IC0405 - Industrial Automation
Short Description
PLC TRAINING PLC BASIC CONCEPTS...
Description
PLC TRAINING PLC Title of presentation BASIC CONCEPTS
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Basics Concepts of PLC
PLC & PC In Comparison PLC
Computer CPU/Memory
CPU/ RAM/ Hard disk
CPU/ RAM/ Flash Card
Power Supply
220V AC, 1 Ph.
220V AC / 24V DC
Key board, Mouse, Remote station (LAN)
Push Button, Selector, Limit Switch, PxS, Bus Interface
Inputs
Outputs
Monitor, Printer, Projector Etc.,
Solenoids, Relays, Lamps, Motors, HMI
Software
OS: Windows XP / SW: MS Office
OS: Firmware / SW: Machine Logic
Internal
Calculator etc.,
Markers, Timers, Counters, FBs
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Basics Concepts of PLC
Machine Automation Over View
Controller
Command Signals
Status Signals
Push Buttons, Selector Switches
Limit Switch, Proximity, Reed Switch etc.,
Inputs Basics Concepts of PLC Outputs
Relays, Solenoids, Power contactors
Actuators: Motors, Cylinders, Heaters, Lamps etc., HMI
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Machine
Basics Concepts of PLC
Inputs – Sample Pictures Selector Switch
Push Button
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Basics Concepts of PLC
Outputs ‐ Switch Gear Products Over View Power Contactor
Over Load Relay
Aux. Contactor
Relay Boards
Relays
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Basics Concepts of PLC
Outputs ‐ Actuators Cylinders
Solenoid Coils
Servo Motor
Manifold Block
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Basics Concepts of PLC
History of PLC
Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was accomplished using hundreds or thousands of relays, cam timers, and drum sequencers and dedicated closed‐loop controllers. The process for updating such facilities for the yearly model change‐over was very time consuming and expensive, as electricians needed to individually rewire each and every relay.
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Basics Concepts of PLC
What is a PLC ?
The PLC is an industrial computer. It is capable of storing instructions to implement control functions such as sequencing, timing, counting, arithmetic, data manipulation and communication. The I/O interfaces provide the connection between the PLC and the information providers (inputs like pushbuttons, sensors,…) and the controllable devices (outputs like valves, relays, lamps,…).
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Basics Concepts of PLC
Where is the PLC used ?
The PLC controls industrial machines and processes. In different areas of the industry PLC are being applied, e.g.: materials handling, packaging, palletizing, milling, boring, grinding, filling, sorting, weighing,...etc.
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Basics Concepts of PLC
How does PLC work ?
In the past the movements of industrial machines were controlled by relay circuits. These relay-controlled systems were replaced by PLC. The primary function of the PLC was to perform the sequential operations that were previously implemented with relays. Before we can talk about the working method of an PLC, we must understand the function of relay circuits.
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Basics Concepts of PLC
What is a Relay ?
A relay is an electrical switch. It contains: a coil a iron core
a switch and a iron bar connected to the switch
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Basics Concepts of PLC
How does a Relay work ?
When a current goes through the coil... I
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Basics Concepts of PLC
How does a Relay work ?
… a magnetic field is produced in the coil and the iron core in the coil becomes magnetic. I
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Basics Concepts of PLC
How does a Relay work ?
The electromagnetic force pulls in the switch and... I
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Basics Concepts of PLC
How does a Relay work ?
…a current can go through the switch. I
I
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Basics Concepts of PLC
How does the PLC replace Relay in an electric circuit ?
The answer to this question shall be shown with the following example circuits, A, B, C, and D.
A). 24V
technical symbol internal of a relay switch
S1 electro magn. connection coil K1
L1
0V
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Basics Concepts of PLC
How does the PLC replace Relay in an electric circuit ?
The answer of this question shall be shown with a little example circuit.
B). Function of the electrical circuit:
24V
When the user presses button S1, the relay K1 pulls in its internal switch and the lamp L1 turns on.
S1
K1
L1
0V
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Basics Concepts of PLC
How does the PLC replace Relay in an electric circuit ?
The answer of this question shall be shown with a little example circuit.
C). 24V
24V
S1 S1 Input
Power
PLC Power K1 0V
Output
L1
L1 0V
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Basics Concepts of PLC
How does the PLC replace Relay in an electric circuit ?
The answer of this question shall be shown with a little example circuit.
D). 24V
24V
S1
PLC logic
S1
K1 0V
L1
L1 0V
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Basics Concepts of PLC
What is PLC logic ?
The PLC logic is not a mechanical part of the controller. The PLC logic is a software program, which runs on the processor in the PLC. This program has to be created with a special programming tool on a PC. After downloading the the program into the PLC, the control 24V automatically starts the program. S1
SPS logic
L1 0V
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Basics Concepts of PLC RELAY LOGIC Ph.
220V AC SUPPLY START PB
STOP PB
N PC
TMR1
PC
TMR1
LADDER PROGRAM I1
M1
I2
Q1
Q1 TMR1 En
Q1
Trig
T#5s
Time
M1 Q
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Basics Concepts of PLC
How a PLC works: internal network
Communication module
Programming tool
power cord
PLC
RAM
E-EPROM
CPU
Power supply
Input modules
Output modules
Machine
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Basics Concepts of PLC
How a PLC works: internal network
Communication module
Programming tool
power cord
PLC RAM
E-EPROM
CPU
Power supply
Central processing unit
Input modules
Output modules
Machine
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Basics Concepts of PLC
How a PLC works: internal network
Communication module
Programming tool
power cord
PLC
RAM
E-EPROM
CPU
Power supply
Working- and program memory
Input modules
Output modules
Machine
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Basics Concepts of PLC
How a PLC works: internal network
Communication module
Programming tool
power cord
PLC RAM
E-EPROM
CPU
Power supply
Input modules
Program editor and monitoring
Output modules
Machine
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Basics Concepts of PLC
How a PLC works: internal network
Communication module
Programming tool
power cord
PLC RAM
E-EPROM
CPU
Power supply
Sensor signal input
Input modules
Output modules
Machine
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Basics Concepts of PLC
How a PLC works: internal network
Communication module
Programming tool
power cord
PLC RAM
E-EPROM
CPU
Power supply
Actuator command output
Input modules
Output modules
Machine
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Basics Concepts of PLC
How a PLC works: internal network
Communication module
Programming tool
power cord
PLC RAM
E-EPROM
CPU
Power supply
Control communication
Input modules
Output modules
Machine
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Basics Concepts of PLC
How PLC works: processing cycle
Start PLC from E-EPROM Read user program & Copy to RAM Read input signals, store in table
processing cycle
Determine new output state of output module Write output commands in table Set output values on output module
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Basics Concepts of PLC
Pick & Place Unit Schematic:
swivel device pick
shuttle cylinder
up/down cylinder
suction pad
place
Starting position: vac. off, slide right, up; swivel not used (front position) Sequence of movements: 1) slide left 5) move down 2) move down & switch on vacuum 6) switch off vacuum 3) move up 7) move up 4) slide right
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Basics Concepts of PLC Animation:
Sequence of movements: slide left move down & vacuum on move up slide right move down vacuum off move up
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