PLC stands for Programmable Logic Controller. It evolved from relay-based hardwired logic controllers to overcome disadvantages like being difficult to troubleshoot, expensive for large applications, and cumbersome to change logic. Solid state logic controllers using integrated circuits improved on this but still required board replacement for logic changes. The evolution culminated in PLCs, which are microprocessor-based and program logics through software, allowing simple and flexible configuration of control logics.
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PLC stands for Programmable Logic Controller. It evolved from relay-based hardwired logic controllers to overcome disadvantages like being difficult to troubleshoot, expensive for large applications, and cumbersome to change logic. Solid state logic controllers using integrated circuits improved on this but still required board replacement for logic changes. The evolution culminated in PLCs, which are microprocessor-based and program logics through software, allowing simple and flexible configuration of control logics.
PLC stands for Programmable Logic Controller. It evolved from relay-based hardwired logic controllers to overcome disadvantages like being difficult to troubleshoot, expensive for large applications, and cumbersome to change logic. Solid state logic controllers using integrated circuits improved on this but still required board replacement for logic changes. The evolution culminated in PLCs, which are microprocessor-based and program logics through software, allowing simple and flexible configuration of control logics.
Copyright:
Attribution Non-Commercial (BY-NC)
Available Formats
Download as DOC, PDF, TXT or read online from Scribd
PLC stands for Programmable Logic Controller. It evolved from relay-based hardwired logic controllers to overcome disadvantages like being difficult to troubleshoot, expensive for large applications, and cumbersome to change logic. Solid state logic controllers using integrated circuits improved on this but still required board replacement for logic changes. The evolution culminated in PLCs, which are microprocessor-based and program logics through software, allowing simple and flexible configuration of control logics.
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EVOLUTION OF PLC
PLC means Programmable logic controller. It is basically a controller which
performs logics and the logics are programmable. Hence to understand the PLC we have to understand first the meaning of controller, logics and programmable.
CONTROLLER
As the name suggests the controller performs control function. This means there is a parameter which need to be controlled at a particular value desired by the user. For example we want to control the temperature of water in a gaiser or say control room temperature using air coolers. In these applications we find that there are two variables.
The temperature of the water or room which can vary and need to be controlled. Unless the measurement of this variable is done it cannot be controlled. This variable is known as process variable or measured variable.
Then the user has a desire in his mind to control this temperature of water or room at a particular point. This variable is known as setvariable/setpoint or desired variable.
Control action means controlling of the measured variable equal to set
variable by taking necessary corrective action. The device that performs this is known as controller.
A look at the control action shows that a controller is basically a comparator.
It compares the values of measured variable and set variable and takes corrective action based on their difference. This difference is called error and the output of the controller is known as manipulated variable. Logics
Logic basically refers to true or false condition in general, In industrial
applications it refers to a particular state of an equipment with no ambiguity. For example on or off, open or closed etc. All these status are clear and distinct. Industrial equipments have the following states.
ON state ------ The equipment is running
OFF state ----- The equipment is stopped. Trip state------- The equipment has stopped against a fault
The difference between a stop and trip is as follows.
A stopped equipment can be started as and when required where as a tripped
equipment can be started only after rectification of fault.
In industrial applications these states are known as logics.
A PLC is basically a logic controller. It takes care of the on/off/trip states
of an equipment as per user requirement.
Evolution of logic controller
The above logics(instructions as to how to start/stop/trip) need to be
implemented and the implementation techniques evolved with time are as follows.
The earliest implementation of logics were carried out using relays and switches. The relays and switches were hardwired as per the requirement of the user. This premier logic controller is known as relay based system.
Any system for that matter need the following.
A source to drive the system. For example power supply, air supply etc.
Minimum of one input and minimum of one output if it is a control system.
thumb wheel switches, dip switches, process switches such as pressure switch thermostat level switch flow switch etc.
Outputs of a logic control system
The outputs are normally relays solenoid valves timers counters indicating lamps etc.
All inputs of a logic system are contacts in nature and all outputs are coil in nature. Hence the logic control system is commonly known as coil and contact system.
In a relay based system the logics were configured by connecting the
coils(outputs) and contacts(inputs) using hardwires. Hence the relay based system which is the mother of all logic controllers is known as hardwired logic controller. With all the advancement in technologies this systems is time tested and still popular with the user.
Advantages
Simple and rugged
Economical for small applications Donot require any special tools or equipments for maintenance Donot require highly skilled people for operation and maintenance
Disadvantages
Operates at high voltages
Consumes more power and generates heat Occupies large space for a medium and large scale applications Trouble shooting is difficult Expensive for medium and large scale applications Changing of logic calls for rewiring and hence cumbersome Malfunctioning due to moving parts such as contacts relays etc Control circuit and power circuit
A glance at the above circuit shows the following
There is a power source across P and N The switch performs on-off action The fan is the load The circuit containing on/off/trip operation is known as control circuit. The circuit through which the load current flows is known as power circuit In this case since the load and the switch are in series the control circuit and power circuit are one and the same.
Such a configuration is possible only in the case of small loads operating at
low voltages say 230v.
In case of higher voltages and high loads the control circuit and power circuit are separated as shown below.
Series circuit in a relay based system
Parallel circuit in a relay based system
It can be seen from the above that a series and parallel circuits are basically AND logic gate and OR logic gate.It is possible to construct other gates such as nor,nand,exclusive or etc using relay system.
Nand gate Not gate
Nor gate Ex-or gate Keeping in mind the disadvantages of relay based system a change in technology was eagerly awaited and the same came upon the advent of INTEGRATED CHIPS.
Diode-Transistor logic----------------------- DTL) supply voltage 5v Transistor-transistor logic--------------------TTL)3 CMOS logic supply 3 to 15v dc Solid state logic controllers Solid state logic controllers were made by configuring the logic required on a printed circuit board and then soldering the components as per the circuit diagram.
Advantages of solid state system
Operating on low voltage dc and consumes less power
Occupies less space Investment cost very low No moving components Less heat generated Good speed of response Disadvantages Logics are configured on the printed circuit board and hence change in logic calls for board replacement.
Programmable Logic Contollers
These are microprocessor based systems and as such has all the advantages of solid state systems. Further the logics are programmed through software Hence configuration of logics is simple and flexible.
