Automatic Control

(AEE 3520)

Assignment 1

Student Name: Saad Bin Abdullah Bin Omran

441105204
ID Number:

Date of Report Submission: 15/10/2023

Supervisor:
Dr Eldaw Eldukhri

Programmable Logic Controller Introduction:

A PLC is a user-friendly, microprocessor based specialized computer that carries out control
functions of many types and level of complexity. Its purpose is to monitor crucial process
parameters and adjust process operations accordingly. It can be programmed, controlled and
operated by a person. Essentially a PLC operator draws the lines and devices of ladder diagram
and functional block diagram with a keyboard onto the display screen. The resulting drawing is
converted into computer machine language and run as a user program.
A programmable logic controller (PLC) is a special form of microprocessor-based controller that
uses programmable memory to store instructions and to implement functions such as logic,
sequencing, timing, counting, and arithmetic in order to control machines and processes. It is
designed to be operated by engineers with perhaps a limited knowledge of computers and
computing languages. They are not designed so that only computer programmers can set up or
change the programs. Thus, the designers of the PLC have preprogrammed it so that the control
program can be entered using a simple, rather intuitive form of language. The term logic is used
because programming is primarily concerned with implementing logic and switching operations;
for example, if A or B occurs, switch on C; if A and B occurs, switch on D. Input devices (that is,
sensors such as switches) and output devices (motors, valves, etc.) in the system being controlled
are connected to the PLC. The operator then enters a sequence of instructions, a program, into the
memory of the PLC. The controller then monitors the inputs and outputs according to this
program and carries out the control rules for which it has been programmed. PLCs have the great
advantage that the same basic controller can be used with a wide range of control systems.

History and Development:

A programmable logic controller (PLC) is an industrially hardened computer based unit that
performs discrete or continuous control functions in a variety of processing plant and factory
environments. It was originally intended as a relay replacement equipment for the automotive
industry. Nowadays the PLC is used in virtually every industry imaginable. Though they were
commonly referred to as PCs before 1980, PLC became the accepted abbreviation for
programmable logic controllers, as the term” PC” became synonymous with personal computers
in recent decades.

The early history of the PLC goes back to the 1960’s when control systems were still handled
using relay control. During this time the control rooms consisted of several walls containing
many relays, terminal blocks and mass of wires. The problems related to such kind of systems
were many, among those one could mention:
• The lack of flexibility to expand the process, as well as the inordinate amount of time
needed to adjust the process when changes were needed.
• Troubleshooting which covered from dirty contacts, loose wires, outdated prints on the
terminal blocks with informal nomenclature, to cryptic connection documentation.
These problems were faced continuously by technician and control engineers.

The first programmable logic controller of Allen Bradley, the Bulletin 1774 PLC. It was invented by Ernst Dummermuth in 1974.

The Modicon 184, second programmable controller of Modicon

Programmable Logic Controllers (PLCs) have a rich history of development, dating back to the
mid-20th century. Here is an overview of the history and development of PLCs:
1. Origins in Relay Logic:
Before PLCs, industrial automation relied on relay logic systems. These systems used
electromechanical relays to control various processes, such as manufacturing and machinery.

2. Emergence of the First PLC:

The first true PLC, known as the "Modicon 084," was developed by Bedford Associates, a
company founded by Dick Morley, in 1969. It was created for General Motors to replace
hardwired relay systems. The first programmable logic controller of Allen Bradley, the Bulletin
1774 PLC.
3. Evolution of PLCs:
The Modicon 084, which was initially limited in capabilities, paved the way for further
development. PLCs evolved rapidly, becoming smaller, more versatile, and easier to program.
4. Adoption in Various Industries:
PLCs found applications in a wide range of industries, including manufacturing, automotive,
food and beverage, and more. They provided a flexible and cost-effective way to control
processes.
5. Integration with SCADA Systems:
PLCs began to integrate with Supervisory Control and Data Acquisition (SCADA) systems to
enable real-time monitoring and control of industrial processes.
6. Expansion of Communication Protocols:
PLCs started using various communication protocols, such as Ethernet, Profibus, and DeviceNet,
allowing for better connectivity and data exchange between different devices.
7. Safety and Redundancy Features:
PLCs incorporated safety features and redundancy options to enhance the reliability of control
systems in critical applications.
8. Industry 4.0 and IIoT:
PLCs have adapted to Industry 4.0 and the Industrial Internet of Things (IIoT) by facilitating data
collection and analysis for improved automation, predictive maintenance, and decision-making.
9. Ongoing Development:
PLCs continue to evolve, with a focus on cloud integration, cybersecurity, and artificial
intelligence to meet the demands of modern industrial automation.
Today, PLCs are an integral part of industrial automation systems, offering reliability, flexibility,
and scalability for a wide range of applications. Their development has been driven by
technological advancements and the need for more efficient and data-driven control systems in
various industries.
Advantages/Disadvantages:
Programmable Logic Controllers (PLCs) are widely used in industrial automation and control
systems, and they offer several advantages and disadvantages:
Advantages of PLCs:
1. Reliability:
PLCs are known for their high reliability and robustness in industrial environments.
They can operate continuously without much downtime.
2. Flexibility:
PLCs are programmable, allowing for easy modification and adaptation to
changes in the manufacturing process without extensive rewiring or hardware changes.
3. Scalability:
PLCs can be easily scaled up or down to accommodate changes in system
complexity or production requirements.
4. Fast Response Time:
PLCs offer fast response times for controlling machinery and processes, making
them suitable for real-time applications.
5. Ease of Programming:
PLC programming is often intuitive, with user-friendly software tools and a range
of programming languages (such as ladder logic, function block diagrams, and structured
text).
6. Built-in Diagnostics:
Most modern PLCs include diagnostic capabilities, which simplify
troubleshooting and reduce downtime.
7. Interoperability:
PLCs support various communication protocols, enabling them to interface with
other devices, sensors, and control systems.
Disadvantages of PLCs:
1. Cost:
PLC hardware and software can be expensive, particularly for complex applications,
although they can offer a return on investment through improved productivity and reduced
downtime.
2. Limited Computing Power:
PLCs are not as powerful as general-purpose computers, which may limit their
ability to handle complex computations or data processing tasks.
3. Learning Curve:
PLC programming may require specialized knowledge and training, which can be
a barrier for some users.
4. Limited Memory:
 PLCs often have limited memory for program storage and data handling, which
can be a limitation for very large or complex applications.
5. Lack of Standardization:
While there are industry standards for PLC programming languages, different
manufacturers may have their own proprietary software and hardware, making it
challenging to switch between brands.
6. Maintenance:
Like all industrial equipment, PLCs require regular maintenance to ensure they
continue to operate reliably.
7. Cybersecurity Risks:
As PLCs become more connected to networks and the internet, they can be
vulnerable to cybersecurity threats if not properly secured.
In summary, PLCs have numerous advantages in terms of reliability, flexibility, and ease of
use in industrial automation. However, they also have limitations, including cost, processing
power, and cybersecurity concerns, which need to be considered when implementing them in
control systems. The choice of using PLCs or other control technologies should be based on
the specific needs and requirements of the application.

Types of Programming Languages:

There are five types of PLC Programming languages all are part of IEC(International Electro
technical Commission) 61131-3 International Standard. According to this standard, the five types
of different PLC Programming Languages are:

1. Ladder Diagram(LD)
2. Function Block Diagram(FBD)
3. Structured Text(ST)
4. Instruction List(IL)
5. Sequential Function Chart(SFC)
1. Ladder Logic (LAD):
Ladder Logic is the most widely used programming language in PLCs. It uses graphical
symbols to represent control logic, resembling electrical relay diagrams. Symbols represent
devices (e.g., switches, sensors, and coils), and rungs consist of horizontal lines that connect
these symbols

This looks like relay racks, each device in the relay rack would be represented by a symbol on
the ladder diagram.

The name ladder diagram is based on the programming language pattern similar to a ladder, with
two vertical rails that shows electrical connection among a series of horizontal rungs between
them.

Advantage of Ladder Diagram (LAD):

• LAD is simple logic construction and more reliable than an electronic circuit controller.
• Easy to learn and read the program.
• Every programming symbol performs specific actions.
• It having good representation for discrete logic.
• Easy to troubleshoot.
• Shut down the power without the switch (i.e. hardware devices).
2. Function Block Diagram (FBD):

FBD is another graphical language that uses blocks to represent functions or operations, which
are connected to create control logic. Function blocks represent various functions, and
inputs/outputs are connected to them.
Function Block Diagram(FBD) is another PLC programming language that is a popular one and
looks like a graphical type like a Ladder Diagram(LD).
In Function Block Diagram inputs and outputs are connected in blocks by connection lines.

Function blocks are mainly used to do repetitive tasks like starters, closed-loop control, PID
loops, etc.

Advantages of Function Block Diagram(FBD):

• Easier because of a graphical representation method
• One block consists of several lines of logic which is like a repetitive task.

3. Structured Text (ST):

Structured Text (ST) is one of the programming languages used in Programmable Logic
Controllers (PLCs) for creating control logic and automation applications. Unlike ladder logic,
which is graphical in nature and resembles electrical relay logic, Structured Text is a high-level
text-based language that is similar to programming languages used in software development.
Here are some key points about Structured Text in PLCs:

High-Level Language: Structured Text is a high-level language, which means it provides a more
natural and powerful way to express complex control logic. It is closer to traditional
programming languages and is often used in applications where complex mathematical
calculations, data manipulation, and advanced control strategies are required.

Text-Based: ST uses text-based statements and syntax, similar to common programming

languages like C, C++, or Pascal. Programmers write code using a structured format, with each
statement specifying a particular action or condition.
4. INSTRUCTION LIST (IL):

Instruction List (IL) is one of the five standard programming languages used in Programmable
Logic Controllers (PLCs), as defined by the IEC 61131-3 standard. IL is a low-level, text-based
language that resembles assembly language and is primarily used for writing simple and direct
control logic in PLCs. Here are some key points about Instruction List in PLC programming:

Low-Level Language: IL is a low-level programming language. It is similar in structure to

assembly language used in microcontrollers and computers. Each statement in IL typically
corresponds to a single machine-level instruction executed by the PLC.

Text-Based: IL uses a text-based format where each line of code represents a specific operation
or instruction. Unlike high-level languages like Structured Text or Function Block Diagrams, IL
does not have a high-level, natural language structure.
5. SEQUENTIAL FUNCTION CHART (SFC):

Sequential Function Chart (SFC) is one of the five standard programming languages used in
Programmable Logic Controllers (PLCs), as defined by the IEC 61131-3 standard. SFC is a
graphical language that is particularly well-suited for designing complex control sequences and
state-based logic. Here are some key points about Sequential Function Charts in PLC
programming:

Graphical Language: SFC is a graphical programming language. It represents control logic

using a series of interconnected steps, transitions, and states, often resembling a flowchart. This
graphical representation makes it easier to visualize and design complex sequences of operations.

Modular and Hierarchical: SFC allows programmers to break down control logic into modular
units called steps and states. This modularity and hierarchical structuring make it easy to design,
understand, and maintain complex control sequences.
 PLC APPLICATIONS
Programmable Logic Controllers (PLCs) are widely used in engineering and various industries
for a wide range of applications. Here are some example applications of PLCs:
• Manufacturing and Production Lines:
PLCs are commonly used to control and automate manufacturing processes. They can
manage the sequencing, timing, and coordination of various machines and devices in production
lines, ensuring efficient and consistent production.
• Conveyor Systems:
PLCs are used to control conveyor systems in industries like logistics, automotive, and
food production. They can manage the speed, direction, and operation of conveyors, including
sorting and routing products.

• Packaging Machinery:
PLCs control packaging machines, ensuring that products are filled, sealed, labeled, and
sorted accurately and efficiently.
• Robotic Systems:
PLCs are used to control industrial robots, managing their movements and tasks in
applications such as welding, painting, and material handling.
• HVAC (Heating, Ventilation, and Air Conditioning) Systems:
PLCs regulate HVAC systems in commercial buildings, controlling temperature,
humidity, and airflow for energy-efficient climate control.
• Water Treatment Plants:
PLCs are essential for controlling the purification and distribution of water, managing
processes like chemical dosing, filtration, and pump control.

• Power Plants:
PLCs are used in power generation and distribution systems, managing turbines,
generators, switchgear, and monitoring critical parameters.
• Food and Beverage Processing:
In the food and beverage industry, PLCs are used to control cooking, mixing, filling, and
packaging processes to ensure product consistency and safety.
• Automotive Manufacturing:
PLCs control various aspects of automobile manufacturing, from welding and assembly
to painting and quality control.
• Petrochemical and Oil Refining:
PLCs are used in the control of complex processes in petrochemical plants and oil
refineries, including distillation, blending, and safety systems.
• Agricultural Automation:
PLCs are used in agriculture for tasks such as controlling irrigation systems, monitoring
environmental conditions, and automating feeding and milking processes on farms.
• Building Automation:
PLCs play a significant role in building automation systems, controlling lighting, security,
access control, and energy management in commercial and residential buildings.
• Pharmaceutical Manufacturing:
In pharmaceutical facilities, PLCs help regulate production processes, including mixing,
granulating, tablet pressing, and filling.
• Mining and Material Handling:
 PLCs are used to control material handling equipment, such as conveyor belts, crushers,
and loaders in the mining industry.
• Wastewater Treatment Plants:
PLCs manage the processes of wastewater treatment, including aeration, sedimentation,
and disinfection, ensuring environmental compliance.
These applications represent just a portion of the many ways PLCs are used across
engineering and industries. PLCs are valued for their ability to automate and control processes
reliably, efficiently, and with the flexibility to adapt to changing requirements.

Quality Control on Conveyor:

Problem Statement
Parts are moving on the conveyor from one process line to other with a constant speed. Out of
1000 part, one part is taken out for quality check.

Solution:
• To detect the parts, detector such as proximity switch, optical sensors or any other sensor is
used.
• Connect output of this detector to Input Module of PLC which sets and resets image memory
according to parts’ detection.
• Give this detection, as an input to Up Counter which is incremented with each part’s
detection.
• Set counter preset value to 1000.
• Operate Solenoid for a few seconds until the part is diverted for quality check.

Inputs/Outputs
List of Inputs and Outputs
I:1/14 = Start (Input)
I:1/15 = Stop (Input)
I:1/0 = Detector input (Input)
B3:0/0 = Latching Coil (Bit)
O:2/0 = Conveyor Motors (Output)
O:2/1 = Solenoid to operate gate (Output)
C5:0 = Up Counter to count 1000 parts (Counter)
T4:0 = Timer to operate solenoid (Timer )
-(RES)- = Reset counter value (Timer/Counter)

Ladder Logic

Program Description  RUNG000 is Master Start and

Stop the process.
• RUNG001 operates Conveyor Motors with address O:2/0 to start moving parts to other
process. This is started as soon as Start PB I:1/14 is pressed.
• RUNG002 comprises Up Counter which counts the number of parts detected by the detector
which is connected to I:1/0. Whenever a part is detected, I:1/0 goes high incrementing
accumulator value of C5:0 Counter.
• When 1000 parts are counted, done bit is generated which is used to operate Solenoid Coil in
RUNG003. It allows the current to pass and solenoid is operated.
• Assuming that it takes 2secs to divert the part for quality check, 2secs of timer T4:0 is used.
This timer bit T4:0/DN resets the counter value to 0 which in turn unlatches solenoid coil
O:2/1 taking gate to its main position.

Oil and Water Separation Process:

Problem:
Implement programming of Oil and Water separation process in PLC using Ladder Diagram
programming language

Problem Solution
• Due to the gravitational force and different liquid density of Water and Oil, when water and
oil both are present in the liquid, oil always reside on top of the liquid. By following this
theory and making an arrangement shown in the diagram above, Oil and Water can be
separated.
• However, this process does not completely remove water particles but only less than 10% of
water contents are present after passing through this process.
• Level of the tank is monitored using level sensor. To control level of the system Inlet is
controlled.
• To control the temperature of this system, ignition is to be controlled. Temperature sensor is
used and gas supply flow is controlled to control temperature. Temperature set point here is
50 degree centigrade.
• Oil outlet is controlled by control valve which is operated by two level switches.

List of Inputs and Outputs

I:1/14 = Start (Input)
I:1/15 = Stop (Input)
O:2/15 = Master Coil (Output)
I:3 = Level sensor output (Input)
N7:0-N7:2 = Level monitoring and controlling registers (Registers)
O:3 = Inlet controlling valve (Output)
O:6 = Level Display (Output)
I:1/1 = High level (Oil) (Input)
I:1/0 = Low level (Oil) (Input)
O:2/0 = Oil output valve (Single actuating) (Output)
I:4 = Temperature output from sensor (Input)
N7:3 to N7:5 = Temperature monitoring and controlling registers (Registers)
O:5 = Gas supply controlling valve (Output)
O:7 = Temperature Display (Output)

• RUNG000 is the master start and stop control rung.

• RUNG001 is for Level Monitoring and control of Oil and Water separation process tank.
• I:3 is an input where Level sensor is connected with. Height of the tank is 200cms. And
we need to control the level till 100cm. hence output of the sensor is divided by 327
which means that per cm, input is added with 327.
• This data is further processed and multiplied by 655, because when output is 100cm, we
have to throttle inlet valve to be fully closed. So when output is 100cm in N7:1 register, it
is multiplied by 655 and the full throttling is received at O:3 which is connected to Inlet
valve through I-P converter.
• N7:1 stores the level of the tank which is moved to O:6 (Display address) through
Decimal to BCD converter.
• Similarly, Temperature monitoring and controlling is done as shown in the Ladder
diagram below.
• Let’s say, temperature to be controlled is 50 degrees centigrade. According to used sensor
RTD PT100, data are processed and required temperature is controlled through Gas
Supply for ignition.
• Here displays output address is O:7.
• RUNG002 is to operate Oil Outlet Valve with address O:2/0.
• When Level low is detected by Low level sensor with address I:1/1, outlet valve is
opened and it is closed when I:1/0 is detected that is high level
Conclusion:
Programmable Logic Controllers (PLCs) have played a pivotal role in the evolution of
industrial automation. Their history traces back to the mid-20th century when they emerged as a
replacement for complex and inflexible relay-based control systems. Over the decades, PLCs
have gone through significant advancements in terms of technology, functionality, and
integration, making them a cornerstone of modern industrial control.
PLCs are programmed using various languages, with ladder logic being the most common
due to its ease of use and visual representation of control logic. Other languages, such as
Structured Text and Function Block Diagrams, offer more advanced and versatile programming
options, allowing for complex control strategies and data processing.
The applications of PLCs are diverse and far-reaching. They are widely used in industries
like manufacturing, energy, automotive, and food processing to automate processes, monitor and
control equipment, and ensure the efficient and reliable operation of production lines. PLCs are
essential in tasks such as regulating temperature, pressure, and flow in industrial systems,
coordinating robotic movements, and managing data acquisition and communication in real-time.
In today's rapidly evolving industrial landscape, PLCs continue to adapt and integrate
with the latest technologies, including the Internet of Things (IoT) and cloud computing. They
are key components in smart factories and Industry 4.0 initiatives, contributing to increased
efficiency, productivity, and cost-effectiveness.
Overall, PLCs have a rich history, a range of programming languages, and an extensive
array of applications. They have consistently proven to be essential tools in the field of industrial
automation, ensuring that complex processes are executed with precision and reliability,
ultimately driving progress and innovation in manufacturing and related industries.

References:
• https://www.sanfoundry.com/plc-program-oil-water-separation-process/
• https://www.sanfoundry.com/plc-program-sort-parts-quality-control-conveyor/
• https://www.gbctechtraining.com/blog/world-plcs-closer-you-think-
plcapplications-our-everyday-lives
• https://dipslab.com/plc-applications/
• https://control.com/technical-articles/the-origin-story-of-the-plc/
• https://dipslab.com/different-types-plc-programming-languages/
• https://automationforum.co/plc-learning-series-8-instruction-list-programming/