Plc presentation

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Plc presentation

  1. 1. PROGRAMMABLE LOGIC CONTROLLER
  2. 2. Control Systems TypesControl Systems Types  Programmable Logic Controllers  Distributed Control System  PC- Based Controls
  3. 3. Programmable Logic ControllersProgrammable Logic Controllers PLC  Sequential logic solver  PID Calculations.  Advanced Subroutines  BIT Operations.  Data Transfer.  Text Handling.
  4. 4. Applications :  Machine controls, Packaging, Palletizing, Material handling, similar Sequential task as well as Process control Advantages of PLC :  They are fast and designed for the rugged industrial environment.  They are attractive on Cost-Per-Point Basis.  These Devices are less Proprietary ( E.g.. Using Open Bus Interface.)  These Systems are upgraded to add more Intelligence and Capabilities with dedicated PID and Ethernet Modules. Disadvantages of PLC :  PLC were Designed for Relay Logic Ladder and have Difficulty with some Smart Devices.  To maximize PLC performance and Flexibility, a number of Optional Modules must be added Programmable Logic ControllersProgrammable Logic Controllers
  5. 5. PLC Types  Nano (Small)  Micro (Medium)  Large Basic criteria for PLC Types  Memory Capacity  I/O Range  Packaging and Cost per Point Programmable Logic ControllersProgrammable Logic Controllers
  6. 6. Components  Central Processing Unit (CPU)  Input Output Modules  Power Supply  Bus system Programmable Logic ControllersProgrammable Logic Controllers
  7. 7. Central Processing Unit  It is a micro-controller based circuitary. The CPU consists of following blocks : Arithmatic Logic Unit (ALU), Program memory Process image memory (Internal memory of CPU) Internal timers and counters Flags  CPU performs the task necessary to fulfill the PLC funtions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device communication, special functions or data handling execution and self diagnistics. Programmable Logic ControllersProgrammable Logic Controllers
  8. 8. Input module  These modules act as interface between real-time status of process variable and the CPU.  Analog input module : Typical input to these modules is 4-20 mA, 0-10 V Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple (mV)  Digital input module : Typical input to these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Switches, Pushbuttons, Relays, pump valve on off status Programmable Logic ControllersProgrammable Logic Controllers
  9. 9. Output module  These modules act as link between the CPU and the output devices in the field.  Analog output module : Typical output from these modules is 4-20 mA, 0-10 V Ex : Control Valve, Speed, Vibration  Digital output module : Typical output from these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on off control Programmable Logic ControllersProgrammable Logic Controllers
  10. 10. Power Supply  The power supply gives the voltage required for electronics module (I/O Logic signals, CPU, memory unit and peripheral devices) of the PLC from the line supply.  The power supply provides isolation necessary to protect the solid state devices from most high voltage line spikes.  As I/O is expanded, some PLC may require additional power supplies in order to maintain proper power levels. Programmable Logic ControllersProgrammable Logic Controllers
  11. 11. Bus System  It is path for the transmission of the signal . Bu system is responsible for the signal exchange between processor and I/O modules  The bus system comprise of several single line ie wires / tracks Programmable Logic ControllersProgrammable Logic Controllers
  12. 12. PLC CyclePLC Cycle Outputs Machine or Process Programmable controller Inputs  Sense the Input  Process the Logic  Give Output
  13. 13. PLC Signal FlowPLC Signal Flow Programming Terminal O:0/7 O:0/7 O:1/5 Output Devices Output ModulesProcessor MemoryInput Module Input Devices Ladder Program O:0/7 O:1/5 I:0/6 I:1/4 O:1/5 I:0/6 I:1/4 I:0/6 I:1/4 DataInput Image Table Output Image Table
  14. 14. PLC Architecture EvolutionPLC Architecture Evolution Mid - 1970s : Discrete Machine Control Programming Terminal PLC I/O Connection is Point to Point Programming Language : - Relay ladder logic - Flexibility in altering Control system operation Connection is Point to Point
  15. 15. Early - to - Mid 1980 : Discrete and Process Control PLC Architecture EvolutionPLC Architecture Evolution Reasonable Computer Running PLC Programming Software PLC I/O Programming Language : - Ladder Program - PID - Data Storage MS - DOS
  16. 16. PLC Architecture EvolutionPLC Architecture Evolution Late 1980’s to early 1990’s : Discrete and Process Control PC running PLC Programming Software PLC I/O Connection in networked allowing Multiple PLC PLC became a part of the developing enterprise resource system Windows PLC
  17. 17. TodayToday :: Distributed I/O ModulesDistributed I/O Modules Distributed I/O modules PL C Distributed I/O scanner Data Communication Bus PLC Architecture EvolutionPLC Architecture Evolution
  18. 18. Remote I/O Network SPLITTERS FIBER OPTIC LINK TAPS Remote I/O Today :Today : Hot Redundant SystemHot Redundant System PLC Architecture EvolutionPLC Architecture Evolution
  19. 19. Controller Controller Controller Controller Workstation Workstation Workstation Workstation Switched Hub PLC Architecture EvolutionPLC Architecture Evolution Today :Today : Ethernet Technology in PLCsEthernet Technology in PLCs
  20. 20. Remote Platform Wireless Modem Wireless Modem PLC H M I Display PC PLC Architecture EvolutionPLC Architecture Evolution Today :Today : Wireless communicationWireless communication PLC
  21. 21. PLC Systems of various vendorsPLC Systems of various vendors Siemens  S5 -110U, 115U, 135U  S7 - 200, 300, 400 Allen Bradley  Micrologix 1000, 1200, 1500  SLC 5/01, 5/02, 5/03  PLC 5/10, 5/25 and 5/40 Modicon  Nano  Micro  Premium  Quantum
  22. 22. 8 Analog Inputs 1 Analog Output Up/Down Fast Counter Up Counter Programming Terminal PC Connection Unitelway Port for connection of up to 5 Slaves PCMCIA memory expansion port PCMCIA communications port TSX37-22 Built in display for I/O (in-rack, AS-i) and Diag I/O Modules Configuration of PLC : ModiconConfiguration of PLC : Modicon
  23. 23. Configuration of PLC : SiemensConfiguration of PLC : Siemens CPU External Power Supply I/O Modules
  24. 24. Configuration of PLC : Allen BradleyConfiguration of PLC : Allen Bradley CPU Power Supply I/O Modules
  25. 25. Configuration of PLC : GE FANUCConfiguration of PLC : GE FANUC CPU I/O Modules Back plane
  26. 26. PLC Programming StandardsPLC Programming Standards The open, manufacturer-independent programming standard for automation is IEC 61131-3. You can thus choose what configuration interface you wish to use when writing your application :  Ladder Diagram  Instruction List  Function Block Diagram  Sequential Function Chart  Structured Text
  27. 27.  Cost of hardware, software, Integration Engineering, Design, Installation, Start-up and Commissioning, Validation documentation and Execution, Training, Spare parts, Maintenance, System service contract and system life cycle.  Reliability, Flexibility, Scalability and Validatability.  Ease of Database configuration, Graphics development, Interlocks and Batch processing.  Integration of High-level Application.  Control Philosophy for Centralized versus Remote Operator Console or both.  Compliance with an Industry batch standard such as ISA SP88 and new Communication Protocol. PLC DCS Selection CriteriaPLC DCS Selection Criteria

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