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Vt training plc_1

  1. 1. TRAINING<br />On<br />PLC <br />PROGRAMMING<br /> - Kumar N<br />
  2. 2. VISION STATEMENT<br />Vashist Tecnologies <br />An ISO 9001 2000 Certified Company<br />: Engineering Solution Provider <br /><ul><li> To be a Leading, Dynamic, Result Oriented Company focused on providing Quality Solutions, Systems and Support
  3. 3. To be consistent by improving continuously through our Quality Management System.</li></li></ul><li>Our PARTNERS <br />ABB , <br />Rockwell Automation , Automation and Control Products<br />Honeywell Automation , Sensing & Control Products<br />Schmersal , Man and Machine Safety Products<br />Bosch Rexroth, Motion Technology Products<br />
  4. 4. Our FOCUS <br />Application Engineering Division<br />The perfection in Application Engineering lies in understanding the application, understanding the product, its power, and its limitations. We also do develop the customized products for the various requirements of the customer.<br />Panel Engineering Division<br />With vast experience in the field, our engineers are talented creative professionals & technology developers, the excel had been proven in various industries, with compact non heating cost effective Panel designs.<br />Product Sales Division<br />The suggestion and selling of right product for right application with the best possible cost effectiveness, knowing the strengths and limitations of the products, has been always the high morale. <br />
  5. 5. Our FOCUS <br />Training Division<br /> At Hitech Electronics Research and Training Zone, HERTZ , A unit of VaShIST Tecnologies, we mobilize the engineering work force for corporate as well as individuals by providing advanced training in <br />PLC’s, <br />Field Sensors and Instruments,<br />Process Control & Instrumentation, <br />Panel engineering, <br />Embedded Programming and Design,<br />Motion Controllers, <br />SCADA HMI<br />DCS <br />
  6. 6. STRATEGY<br /><ul><li>Project Management.
  7. 7. Design, Engineering & Supply.
  8. 8. Software Development.
  9. 9. Total Staging / Factory acceptance test.
  10. 10. Supervision of erection and commissioning.
  11. 11. Training
  12. 12. Documentation</li></li></ul><li>SCOPE / DOMAIN<br /><ul><li>Panel Engineering
  13. 13. PLC /SCADA System integration
  14. 14. Embedded Systems / Controllers
  15. 15. Servo/AC drives applications
  16. 16. Products / Components
  17. 17. Sensors and Switches marketing
  18. 18. Commissioning
  19. 19. Training</li></li></ul><li>BUSINESS BY INDUSTRY SEGMENT <br /><ul><li> Military / Defense,
  20. 20. Aerospace,
  21. 21. Avionics,
  22. 22. Telecommunications,
  23. 23. Automotive,
  24. 24. Semiconductor / electronics / electrical,
  25. 25. Machinery,
  26. 26. Medical and life science markets.</li></li></ul><li>What is AUTOMATION<br />Making “ Automate - (ic) ”<br />Auto – to do by itself<br />
  27. 27. What happens if “man” works,Constantly and continuously ???<br />ERRORS !!!, ERRORS !!! , ERRORS !!!<br />Why ??<br />Due to fatigue and over confidence<br />
  28. 28. Automation<br />In other words,Using technology in the placeswhere “human errors” are possible.And using “manpower” in “appropriate way”<br />
  29. 29. How do you do ?<br />Simplification<br />through applying ideas of <br />appropriate Branch of Engineering<br /> Electrical, <br /> Electronics, <br /> Mechanical, <br /> Instrumentation, <br /> Mechatronics, <br /> Optical,<br />Almost You apply All branches of SCIENCE and ENGINEERING<br />
  30. 30. Replace Human . . ,<br />What do you do ?<br />If we <br />Consider,<br />Then,<br />MAN : MACHINE<br />EYE : Photo-Electric Sensors , Vision systems<br />EAR : Ultrasonic, Sound ,Vibratory Sensors<br />SKIN : Temperature, Magnetic, Tactile, Shock, Viscosity, Flow, Etc..<br />NOSE : Chemical Sensors,<br />TONGUE : Bio sensors<br />INPUTS<br />HANDS : Grippers , Motion Controllers<br />LEGS : Motion Controllers,<br />MOUTH : Speakers, Indicators, Communication Devices,<br />OUTPUTS<br />CONTROL SYSTEM<br />BRAIN : CONTROLLERS<br />
  31. 31. 14<br />How Industrial Automation Helps?<br />1- You get product CONSISTENCY<br />2- PRODUCTION rate is maximised<br />3- You Save lot of POWER<br />4- Easy Maintenance<br />5- Prevention of Human accidents<br />6- Minimizing Wastages<br />7- Reducing Man Power<br />8- Saving Time<br />9- Easy & Systematic accounting<br />
  32. 32. WHAT IS A <br />PLC ? ? ?<br />
  33. 33. PLC <br />A device used to automate monitoring and control of industrial plant can be used stand-alone or in conjunction with a SCADA or other system.<br />PROGRAMMABLE LOGIC CONTROLLER<br />(IN OTHER WORDS..)<br /> The “logic” “controller” which is “programmable”<br />DEFINITION:<br />
  34. 34. PROGRAMMABLE LOGIC CONTROLLER<br />Invented in 1968 as a substitute for hardwired relay panels.<br />"A digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions such as logic sequencing, timing, counting, and arithmetic to control, through digital or analog input/output modules, various types of machines or processes. <br /> The digital computer which is used to perform the functions of a programmable controller is considered to be within this scope. Excluded are drum and other similar mechanical sequencing controllers."<br />
  35. 35. Understanding PLC<br />Understanding the Logic<br />Understanding the Controller<br />Understanding the Program.<br />
  36. 36. LOGIC<br />Meaningful things<br />Electrically Meaningful – <br />Electrical Logic<br />True logic:<br />It can be expressed in truth table<br />Pseudo logic:<br />It cannot be expressed in truth table <br />
  41. 41. THE CONTROLLER WILL CONTROL THE LOGIC, AS PER THE DEFINED PROGRAM</li></li></ul><li>A small PLC (Allen Bradley MicroLogix 1000)(Courtesy of Allen-Bradley).<br />
  42. 42. Definition of PLC<br />PLC is a digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions such as logic sequencing, timing, counting, and arithmetic to control, through digital or analog input/output modules, various types of machines or processes.<br />Modern PLC can be viewed as specialized computer<br />Specialized in logic control<br />Handle harsh and noisy environment <br />
  43. 43. Structures<br />
  44. 44. 5/17/2011<br />Input / Output module<br />Analog inputs<br />Flow sensors<br />Humidity sensors<br />Potentiometers<br />Pressure sensors<br />Temperature sensors<br />Analog outputs<br />Analog meters<br />Analog valves and actuators<br />DC and AC motor drives<br />Digital input/output<br />Bar code, encoder<br />Display<br />Special purpose I/O<br />PID controller<br />Fast input<br />Network module<br />
  45. 45. 5/17/2011<br />Memory<br />ROM<br />RAM<br />PROM<br />EPROM<br />etc<br />
  46. 46. Peripherals<br />Operator console<br />Printer<br />Simulator<br />EPROM loader<br />Network communication<br />PC based programming software<br />
  47. 47. Functions of PLC<br />Relay<br />Timer and counter<br />Program control<br />Arithmetic<br />Data manipulation<br />Data transfer<br />Others, such as sequencers<br />
  48. 48. A Relay<br />
  49. 49. A counter<br />
  50. 50. Counter timing diagram (the count value is 5)<br />
  51. 51. A timer<br />
  52. 52. Timer timing diagram (the timing value is 5)<br />
  53. 53. Logic control<br />Control actions are taken by making decisions depending on the values associated with various inputs or variables and the control logic in the program.<br />Decisions by attributes (go-nogo decision)<br />Is the machine turned on?<br />Is the gate to the work cell open?<br />Has the AGV arrived at the docking station?<br />Decision by variables<br />How deep is the hole?<br />What is the cutting speed?<br />What is the required surface finish?<br />How many parts are to be made?<br />
  54. 54. Logic control<br />Attribute decision can be represented by a logic variable (true or false) and its value can be determined by a logic expression<br />Boolean algebra is used for logic expression<br />
  55. 55. Logic network diagram and ladder diagram<br />
  56. 56. Example 1<br />A robot is to be used to unload finished parts from a machine onto an AGV and to load raw parts from the AGV to the machine. <br />Assume that there are sensors at the AGV's docking station to indicate the arrival of a vehicle and onboard sensors indicating whether the vehicle has brought a raw part to be processed as well as whether the AGV has space to carry away a finished part.<br /> Also assume there are sensors on the machine to indicate whether the machine is loaded with a part and also to signal completion of part processing. <br />The robot is required to unload a processed part from the machine onto the AGV, pick up a new part for processing from the AGV, and load it onto the machine. <br />The AGV is to be dispatched after completion of the cycle. Construct a ladder logic diagram for this task.<br />
  57. 57. Identify I/Os<br />01 AGV has arrived<br />02 AGV is carrying a new part to be processed<br />03 AGV has space to store a processed part<br />04 Machine has a finished part to be unloaded<br />20 Unload old part from machine onto the AGV<br />21 Pick new part from the AGV and load onto the machine<br />22 Dispatch the AGV<br />
  58. 58. The Ladder Diagram<br />
  59. 59. Features of Ladder Diagram<br />A ladder logic diagram is made up of inputs and outputs connected according to the appropriate logic.<br />Each rung in the ladder represents a set of logical relationships between the inputs that leads to a particular output. <br />The output from one rung of the ladder could be used as an input in another rung of the same ladder. <br />Except when special provisions are made, it is considered that all rungs in a given ladder logic diagram are executed simultaneously, so the order of the rungs on the ladder in general does not matter.<br />
  60. 60. PLC scan<br />
  61. 61. Example 2<br />
  62. 62. 5/17/2011<br />Identified I/Os<br />
  63. 63. 5/17/2011<br />Program<br />
  64. 64. Wiring diagram<br />
  65. 65. Example 3<br />During the powder metallurgy process, a punch is used to press blended metal powder into a compact inside a die.<br /> A pushbutton is used to start the process. When the start button is pressed, the die is filled with powder.<br /> The punch is then advanced and it applies pressure to the powder for a duration of 10 s, after which it is retracted. <br />The pressed compact is then ejected from the die and the cycle repeats. The cycle can be interrupted by pressing a stop button. <br />If the stop button is pressed, the punch is required to retract (if it had been advanced) before the process is stopped. We are required to construct a ladder logic diagram for this task.<br />
  66. 66. Identify I/Os<br />
  67. 67. Ladder Diagram<br />
  68. 68. Example 4<br />This example illustrates the use of both the timing and counting functions.<br />Consider a production line in which parts requiring processing are brought to a machine by a conveyor. <br />A robot is used to load parts from the conveyor onto the machine and, after the part has been processed, unload the part from the machine and place it on a pallet. <br />The cycle time for processing each part is 10 min. The robot is to palletize the parts by placing 125 parts on each pallet. The parts are to be arranged on the pallet in five layers of 25 parts each.<br />Once a pallet is complete, it is dispatched and a new pallet is started. An allowance of 30 s is to be made for pallet dispatching and presentation of a new pallet. Construct a ladder logic diagram to effect the required control.<br />