This document provides an overview of programmable logic controllers (PLCs) and PLC programming. It discusses the basic concepts of binary logic, Boolean algebra, and logic gates like AND, OR, and NOT. Truth tables are presented for different logic functions. The document also presents an example of using ladder logic to program a PLC to control a mixer motor based on temperature and pressure inputs. PLC programming allows implementing control logic electronically using a logic diagram instead of complex hardwired relay circuits.
This document provides an overview of programmable logic controllers (PLCs) and PLC programming. It discusses the basic concepts of binary logic, Boolean algebra, and logic gates like AND, OR, and NOT. Truth tables are presented for different logic functions. The document also presents an example of using ladder logic to program a PLC to control a mixer motor based on temperature and pressure inputs. PLC programming allows implementing control logic electronically using a logic diagram instead of complex hardwired relay circuits.
This document provides an overview of programmable logic controllers (PLCs) and PLC programming. It discusses the basic concepts of binary logic, Boolean algebra, and logic gates like AND, OR, and NOT. Truth tables are presented for different logic functions. The document also presents an example of using ladder logic to program a PLC to control a mixer motor based on temperature and pressure inputs. PLC programming allows implementing control logic electronically using a logic diagram instead of complex hardwired relay circuits.
This document provides an overview of programmable logic controllers (PLCs) and PLC programming. It discusses the basic concepts of binary logic, Boolean algebra, and logic gates like AND, OR, and NOT. Truth tables are presented for different logic functions. The document also presents an example of using ladder logic to program a PLC to control a mixer motor based on temperature and pressure inputs. PLC programming allows implementing control logic electronically using a logic diagram instead of complex hardwired relay circuits.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 1 / 71 Learning Objectives 1 Use conventional (relay logic) and ladder logic to program a PLC with documentation. 2 Use logic fundamentals (AND, OR, and NOT), Boolean expressions, and truth tables as a basis for PLC ladder logic diagrams and programs for the PLC, as appropriate. 3 Use PLC ladder logic to control a motor.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 2 / 71 The Binary Concept 1 Binary refers to the idea that many things can be thought of as existing in only one of two states. The binary states are 1 and 0 2 The 1 and 0 can represent: ON or OFF; Open or Closed True or False or High or Low
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 3 / 71 AND, OR, and NOT Functions The AND Function An AND gate is a device with two or more inputs and one output.
output is 1 only if all inputs are 1.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 4 / 71 The AND gate If all inputs are 1, the output will be 1. If any input is 0, the output will be 0.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 5 / 71 Hardwired AND
The corresponding truth table is
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 6 / 71 The OR gate The OR Function
An OR gate can have any number of inputs but only one output.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 7 / 71 The OR gate The OR gate output is 1 if one or more inputs are 1. If all inputs are 0, the output will be 0.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 8 / 71 Hardwired OR The OR logic gate operates similarly to control devices connected in parallel. The light will be on if switch A or switch B or both are closed.
The corresponding truth table is
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 9 / 71 The NOT Function
The NOT function can have only one input. The NOT output is 1 if the input is 0. The output is 0 if the input is 1.Since the output is always the reverse of the input it is called an inverter.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 10 / 71 Hardwired NOT Function The NOT function can be performed on a contact input simply by using a normally closed instead of a normally open contact.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 11 / 71 Example: NOT Gate Application - Low-pressure indicating circuit If the power is “on” (1) and the pressure switch is not closed (0), the warning indicator will be “on”
When the pressure rises to close
the pressure switch, the warning indicator will be switched "off"
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 12 / 71 The NAND Function An AND gate with an inverted output is called a NAND gate.
The NAND gate has the opposite outputs to the AND gate.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 13 / 71 The NOR Function A OR gate with an inverted output is called a NOR gate.
The NOR gate has the opposite outputs to the OR gate.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 14 / 71 The Exclusive-OR (XOR) Function
The output of the XOR gate is HIGH (1) only when one input or the other is HIGH, but not both. It is commonly used for the comparison of two binary numbers.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 15 / 71 Boolean Algebra 1 The mathematical study of the binary number system and logic is called Boolean algebra. 2 Boolean algebra is used to write combinations of logic statements that are used to solve PLC programming problems.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 16 / 71 Logical expressions (Boolean equations)
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 17 / 71 Logical expressions (Boolean equations)
Q) write down the resulting boolean expression for the digital
circuit below
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 18 / 71 Laws of Boolean algebra Some laws of Boolean algebra are similar to those of ordinary algebra. (the distributive law holds true only in Boolean algebra)
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 19 / 71 Developing Logic Circuits from Boolean Expressions Logic gate circuit developed from the Boolean expression Y = AB + C. Gates required: AND gate with input A and B OR gate with input C and output from previous AND gate
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 20 / 71 Developing Logic Circuits from Boolean Expressions Logic gate circuit developed from the Boolean expression Y = A (BC + D). Gates required: - AND gate with input B and C - OR gate with inputs BC and D - AND gate with inputs A and the output from the OR gate
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 21 / 71 Boolean Equations from Logic Circuits The output of the OR gate is A + B The output of the inverter is D Based on the input combination applied to the AND gate the Boolean equation for the circuit is Y = C D (A +B)
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 22 / 71 Boolean Equations from Logic Circuits -1 The output of AND gate 1 is A’B The output of AND gate 2 is AB’ Based on the combination of inputs applied to the OR gate the Boolean equation for the circuit is Y = A’ B + AB’
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 23 / 71 Exercise: Circuit Development Using A Boolean Expression draw the digital circuit for
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 24 / 71 Exercise: Circuit Development Using A Boolean Expression draw the digital circuit for
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 25 / 71 Excersise: Producing A Boolean Expression From A Given Circuit find the corresponding logical expression
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 26 / 71 Excersise: Producing A Boolean Expression From A Given Circuit Is this an XOR gate?
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 27 / 71 PLC program 1 A program is a series of instructions that directs the PLC to execute actions. 2 The PLC program is executed as part of a repetitive process referred to as a scan.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 28 / 71 Relay ladder logic Relay ladder logic is based on electromagnetic relay control can be hard and complex to implement.
Source: Courtesy GE Intelligent Platforms
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 29 / 71 Example: Mixer Process Control 1 A mixer motor is to be used to automatically stir the liquid in a vat when the temperature and pressure reach preset values. 2 Manual operation of the motor is provided by means of a separate pushbutton station.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 30 / 71 Hardwired relay logic The motor starter coil (M) is energized when both the pressure and temperature switches are closed or when the manual pushbutton is pressed.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 31 / 71 Mixer Process: PLC implementation Connect Field devices to I/O modules (hard wired) (i.e. pressure and temperature switches (sensors), and mixer motor)
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 32 / 71 Mixer Process: PLC implementation Enter the PLC ladder logic program into the memory of the CPU.
1 The symbols represent instructions and the numbers represent the instruction’s addresses. 2 Each input and output device is given an address, which lets the PLC know where it is connected.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 33 / 71 Mixer Process: PLC implementation 1 For the program to operate, the controller is placed in the RUN mode. 2 During each scan the controller examines the status of input devices, executes the user program, and changes outputs accordingly. 3 The coil O/1 is energized when contacts I/1 and I/2 are closed or when contact I/3 is closed. 4 Either of these conditions provides a continuous logic path across the rung that includes the coil.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 34 / 71 Mixer Process: PLC implementation-1
Source: Photo courtesy Tyco Electronics
Image used with Permission of Rockwell Automatio
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 35 / 71 Modified Program 1 One of the important features of a PLC is the ease with which the program can be changed. 2 Original hardwired process control circuit modified. 3 Change requires that the manual pushbutton control be permitted to operate at any pressure, but not unless the specified temperature setting has been reached.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 36 / 71 Modified Program 1 If a relay system were used, it would require some rewiring of the circuit. 2 Original hardwired process control circuit modified. 3 If a PLC system were used, no rewiring would be necessary. The inputs and outputs are still the same. All that is required is to change the PLC ladder logic program.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 37 / 71 Hardwired Stop/Start Motor Control Circuit The term hardwired logic refers to logic control functions that are determined by the way devices are interconnected.
Hardwired logic can be implemented using relays and relay ladder
schematics.
Hardwired logic is fixed: it is changeable only by altering the way
devices are connected. Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 38 / 71 Hardwired Logic versus Programmed Logic-1 Hardwired Stop/Start Motor Control Circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 39 / 71 Programmed Stop/Start Motor Control Circuit 1 Each rung is a combination of input conditions connected from left to right with the symbol that represents the output at the far right. 2 The input and output field devices remain the same as those required for the hardwired circuit. 3 The instructions used are the relay equivalent of normally open (NO) and normally closed (NC) Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 40 / 71 lader logic program The most common PLC programming language is ladder logic .
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 41 / 71 Symbols used for Electrical Ladder Diagrams
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 42 / 71 ladder program • A ladder logic program consists of several rungs, each of which controls an output. • Each rung is a combination of input conditions (symbols) connected from left to right, with the symbol that represents the output at the far right. • Relationship between the relay ladder schematic, the ladder logic program, and the equivalent logic gate circuit.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 43 / 71 relay ladder schematic, ladder logic program, and digital circuit
Program simulation of two switches in series used to control an output.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 44 / 71 relay ladder schematic, ladder logic program, and digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 45 / 71 relay ladder schematic, ladder logic program, and digital circuit Two limit switches connected in parallel and used to control a solenoid valve.
Equivalent logic circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 46 / 71 relay ladder schematic, ladder logic program, and digital circuit Two limit switches connected in parallel with each other and in series with a pressure switch to control a pilot light.
Equivalent digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 47 / 71 relay ladder schematic, ladder logic program, and digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 48 / 71 relay ladder schematic, ladder logic program, and digital circuit Two limit switches connected in series with each other and in parallel with two other limit switches (in series), and used to control a pilot light.
Equivalent logic circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 49 / 71 relay ladder schematic, ladder logic program, and digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 50 / 71 relay ladder schematic, ladder logic program, and digital circuit Two limit switches connected in series with each other and in parallel with a third limit switch, and used to control a warning horn.
Equivalent logic circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 51 / 71 relay ladder schematic, ladder logic program, and digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 52 / 71 relay ladder schematic, ladder logic program, and digital circuit One limit switch connected in series with a normally closed pushbutton and used to control a solenoid valve.
Equivalent digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 53 / 71 relay ladder schematic, ladder logic program, and digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 54 / 71 relay ladder schematic, ladder logic program, and digital circuit The output lamp of this circuit is ON only when pushbutton A or B is pressed, but not both.
Equivalent digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 55 / 71 relay ladder schematic, ladder logic program, and digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 56 / 71 relay ladder schematic, ladder logic program, and digital circuit When either start button is depressed, the motor runs. Either stop button stops the motor when it is depressed.
Equivalent digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 57 / 71 relay ladder schematic, ladder logic program, and digital circuit
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 58 / 71 Programming Word Level Logic Instructions Selecting Word Logic Instructions
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 59 / 71 Programmed AND Instruction
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 60 / 71 Programmed AND Instruction This instruction tells the processor to perform an AND operation on B3:5 and B3:7 and to store the result in destination B3:10 when input device A is true.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 61 / 71 Program simulation of the word level AND instruction.
I/O B3 Data Table
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 62 / 71 Programmed OR Instruction
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 63 / 71 Programmed OR Instruction This instruction ORs the data in Source A, bit by bit, with the data in Source B and stores the result at the destination address.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 64 / 71 Programmed OR Instruction Program simulation of the word level OR instruction.
I/O B3 Data Table
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 65 / 71 Programmed XOR Instruction
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 66 / 71 Programmed XOR Instruction Data from input I:1.0 are compared, bit by bit, with data from input I:3.0. Any mismatches energize the corresponding bit in word O:4.0.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 67 / 71 Programmed XOR Instruction Program simulation of the word level XOR instruction
I:1 I:3 O:4 Input Table
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 68 / 71 input A is true
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 69 / 71 Word-level NOT operation. The bit pattern in B3:10 is the result of the instruction being true and is the inverse of the bit pattern in B3:9.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 70 / 71 Program simulation of the word level NOT instruction
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 71 / 71 Shift registers Basic Concept: A bit shift register is a register that allows the shifting of bits through a single register or group of registers. The bit shift register shifts bits serially (from bit to bit) through an array in an orderly fashion.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 72 / 71 Types of shift registers: BSL (Bit Shift Left) —Loads a bit of data into a bit array, shifts the pattern of data through the array to the left, and unloads the last bit of data in the array.
BSR (Bit Shift Right) —Loads a bit of data into a bit
array, shifts the pattern of data through the array to the right, and unloads the last bit of data in the array.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 73 / 71 Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 74 / 71 Applications of shift registers: A shift register can be used to simulate the movement, or track the flow, of parts and information. We use the shift register whenever we need to store the status of an event so that we can act on it at a later time.
The figure illustrates cartons traveling on a conveyor
being detected by a photoelectric sensor. The sensor that drives the data line on a shift register is fixed such that the beam detects the presence or absence of a carton. A logic 1 sensor condition state can indicate the presence of a carton, and a 0 the absence.
Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 75 / 71 Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 76 / 71
