Programmable Logic Controllers

(PLC) DEFINITION

 Are solid-state members of the computer family, using

integrated circuits instead of electromechanical devices
to implement control functions.
 They are capable of storing instructions, such as
sequencing, timing, counting, arithmetic, data
manipulation, and communication, to control industrial
machines and processes.
 A HISTORICAL BACKGROUND

• 1960s: The Birth of PLCs

1968: The first PLC, the
Modicon 084, was developed
by Richard Morley for
General Motors. It was
designed to replace hard-
wired relay systems in
manufacturing processes.
 A HISTORICAL BACKGROUND
 1970s: PLCs gained popularity in industrial automation. Companies began using them for controlling machinery,

assembly lines, and processes due to their flexibility and ease of programming.

Standardization: The introduction of programming languages such as Ladder Logic made PLC programming

accessible to engineers.
 1980s: Advancements and Features

Microprocessors: The advent of microprocessor technology allowed for smaller, more powerful PLCs.

Networking: PLCs began to incorporate networking capabilities, enabling multiple PLCs and devices to

communicate.
 1990s: Integration and Expansion

Integration with PCs: PLCs started to integrate with personal computers, allowing for more advanced programming

environments and data handling.

Fieldbus Technology: New protocols improved communication between devices, enhancing automation systems
 A HISTORICAL BACKGROUND
 2000s: Smart Automation
Ethernet and IoT: The rise of Ethernet and the Internet of Things (IoT) led to more
interconnected and smart automation solutions.
Advanced Features: PLCs began to include features such as data logging, web
access, and advanced diagnostics.

2010s and Beyond: Industry 4.0

Cyber-Physical Systems: PLCs are now integral to Industry 4.0, enabling smart
factories with real-time data analytics and remote monitoring.
Cloud Integration: Many PLCs now support cloud connectivity, allowing for data
storage and processing in the cloud.
Conceptual Application Diagram
Process
or
Machine

Measure Control

Programmable
Controller
Field Field
Inputs Outputs
The PLC system
The basic functional components of PLC

 The processor unit or central processing unit (CPU) is the unit

containing the microprocessor. This unit interprets the input signals and
carries out the control actions according to the program stored in its
memory, communicating the decisions as action signals to the outputs.
 The power supply unit is needed to convert the mains AC voltage to
the low DC voltage necessary for the processor and the circuits in the
input and output interface modules.
The basic functional components of PLC

The programming device is used to enter the required program

into the memory of the processor. The program is developed in
the device and then transferred to the memory unit of the PLC.
The memory unit is where the program containing the control
actions to be exercised by the microprocessor is stored and
where the data is stored from the input for processing and for
the output.
 The basic functional components of PLC
The input and output sections are where the processor receives data
from external devices and communicates information to external devices.

The inputs might thus be from The outputs might be to Input and output devices can be
Switches • Motor starter coils classified as giving signals that are
• solenoid valves a) discrete,
Photoelectric cells • Or similar things b) Digital
c) Analog
Temperature sensors

Flow sensors
The basic functional components of PLC
Devices giving discrete or digital signals are ones where the signals
are either off or on. Thus a switch is a device giving a discrete signal,
either no voltage or a voltage. Digital devices can be considered
essentially as discrete devices that give a sequence of on/off signals.
Analog devices give signals of which the size is proportional to the
size of the variable being monitored. For example, a temperature
sensor may give a voltage proportional to the temperature.
The basic functional components of PLC
• The communications interface is
used to receive and transmit data on
communication networks from or to
other remote PLCs. It is concerned
with such actions as device
verification, data acquisition,
synchronization between user Basic communications model
applications, and connection
management.
 SCANNING CYCLE
 During its operation, the CPU completes three
processes:
1.it reads, or accepts, the input data from the
field devices via the
input interfaces,
2.It executes, or performs, the control program
stored in the
memory system, and
3.it writes, or updates, the output devices via the
output
interfaces.
 This process of sequentially reading the inputs,
executing the
program in memory, and updating the
outputs is known as
scanning Cycle.
Ladder Logic / Ladder Program / Ladder diagram (LD)
LADDER DIAGRAMS AND THE PLC
• The ladder diagram has and continues to be the traditional way of
representing electrical sequences of operations.
• These diagrams represent the interconnection of field devices in such
a way that the activation, or turning ON, of one device will turn ON
another device according to a predetermined sequence of events.
 Ladder Logic / Ladder Program
Concept of Ladder Logic

• It is used to program a PLCs.

• It is a graphical programming language which expresses logical operations with

symbolic notation using ladder diagrams.

• It is used by engineers and electricians to execute logical, sequential, counting,

timing and arithmetic tasks in order to carry industrial automation applications.

• Ladder logic programming is still used today because the core fundamental logic

principles for machine and process control are still the same.
Ladder Logic / Ladder Program
Concept of Ladder Logic

• In the earlier days, machine and process automation

was accomplished using a hard wired control system

known as relay logic.

• Ladder logic was originally designed to replace the

use of hard wired relay logic circuits for machine

control.

• The ladder logic programming code actual looks like

an electrical schematic drawing.

 Ladder Logic / Ladder Program
Concept of Ladder Logic

• In PLC programming, ladder logic is a programming language, used for

developing logical expressions in order to automate tasks / process.

 Ladder Logic / Ladder Program
Concepts Ladder Logic

• Ladder logic is used extensively for programming PLCs in industrial automation

applications.

• E.g. : Material Handling Conveyor System / Pallet Packing and Strapping.

• Ball Mill Lubrication System / Logistics Package Conveying and Sorting.

• Cement Batching / Beverage Bottling and Labelling.

• Hopper and Tank Level Control / Air / Liquid Flow and Pressure Control.
 Ladder Logic / Ladder Program
What is a Ladder Diagram?

• A ladder diagram is a type of schematic diagram used in industrial automation that represents

logic control circuits.

• Ladder diagrams are composed of two vertical power rails and horizontal logic rungs to form what

looks like a ladder. The control logic in a ladder diagram is contained within the rungs.

• The name “ladder diagram” is derived

from the program’s resemblance to a
ladder with two vertical rails and a series
of horizontal rungs between them.
• The rails are called “power rails” in the
ladder diagram.
 Ladder Logic / Ladder Program

Why is a ladder diagram used for PLC programming?

• The reason is because the early control system designers were accustomed to relay logic control

circuits and ladder diagrams closely mimic these.

• The person / staff already knows how to read relay control circuits, so using ladder diagrams for

programming a PLC.

• Also, they were easily able to troubleshooting control system problems.

 Ladder diagram / Logic

• Ladder diagram (LD): official name given in the international PLC programming

standard IEC-61131. (International Electrotechnical Commission)

• Symbols represent opening and closing relays, counters, timers, shift registers,

etc.

• Symbols are arranged in the desired program routine.

• Rules in ladder logic are termed “rungs.”

• Each rung has a single output.

 The Logic Behind The Ladder
Seven basic steps of a ladder diagram.

1. Rails: Two rails (power rails) in a ladder diagram, represented by vertical lines.

•The power flows from the left hand side to the right hand side.

2. Rungs: Horizontal lines, connects the rails to the logic expressions.

 The Logic Behind The Ladder
if A and B are both closed then a solenoid (output) is energised.

(a), (b) Alternative ways of drawing an electric circuit, (c) comparable rung in a ladder program.
The sequence followed by a PLC when carrying out a program as follows.
1. Scan the inputs associated with one rung of the ladder program.
2. Solve the logic operation involving those inputs.
3. Set/reset the outputs for that rung.
4. Move on to the next rung and repeat operations 1, 2, 3.
5. Move on to the next rung and repeat operations 1, 2, 3.
6. And so on until the end of the program with each rung of the ladder program scanned in turn.
7. The PLC then goes back to the beginning of the program and starts again.
 The Logic Behind The Ladder

3. Inputs: Inputs are external control actions (Sensors and Transducers).

E.g. Push button being pressed, limit switch being triggered.

• Inputs are hardwired to the PLC terminals.

• Represented in the ladder diagram by a normally open (NO) or normally closed

(NC) contact symbol.

 The Logic Behind The Ladder
4. Outputs: Outputs are external devices (Actuators).

E.g. Turn on and off an electric motor or a solenoid valve.

• The outputs are hardwired to the PLC terminals.

• Represented in the ladder diagram by a relay coil symbol.

 The Logic Behind The Ladder
5. Logic Expressions: The logic expressions are used in combination with the

inputs and outputs to formulate the desired control

operations.

6. Address Notation: Address notation describes the input, output, logic expression,

memory addressing structure of the PLC.

• Tag names: descriptions allocated to the addresses.

 The Logic Behind The Ladder

7. Comments:

• Important part of a ladder diagram.

• Comments are displayed at the start of each rung.

• Used to describe the logical expressions and control operations of that rung.

• Understanding ladder diagrams are easier by using comments.

 How to Read Ladder Logic
Microprocessors operates on the binary concept.

‘Binary’: principle, is that the event/s can be thought of in one of two states.
The states can be defined as:
• 1 or 0
• True or False
• On or Off
• High or Low
• Yes or No
 How to Read Ladder Logic

• Ladder logic uses symbolic expressions and a graphical editor for reading and

writing code making it easier.

• If real world event is translated into ladder logic, it symbolically expressed in the

form of a normally open (NO) contact.

E.g. events like a button being pushed or a limit switch being activated.
 How to Read Ladder Logic
Example

• Consider event ‘A’, has one of two states, TRUE or FALSE (1 or 0).

• Event is associated with the normally open (NO) contact can be TRUE or FALSE.

• If the event is TRUE, highlighted in green.

ladder logic truth table

 How to Read Ladder Logic

• A normally open (NO) contact alone cannot decide what action to take to

automate the event

• It merely tells, what is the state of the event.

• Logic is the ability to decide what action needs to be taken depending on the
state of one or more events.

• Logic concept – IF, THEN logic functions.

 Ladder Logic Functions

• Consider an event = A. Allocated to normally open (NO) contact.

• In ladder logic, the events are defined as PLC inputs.
• Let the result of the logic function = ‘Y’.
• The result of a rung logic function is defined as a PLC output.
• The two fundamental elements on a rung in a ladder diagram is first line of code.
 Ladder Logic Functions
Ladder Logic Basics – In Built Functions

Two possible logic iterations:

• IF A = FALSE THEN Y = FALSE

• IF A = TRUE THEN Y = TRUE

 Ladder Logic Functions
Ladder Logic Basics – In Built Functions

Two possible logic iterations:

• IF A = FALSE THEN Y = FALSE
• IF A = TRUE THEN Y = TRUE

Ladder logic diagram expressed symbolically in the

form of a normally open (NO) contact for the input and
the output relay coil.
 Ladder Logic Functions
In ladder logic fundamental logic functions are;

1. AND

2. OR

3. NOR

4. NAND

5. XOR
 Logic functions

(a) AND, (b) OR, (c) NOR, (d) NAND, (e) XOR
Ladder Logic AND Functions
Ladder Logic OR Functions
 Ladder Logic
The sequence followed by a PLC when carrying out a program

1. Scan the inputs associated with one rung of the ladder program.

2. Solve the logic operation involving those inputs.

3. Set/reset the outputs for that rung.

4. Move on to the next rung and repeat operations 1, 2, 3.

5. Move on to the next rung and repeat operations 1, 2, 3.

6. So on until the end of the program with each rung of the ladder program.

The PLC then goes back to the beginning of the program and starts again.
Ladder Logic
 Concept of Latching

• There are situations where it is necessary to hold a coil energized, even when the input which

energized it ceases.

• The term latch circuit is used for the circuit which carries out such an operation.

• It is a self-maintaining circuit, after being energized, it maintains that state until another input is

received.
 Concept of Latching

• When Input 1 is energized and closes, there is an output. However, when there is an output, a

set of contacts associated with the output is energized and closes. The contacts is in OR the

Input 1 contacts.

• Even if Input 1 contacts open, the circuit will still maintain the output energized.

• The only way to release the output is by operating the normally closed contact Input 2
 Concept of Latching
An example of a latch circuit: consider the requirement for a PLC to control a motor

Stop system: (b) safe

• We require is a system that will still stop if a failure occurs in the stop switch.
• The program now has the stop switch as open contacts. However, because the hard-wired stop
switch has normally closed contacts, then the program receives the signal to close the program
contacts.
• Pressing the stop switch then opens the program contacts and stops the system
 Assignment

• Make a report on the advantages and disadvantages of

PLC