiple brands available for PLC systems. The Asea
Brown Boveri (ABB), Allen Bradley (AB), General Electric (GE), Siemens,
Delta, Mitsubishi, Omron, and Schneider are some of the very popular PLC
brands.
Based on the usage, Siemens PLC tops the position. Allen Bradley PLC is at
the second position in Automation.
You can use any brand of PLC as per your project requirements, study, and
industry need.
What are the Applications of PLC?
For automation, multiple PLCs are used to monitor and control building
systems in production processes.
PLCs are used in various industries like the steel industry, glass industry,
cement industry, paper mill, coal mine, automobile industry, chemical
industry, textile industry, robotic system, and food processing system.

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