This document provides an overview of programmable logic controllers (PLCs), including their history, components, and applications across various industries. It details the functionalities of PLCs, such as input/output processing, monitoring sensors, and controlling systems, and also introduces microcontrollers and the architecture of PLCs. Additionally, it explains various control systems and the types of processes that PLCs can manage, highlighting their significance in automation and industrial control.

1. Session 01
By Emamof
Presented in 02-02-2009

3. TARGET TO 
 CONTROL SYS.
 Automatic Controller
 WHAT
 Origin of PLC
 History
 Sizes of PLC’s
 Cycle of Operation
 Which
 APPLICATIONS N REAL
 PLC H.W Components:
 INPUT TO PLC ,SENSING CONCEPTS

5. Open
loop
Closed
loop
Control
System

7. Analog
Digital
Control
System

8. Control
system
Motion Sequential

9. Batch Process
has a beginning and an end “complete
product control process” , Some
applications require that specific quantities
of raw materials be combined in specific
ways for particular durations to produce
an intermediate or end result.
Example:
production of food and medicine.

10. Continuous Process
Often, a physical system is represented though
variables that are smooth and uninterrupted in
time.
Example :control of the water temperature in a
heating jacket,

11. Discrete
It is Not independent, Most discrete
manufacturing involves the production of
discrete pieces of product
Examples :
 metal stamping.
 automotive production.

12. Hybrid
 Applications having elements of
discrete, batch and continuous process
control are often called hybrid
applications.

13. Sequential Control
Control a process that is a series of tasks to be
performed (sequence of operation ),each task
is performed under :-
 Time driven . Common in open loop sys
 Event driven . Common in closed loop sys
Example washing machine
In PLC the SFC is powerful Lang for it .

14. Motion Control
Controlling motion in electromechanical sys
 Rotational or Linear by Servomotor.
 Digital by NC (Numerical Control).
 3 dimension by Robotic.

16. µC
DCS PC
Mr.
CNC CONTROLLER
PLC
SCADA PAC
FPGA

17. Automatic controllers
 µC==Microcontroller.
 FPGA not FBGA.
 PC
 Mr. PLC
 DCS== Distributed Control System
 SCADA == Supervisory Control And Data Acquisition
 CNC == Computer Numerical Control
 PAC ==Programmable Automation Controller

18. SCADA

21. WHAT
 Programmable logic controllers, also called
programmable controllers or PLCs, are
solid-state members of the computer
family, using integrated circuits instead of
electromechanical devices to implement
control functions.
 They are capable of storing
instructions, such as
sequencing, timing, counting, arithmetic, dat
a manipulation, and communication, to
control industrial machines and processes

23. Intro 2 Microprocessor and
Microcontroller world.

24. Microprocessor
The block that will have a built in
capability to Add “multiply, divide,
subtract”, and move its contents from
one memory location onto another is
called "central processing unit" (CPU).

25. Characteristics differentiate
microprocessors
 Instruction set The set of instructions that
the microprocessor can execute
 bandwidth The number of bits processed
in a single instruction
 clock speed Given in megahertz MHz
the clock speed determines how many
instructions per second the processor can
execute

26. Microcontroller
A microcontroller (also MCU or µC) is a
functional computer system-on-a-chip.
It contains a processor core, memory, and
programmable input/output peripherals.

27. Microcontroller Architecture

28. Why
 Coz we can say
 Microcontroller= Microprocessor +Memory
+i/o Peripherals.
 PLC’s=Microcontroller +I/O Interfaces.

30. Dick Morley==Richard E. Morley
Founder of Modicon (now Schneider Automation, Inc)

31. History of PLCs
 The first Programmable Logic Controllers were
designed and developed by Modicon as a relay
replacer for GM and Landis
 The first PLC, model 084, was invented by Dick
Morley in 1969
 The first commercial successful PLC, the 184, was
designed by Michael Greenberg in 1973

33. Sizes of PLC’s

34. Single Board PLCs “ Open Frame
PLCs”.

36. PLC System With High-Density
I/O (64-point modules).

37. PLC market can
be segmented
into five groups:
1. micro
2. small
3. medium
4. large
5. very large

41. Cycle of operate PLC’s
input 
scan

execute
programme

degonistic and
commenucation
scan

output scan

43. PLC conceptual application
diagram.

44. Sequence of PLC control
 When a process is controlled by a PLC it
uses inputs from sensors to make
decisions and update outputs to drive
actuators
 The process is a real process that will
change over time. Actuators will drive the
system to new states (or modes of
operation). This means that the controller is
limited by the sensors available, if an input
is not available, the controller will have no
way to detect a condition “real time
system “.

46. Number Of
Scan Special I/O
Time Modules
Memory Communications
Software
Number Of
Availability
Logical I/O
Select
PLC Peripherals
Type Of
Controller

48. Packaging Machine

49. Pick And Place Robot Control

50. swimming pool

51. sewage/water treatment

52. Chemical processing plant

53. Food/Drugs Production

54. Petrochemical ,Petrol/Gas Plant

55. Amusement Park Control

56. Scientific Experiments CERN LHC
CERN built LHC 27Klm …this experiment is controlled by PLC

57. Also
 Martial Handling Plastic Machine
 Conveyor System Semi Conductors/IC
 Pump Control Manufacturing
 Paper And Pulp Industries Air Condition Control "For
 Glass Manufacturing Huge Sheller "
 Precast Concrete Generator Control System
Industries Lift Control System
 Cement Manufacture Iron And Steel
Manufacturing
 Printing Industries
Traffic Light System
 Electro-plating Plants Power Stations
 Machine Tools

58. BUT
there is NO horizon for the Applications !!

60. PLC H.W Components:
 CPU =ALU +CU
 System Busses
 Memory
 I/O Sections
 Power Supply Unit
 Programming Device

61. Programming Device
The programming device is used to enter
the required program into the memory of
the processor.
The program is DEVELOPED in the
programming device and then
TRANSFERRED TO MEMORY unit of
the PLC.

62. CPU
Microprocessor based, allow arithmetic
operations, logic operators, block memory
moves, computer interface ,and local area
network, functions,.. etc.
CPU makes a great number of CHECK-UPS of the
PLC controller itself so eventual errors would be
discovered early.
This is an intro to a point in next session

63. I/O Sections
Inputs monitor field devices, such as
switches and sensors.
Outputs control other devices, such as
motors, pumps, solenoid valves, and
lights.

64. Power Supply Unit
Most PLC controllers work either at 24
VDC or 220 VAC.
Some PLC controllers have electrical
supply as a separate module, while
small and medium series already
contain the supply module.
Max current is 10mA.

65. Memory
System (ROM) to give permanent storage
for the operating system and the fixed
data used by the CPU.RAM for data.
This is where information is stored on
the status of input and output devices
and the values of timers and counters
and other internal devices. EPROM for
ROM’s that can be programmed and
then the program made permanent.

66. Cpu

67. Von Neumann

68. System Busses
The internal paths along which the digital
signals flow within the PLC are called
busses.
The system has four busses:
 The CPU uses the DATA BUS for sending data
between the different elements,
 The ADDRESS BUS to send the addresses of
locations for accessing stored data,
 The CONTROL BUS for signals relating to
internal control actions,
 The SYSTEM BUS is used for communications
between the I/O ports and the I/O unit.

70. Switches

74. Proximity
switch
Inductive Capacitive

76. Sensors
 Feed back elements which convert the
physical quantity into electrical signals
 Now we introduce some sensors as
refreshment ,Let me go ahead ☺

77. Useful Rule
If
U can measure it ,
U can control it
Obama say if the sun light is can measure it and emamof say this is the 1st exception is provide the truth of
the rule 

78. 1- Potentiometers

80. 2- Encoders

81. Incremental encoder

82. 3 -Tachometers

83. Tachometers

84. 4- Linear Variable Differential
Transformers (LVDTs)

85. LVDTs

86. 5 - Moire Fringes

87. $5 Moire Fringes
 These are used in high precision applications
over long distances, often meters.
 They can be purchased from a number of
suppliers, but the cost will be high. Typical
applications include Coordinate Measuring
Machines (CMMs).

88. $6 Accelerometers

90. 6- Chemical pH
 The pH of an ionic fluid can be measured
over the range from a strong base
(alkaline) with pH=14, to a neutral value,
pH=7, to a strong acid, pH=0. These
measurements are normally made with
electrodes that are in direct contact with
the fluids.

92. 7 -Thermocouples

94. 8 -Resistive Temperature
Detectors (RTDs)

95. RTDs

96. 9 -Venturi Valves

97. 10-Photoelectric

98. OPPOSED

99. RETRO REFLECTIVE

100. REFLECTION

103. IR TEMP SENSORS

104. 11- Pressure

106. Break
 Can u tell me which of sensors can use
as position sensor in last example ?

107.  This is not all thing about sensors we
can not talk about more, Coz the target
is DONE ISA

108. KEY TERMS 
 DICK MORLY
 EMAMOF
 FDX CYCLE
 OPERATION CYCLE
 SELECTION of Ms. PLC
 TYPES, SIZE, INFRASTRUCTURE
 SENSING TECHNIQUES