Mechatronics Plc by Nishant
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Transcript of Mechatronics Plc by Nishant
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Programmable Logic Controller
(PLC)
By
NISHANT V. CHAUDHARI
M.A.E. ALANDI
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PLC
NEMA defines a PROGRAMMABLE LOGICCONTROLLER as:A digitally operating electronic apparatus whichuses a programmable memory for the internalstorage of instructions by implementing specificfunctions such as logic sequencing
timing
Counting arithmetic to control
through digital or analog input/output modules,various types of machines or processes.
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PLC History The Hydramatic Division of the General
Motors Corporation specified the design
criteria for the first programmable
controller in 1968 Their primary goal was to eliminate the
high costs associated with inflexible, relay
controlled systems
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The specifications required a solid-statesystem with computer flexibility able to:
1. Survive in an industrial environment.
2. be easily programmed and maintained by
plant engineers and technicians.
3. be reusable
Such a control system would reduce
machine downtime and provideexpandability for the future
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Some of the initial specifications included the
following: The new control system had to be price competitive with the use
of relay systems.
The system had to be capable of sustaining an industrial
environment.
The input and output interfaces had to be easily replaceable.
The controller had to be designed in modular form, so that
subassemblies could be removed easily for replacement or
repair.
The control system needed the capability to pass data collection
to a central system. The method used to program the controller had to be simple, so
that it could be easily understood by plant personnel.
The system had to be reusable.
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Conceptual Design of PLC
The first programmable controllers were more or lessjust relay replacers.
Their primary function was to perform the sequentialoperations that were previously implemented with relays
These operations included ON/OFF control of machinesand processes that required repetitive operations, suchas transfer lines and grinding and boring machines etc.
These programmable controllers were a vastimprovement over relays
They were easily installed, used considerably less spaceand energy, had diagnostic indicators that aidedtroubleshooting, and unlike relays, were reusable if aproject was scrapped.
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Todays PLC
Many technological advances in the
programmable controller industry continue
today.
These advances not only affect programmable
controller design, but also the philosophical
approach to control system architecture.
Changes include bothh
ardware (physicalcomponents) and software (control program)
upgrades
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The following list describes some recent PLChardware enhancements: Faster scan times are being achieved using new,
advanced microprocessor and electronic technology.
Small, low-cost PLCs, which can replace four to tenrelays, now have more power than their predecessor,
the simple relay replacer. High-density input/output (I/O) systems provide
space-efficient interfaces at low cost.
Intelligent, microprocessor-based I/O interfaces haveexpanded distributed processing.
Typical interfaces include PID (proportional integral-derivative), network, CAN-bus, field-bus, ASCIIcommunication, positioning, host computer, andlanguage modules
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Hardware Components of a PLC
System Processor unit (CPU)
Memory
Input/Output modules Power supply unit
Programming device
Communication modules Remote I/O modules
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PLC Block Diagram
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Major CPU Components
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Input Output Interface
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Functional Interaction of PLC system
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Programming Devices
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Typical Areas Of Application
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Typical Areas Of Application
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Market share
Micro: 15 to 128 I/O pointsMedium: 128 - 512 I/O points
Large: > 512 I/O points
Nano: < 15 I/O points
PC-basedSoftware PLC
Embedded control
32%29%
20%
7%
6%4%
2%
% installed PLCs
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Type of PLCs
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Micro PLC
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Small PLC
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Medium PLC
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Large PLCs
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Large PLCs
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Very Large PLCs
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Global players
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PLC Programming Languages
As Per IEC 61131-3 Standard
Ladder Diagram (LD)
Sequential Function Chart (SFC)
Function Block Diagram (FBD)
Structured Text (ST)
Instruction List (IL)
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Ladder Diagram
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Structured Text
TONR_01.Preset := 500;
TONR_O1.Reset := reset;
TONR_01.TimerEnable :=
limit_switch1;
TONR(TONR_01)
timer_state := TONR_01.DN;
???
TONR_01
TONR ...
Timer On Delay with Reset
TimerEnable
PRE
Reset
ACC0
DN0
?
??
?
??
?
ENDN
Timer On DelayTimer ?Preset ?
A m ?
TON
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I/O connection Diagram
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PLC System
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Local Rack Configuration
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Remote Rack Configuration
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I/O Addressing
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Logic Functions (AND)
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OR Function
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NOT
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Example of hardwiring changes as
opposed to soft wiring changes
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PLC Scan
Read the Data from Sensors
or Input Devices
Execute the users Logic
Program
Update the output Devices or
Actuators
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System Programming and
Implementation
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PLC Panel
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Control System OrganizationIndividual Control
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Centralized Control
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Distributed Control
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