IST / DEEC / API

Industrial Automation
(Automao de Processos Industriais)

Introduction to PLCs
http://users.isr.ist.utl.pt/~jag/aulas/api1213/api1213.html
Slides 2010/2011 Prof. Paulo Jorge Oliveira
Rev. 2011-2013 Prof. Jos Gaspar

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Industrial Automation

Syllabus:
Chap. 1 Introduction to Automation [1 week]
...
Chap. 2 Introduction to PLCs [2 weeks]
Internal architecture and functional structure.
Input / output interfaces. Interconnection of PLCs .
Components of Programmable Logic Controllers (PLCs).
...
Chap. 3 PLCs Programming Languages [2 weeks]

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Chap. 2 Introduction to PLCs

Some resources available online on PLCs

History :

http://www.plcs.net/chapters/history2.htm

Tutorial:

http://www.koldwater.com
http://www.htservices.com/Tutorials/plctutorial1.htm
http://www.sea.siemens.com/step/templates/lesson.mason?plcs:1:1:1

Simulators:

http://thelearningpit.com/plc/psim/psim.html
http://www.keyence.com/plc/kvl.htm
http://www.autoware.com/english/demo.htm
SW used in lab, Schneider/SoCollaborative Unity Pro, has simulator

Bibliography :

Automatic Manufacturing Systems with PLCs, Hugh Jack

(online version available)
Programming Logic Controllers, Frank D. Petruzella
...

Standards:

http://www.plcopen.org/
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Phases of a Project in EE&CS:

(Automation included)
Preliminary Study
Preparation

Specifications
Technical solution choice
Execution of tech. drawings
Documentation
Software development

Execution

Installation
Software installation
Tests

Conclusion

Start of operation
Start of exploitation

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Chap. 2 Introduction to PLCs

An Automation Example
Solution based on PLCs
Example:
Automation of the Main Entrance Door, in PLCs Theory, [Omron]

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Chap. 2 Introduction to PLCs

Example:
Automation of the Main Entrance Door, in PLCs Theory, [Omron]
Functional Specifications
An automatic system that could command the opening and close of a door is the main purpose
of these specifications.
The command operation will be automatic and manual. There must be a selector with two
positions in a front panel of command to select the mode of operation.
The manual mode resorts to the use of two push buttons to open and close the door. Once the
OPEN push button is pressed, the door will be opened until the operation is completed, as
detected by a limit switch. Upon pushing the CLOSE button the door will be commanded to
close, until the end of the operation is detected by other limit switch.
The automatic mode of operation resorts to the use of two sensors, that detect the proximity of
the users. When a person is detected the automatic opening of the door starts. The door
remains open for a period from 5 to 20 seconds, following the null detection of the user. After
that period the door starts to close. If during this last phase the presence of another user is
detected the close operation is aborted and a new cycle of opening starts.

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Example:
Automation of the Main Entrance Door, in PLCs Theory, [Omron]
Technological Specifications
The proximity sensor that detects the users must be of a model that can be installed over the
door (one in the interior and other in the exterior), and must be based on the reflection of
infrared radiations, with output by transistor. The sensor sensitivity must be tuned such that its
output becomes active if an user is at 2 meters of distance or less.
The motor that activates the open and close of the door must be electrical , three-phase, ..., etc.

Operating Specifications
A key must be required to be used in the model of the automatic-manual selector. A counter of
the number of operations should be incorporated in the solution, to identify when maintenance
is required. The maintenance must be at each 10000 operations, ... etc

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Chap. 2 Introduction to PLCs

Example:
Automation of the Main Entrance Door, in PLCs Theory, [Omron]
Hardware list
Input (sensors):
- Selector manual / automatic
- Push button open door
- Push button close door
- Proximity sensors
- Limit switch fully open
- Limit switch fully closed

Output (actuators):
- Motor actuation to open door
- Motor actuation to close door

Combining all
- Connect input and output hardware
- Implement functional and operational specifications, according to the
technological specifications
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Automation Problems
PLC based solutions
Process

Sensors

Actuators
Programmable
Logic Controller

To use PLCS the connection to input devices (for detection and sensing) and
to output devices (for command and control) is required.
A software program to implement the proposed solution has to be
implemented in the PLC.
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Chap. 2 Introduction to PLCs

Architecture of PLCs

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Architecture of PLCs
... and internally, how is it implemented?
Program

Memory

Input/output

address
data
control

Central Processing Unit

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Architecture of PLCs
rack

Types of PLCs

mini

micro

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Architecture of PLCs

PLC

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Chap. 2 Introduction to PLCs

Example: Mixer Motor

Problem [Petruzella96]: A mixer motor is to be used to automatically stir the liquid in a
vat when the temperature and pressure reach preset values. In addition, direct
manual operation of the motor is provided by means of a separate pushbutton station.
Solution using the relay diagram:

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Chap. 2 Introduction to PLCs

Example: Mixer Motor, input

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Chap. 2 Introduction to PLCs

Example: Mixer Motor, output

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Example: Mixer Motor, input + CPU/Memory + output

PLC CPU
and Memory

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Chap. 2 Introduction to PLCs

Internal structure and

Work principles
Example:
Command of a motor from a console
with start and stop buttons.

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Chap. 2 Introduction to PLCs

Internal structure and

Work principles

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Internal structure and

Work principles

2
1

4
5

1, 2, 3

4, 5

3, 4

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Chap. 2 Introduction to PLCs

Internal structure and work principles

8.2.1 The Input and Output Scans

When the inputs to the PLC are scanned the physical input values are copied into
memory. When the outputs to a PLC are scanned they are copied from memory to the
physical outputs. When the ladder logic is scanned it uses the values in memory, not
the actual input or output values. The primary reason for doing this is so that if a
program uses an input value in multiple places, a change in the input value will not
invalidate the logic. Also, if output bits were changed as each bit was changed, instead
of all at once at the end of the scan the PLC would operate much slower.
[From Hugh Jack (PLCs book)]
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Chap. 2 Introduction to PLCs

Internal structure and work principles

Scan Cycle, Scan Period

The inputs must be active for at least one scan cycle to have impact (no
uncertainty) in the internal PLC state and indirectly in the outputs.
Exception: interrupts...
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Internal structure and work principles

Worst time
Best time

Q: Worst time interval for an input to have impact on an output (with probability one)?
A:

2 * Scan Period

Q: Smallest time interval (with probability greater than zero) that the change in one
input can impact in one output?
A:

Scan Period Read Time Write Time = Execution Time

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Chap. 2 Introduction to PLCs

Internal structure and work principles

Horizontal scanning

Vertical
scanning

Interface for inputs and outputs

Scanning rungs...
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Chap. 2 Introduction to PLCs

8.2.2 The Logic Scan

Ladder logic programs are modeled after relay logic. In relay logic each element in the ladder
will switch as quickly as possible. But in a program elements can only be examined one at
a time in a fixed sequence. Consider the ladder logic in Figure 8.4, the ladder logic will be
interpreted left-to-right, top-to-bottom. In the figure the ladder logic scan begins at the top
rung. At the end of the rung it interprets the top output first, then the output branched below
it. On the second rung it solves branches, before moving along the ladder logic rung.
[From Hugh Jack (PLCs book)]
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Chap. 2 Introduction to PLCs

Components of Programmable Logic Controllers

1. Programming using
specific devices

OMRON console
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Chap. 2 Introduction to PLCs

Components of PLCs: Input and output interfaces

2.1 AC input module
(discrete)

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Chap. 2 Introduction to PLCs

Components of PLCs: Input and output interfaces

2.1 AC input module:
simplified implementation

Electronic circuit
Connections to the PLC terminals
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Chap. 2 Introduction to PLCs

Components of PLCs: Input and output interfaces

2.2 AC output module
(discrete)

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Chap. 2 Introduction to PLCs

Components of PLCs: Input and output interfaces

2.2 AC output module (discrete)

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Chap. 2 Introduction to PLCs

Components of PLCs: Input and output interfaces

2.3 DC input module (discrete)

Relay
External
terminals

Attention to:
Galvanic isolation

Economy
Consumption

Transistor
External
terminals

Switching speed
Noise immunity

Opto-coupler
External
terminals

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Components of PLCs: Input and output interfaces

2.4 DC output module (discrete)

Connections to terminals ...

External
terminals

External
terminals

Relay

To
the
CPU

To the
CPU

... and protections.

Transistor

To the
CPU

External
terminals

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Chap. 2 Introduction to PLCs

Components of Programmable Logic Controllers

3. Power sources
Attention to:

Isolation to the noise

Isolation relative to
disturbances on the network
Efficiency
Consumption
Size (volume and weight)

Switching power sources

Robustness relative to load

variations
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