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    Programmable Logic Controllers: A Concise Exploration

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    mjrsudhakar
    Programmable Logic Controllers (PLCs) are commonly used in industrial automation to control machines and processes. PLCs were developed in the 1970s to provide a more flexible and reprogrammable system compared to hardwired relay logic. PLCs use ladder logic to represent conditional operations in a similar way as relay circuits. Modern PLCs can perform additional functions like timing, counting, and sequencing. PLC programming is done by arranging logic rungs that represent the control flow of an industrial process.

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    Programmable Logic Controllers: A Concise Exploration

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    mjrsudhakar
    33 views33 pages
    Programmable Logic Controllers (PLCs) are commonly used in industrial automation to control machines and processes. PLCs were developed in the 1970s to provide a more flexible and reprogrammable system compared to hardwired relay logic. PLCs use ladder logic to represent conditional operations in a similar way as relay circuits. Modern PLCs can perform additional functions like timing, counting, and sequencing. PLC programming is done by arranging logic rungs that represent the control flow of an industrial process.

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    Programmable Logic Controllers (PLCs) are commonly used in industrial automation to control machines and processes. PLCs were developed in the 1970s to provide a more flexible and reprogrammable system compared to hardwired relay logic. PLCs use ladder logic to represent conditional operations in a similar way as relay circuits. Modern PLCs can perform additional functions like timing, counting, and sequencing. PLC programming is done by arranging logic rungs that represent the control flow of an industrial process.

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    33 views33 pages

    Programmable Logic Controllers: A Concise Exploration

    Uploaded by

    mjrsudhakar
    Programmable Logic Controllers (PLCs) are commonly used in industrial automation to control machines and processes. PLCs were developed in the 1970s to provide a more flexible and reprogrammable system compared to hardwired relay logic. PLCs use ladder logic to represent conditional operations in a similar way as relay circuits. Modern PLCs can perform additional functions like timing, counting, and sequencing. PLC programming is done by arranging logic rungs that represent the control flow of an industrial process.

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    of 33

    Programmable Logic

    Controllers

    A Concise Exploration
    I. Industrial Automation
    • Common knowledge: computers are used
    in factories...
    • Robotic arm, CNC, injection molding
    I. Industrial Automation
    • Donut machine, Ice cream sandwich
    machines
    I. Industrial Automation
    • Not common knowledge: today this is
    usually accomplished with Programmable
    Logic Controllers (PLCs)

    • PLCs are the answer to a variety of needs:


    durability, reliability, flexibility, scalability,
    reprogrammability, etc...
    I. Industrial Automation
    • Why should you care? Because you will run into
    PLCs...
    • Did you know? <Insert shocking Buckley
    statistic here>
    • Median starting salary for entry-level “Electrical
    Controls Engineer” is $57,452. (EE is $55K, HW
    Eng is $48K, SW Eng is $53K) [monster.com]
    • As long as there is industry, it will be computer
    controlled and engineers will earn paychecks.
    II. History
    • Relentless trend toward tools in industry.

     Handicraft (forever)
     Water-powered silk mill (1721)
     Spinning Jenny (1764)
     Steam power (1780s)
     Gas lighting (1810s)
     Etc…
    II. History
    • Obvious next step: Electricity

    • [Aside: why was Buffalo the place to be


    100 years ago? ... Hydroelectric power! –
    started circa 1853]

    • Electric tools, but still micromanaged by


    humans.
    II. History
    • Machines become autonomous.

    • Common method: relay logic


    III. Relay Logic

    • Conditional logic can be represented in


    terms of contacts and coils.
    • Contact: A simple input switch.
    • Coil: An output load, e.g., a relay or motor.
    • Symbolic representation called ladder
    logic.
    III. Relay Logic
    • To clarify: “Ladder Logic” is a notation
    originally used to describe/document
    relay logic configurations.
    • Later became the basis for PLC
    programming languages
    • (This parallels HW Desc. Langs. (HDLs)...
    VHDL was intended by DoD to document
    ASICs... Learn more in CSE 341 and
    especially CSE 490)
    IV. Ladder Logic

    • Power supply rails drawn as parallel


    vertical lines on left and right
    • Connection of rails implies current will flow
    • An output is “on” when a connection is
    completed and current flows through the
    load’s coil
    IV. Ladder Logic
    • Simple “always on” load:

    [Always_On = 1]

    • Boring... Load controlled by a single


    contact:

    [Switch_Con = Switch]
    IV. Ladder Logic

    • Boolean logic - C = A and B

    • C = A or B
    IV. Ladder Logic
    • C = not A

    • A contact with a slash through it is


    “normally closed.” This indicates a
    connection when A is NOT triggered.
    • So when sensor/input A is activated, there
    is an open circuit
    IV. Ladder Logic
    • Each rung of the ladder is a statement that is
    asynchronous when implemented in relay
    logic, but evaluated sequentially by the PLC.

    • X = (A or B) and (C or D),
    Y = ~A and [B or (C and D)]
    IV. Ladder Logic

    • Converting between ladder logic and


    physical electronics is straight forward.

    • So this…
    IV. Ladder Logic

    • …becomes this:
    V. PLC
    • The first PLC was invented by Dick Morely in
    1978.
    • Morely designed a computer with three
    components: a processor, memory, and a logic
    solver.
    • “[The logic solver] allowed us to get the speed
    we needed in this application-specific computer
    to solve the perceptually simple problem of
    several cabinets full of relay wiring.” -Morely
    V. PLC
    • The first PLC (the 084) was extremely durable
    and reliable...
    • “We used to test the programmable controllers
    with a Tesla coil that struck a quarter inch to half-
    inch arch anywhere on the system, and the
    programmable controller still had to continue to
    run.” –Morely

    • FYI, this is a Tesla coil: http://


    www.youtube.com/watch?v=oNrgXtCu4aU
    V. PLC
    • Hello World on the PLC. Real hardware:

    • In ladder logic:
    V. PLC
    • Not very interesting… how about a “stay-
    on” variation? (When the switch is
    released, the light stays on)
    • PLC benefit: The state of an “output” in one
    rung may be used as a “contact” in another.
    • In fact, there are “internal utility relays” –
    virtual outputs that act as intermediate
    steps toward real outputs.
    V. PLC

    • Latched (“stay-on”) Hello World:

    • When the switch is pressed, “Neon” will be


    active in the first evaluation.
    • In subsequent evaluations, “Neon” will
    force itself to stay on.
    V. PLC
    • A bit more convoluted: toggling Hello World
    with a single button.

    Latch = (Switch AND notNeon) OR (Latch AND notNeon)


    Neon = (Latch AND notSwitch) OR (Neon AND Switch)
    • Remember - Switch state: ON OFF ON OFF
    • Figure it out
    V. PLC
    • PLCs also support a range of special
    functions: timers, counters, sequencers,
    memory instructions, etc…

    • Beyond the basics, they are non-standard


    and manufacturer-specific.
    V. PLC
    • Timer:

    • Counter:
    VI. Washing Machine
    • Washing machine example, using
    sequencer.
    5. “Agitate” and drain - spin
    0. Fill with hot water -pump,
    motor, agitate motor, drain
    • Steps: hot water valve
    valve
    1. “Agitate” – spin motor,
    6. Fill with cold water -pump
    agitate motor
    2. “Agitate” and drain – spin
    7. Spin and drain –spin motor,
    motor, agitate motor, drain
    drain valve
    valve
    3. Fill with hot water -pump,
    8. Stop
    hot water valve
    4. “Agitate” - spin motor,
    agitate motor
    VI. Washing Machine
    • Reorganize into the “outputs”: edit the I/O
    Table
    Output Active in steps…
    Pump 0, 3, and 6
    Hot water valve 0 and 3
    Spin Motor 1, 2, 4, 5, and 7
    Agitate Motor 1, 2, 4, and 5
    Drain valve 2, 5, and 7

    • Assignment – complete the program – due


    2/27
    I/O Table – 1 step
    st
    Exercises
    • Turn 8 LEDs on and off in sequence,
    repeat.

    • Turn a pump on for 60 seconds, then off


    for 40 seconds, then repeat. Use a switch
    to start it off.
    Using a sequencer
    • Define a Counter output – call it Seq1
    • Give it a set value 1 greater than your
    desired sequences:
    – e.g. if 4, then 0 thru 4 = a set value of 5
    • Use special bits as inputs
    • Use Seq1:0 to reset the sequencer by
    defining an output FUNC
    60 on / 40 off
    60 on / 40 off
    Latch an output (keeps it ON)

    Count down TMR60 from 60 to 0

    While TMR60 is counting down (not at 0) run PUMP

    While TMR60 is at 0, count down TMR40


    VII. …
    References

    http://en.wikipedia.org/wiki/Programmable_logic_controller
    http://www.plcs.net/contents.shtml
    http://www.plcdev.com/plc_timeline
    http://www.barn.org/FILES/historyofplc.html
    http://www.jach.hawaii.edu/ets/mech/JCMT/carousel/car_eng.html - Old relay logic
    http://www.rootcompromise.org/gallery/v/blackhat/bh-windows-2004/bh_windows_2004_014.jpg.html - Donut machine
    http://www.fiona.co.jp/BOOK_JUV_PAGE/homerprice.htm - Homer Price
    http://www.youtube.com/watch?v=gKzJqXSPuRE - Krispie Kreme
    http://www.youtube.com/watch?v=-kiSQx0imxs – Ice Cream Sandwiches
    http://www.youtube.com/watch?v=0PUFwwSDAWg – DVD Boxes
    http://www.youtube.com/watch?v=ibc69W_N2h0 – Plasma Cutting
    http://www.youtube.com/watch?v=y2mzjExWXzo – Injection Molding
    http://rds.yahoo.com/_ylt=A9gnMiYBqv1FGjkBFlGjzbkF;_ylu=X3oDMTBsdmIydTZhBHNlYwNwcm9mBHZ0aWQDSTAwMV83MA--/SIG=12imesfu9/EXP=1174338
    433/**http%3A//www.plastic-gear-manufacturer.com/injection-molding.htm -- Injection Molding
    http://rds.yahoo.com/_ylt=A9gnMiIVqv1Fs60AJw.jzbkF;_ylu=X3oDMTBsdmIydTZhBHNlYwNwcm9mBHZ0aWQDSTAwMV83MA--/SIG=12pk1f58s/EXP=1174338
    453/**http%3A//www.offshoresolutions.com/products/plastic/injectionMolded.htm -- Injection Molding
    http://home.howstuffworks.com/washer.htm
    http://en.wikipedia.org/wiki/Industrial_revolution
    http://en.wikipedia.org/wiki/Niagara_falls#Historical_background
    http://en.wikipedia.org/wiki/VHDL

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