International Journal of Advancements in Research & Technology, Volume 3, Issue 8, August-2014 25

ISSN 2278-7763

Conveyor Control Using Programmable Logic Controller

*
Chitra.S,* Lecturer, **Vijaya Raghavan. **Assistant
Department of Electronics and professor, Department of Mining
Communication Engg, Dr.TTIT, Engg, Dr.TTIT, K.G.F,
K.G.F, Email:raghavan_pp@rediffmail.
Email:chitra.sd10@gmail.com com

Abstract
A programmable Logic Controller (PLC) is a as temperature and pressure), and the positions of
specialized computer used for the control and complex positioning systems. PLCs operate electric
operation of manufacturing process and motors, pneumatic or hydraulic cylinders, magnetic
machinery. It uses a programmable memory to relays or solenoids, or analog outputs. The
store instructions and execute functions including input/output arrangements may be built into a
on/off control, timing, counting, sequencing, simple PLC, or the PLC may have external I/O
arithmetic, and data handling. Programmable modules attached to a computer network that plugs
Logic Controllers (PLC) is used in almost every into the PLC. PLCs were invented as replacements
aspect of industry to expand and enhance for automated systems that would use hundreds or

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production. Where older automated systems thousands of relays, cam timers, and drum
would use hundreds or thousands of sequencers. Often, a single PLC can be
electromechanical relays, a single PLC can be programmed to replace thousands of relays.
programmed as an efficient replacement. The Programmable controllers were initially adopted by
functionality of the PLCs has evolved over the the automotive manufacturing industry, where
years to include capabilities beyond typical relay software revision replaced the re-wiring of hard-
control. Sophisticated motion control, process wired control panels when production models
control, distributive control systems, and complex changed. Many of the earliest PLCs expressed all
networking have now been added to the PLC’s decision making logic in simple ladder logic which
Functions. Therefore, PLCs provide many appeared similar to electrical schematic diagrams.
advantages over conventional relay type of control, The electricians were quite able to trace out circuit
including increased reliability, more flexibility, problems with schematic diagrams using ladder
lower cost, communication capability, faster logic. This program notation was chosen to reduce
response time and convenience to troubleshoot. training demands for the existing technicians. Other
The paper is based on systematic conveyor early PLCs used a form of instruction list
controller programming by programmable logic programming, based on a stack-based logic solver.
controller using omron software which is a world The functionality of the PLC has evolved over the
smallest plc, offers variety of expansion options years to include sequential relay control, motion
and has user-friendly software. control, process control, distributed control systems
and networking. The data handling, storage,
processing power and communication capabilities
1. Introduction of some modern PLCs are approximately
equivalent to desktop computers. PLC-like
The PLC is a microcontroller based device with programming combined with remote I/O hardware,
input/output circuitry that monitors the status of allow a general-purpose desktop computer to
field connected sensor (inputs) and controls the overlap some PLCs in certain applications. PLCs
attached (output) actuators (motor -starters, can be programmed using standards-based
Solenoids, Speed drives, Valves etc.) according to programming languages. A graphical programming
a user created logic program stored in the memory. notation called Sequential Function Charts is
The main difference from other computers is that available on certain programmable controllers. The
PLCs are armored for severe condition (dust, primary reason for designing such a device was
moisture, heat, cold, etc) and have the facility for eliminating the large cost involved in replacing the
extensive input/output (I/O) arrangements. These complicated relay based machine control system.
connect the PLC to sensors and actuators. PLCs 1.1 PLC system
read limit switches, analog process variables (such

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• Modules are built into the PLC. The

modules come together in one physical
block. The backplane in this case is
transparent to the user.

Figure 1.1: Block diagram of PLC system.

There are five basic components in a PLC system: Fig 1.2: Backplane in a chassis based system
• The PLC processor or controller
• I/O (Input /Output) modules 1.1.4. Power Supply. A power supply is needed to
• Chassis or backplane provide power to the PLC and any other modules.
• Power supply Power supplies come in various forms:
• Programming software that runs in a PC
• Network Interface • Power supply modules that fit into one
of the slots in a chassis.

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1.1.1. The PLC processor. It stores the control • External power supplies that mount to
program and data in its memory. Reads the status the outside of a chassis.
of connected input devices. Executes the • Stand alone power supplies that
control program. Commands connected outputs to connect to the PLC or I/O through a
change state based on program execution For power cable.
example: Turn a light on, start a fan, adjust a speed, • Embedded power supplies that come as
or temperature and Comes in various physical part of the PLC block.
forms.
1.1.5 Programming Software. Software that runs
1.1.2 I/O Modules. They Physically connect to on a PC is required to configure and program
field devices. Input modules convert electrical PLCs. Different products may require different
signals coming in from input field devices such as programming software. Software allows programs
pushbuttons, to electrical signals that the PLC can to be written in several different languages.
understand. Output modules take information
coming from the PLC and convert it to electrical
signals the output field devices can understand,
such as a motor starter, or a hydraulic solenoid
valve. I/O comes in various forms.

1.1.3 Chassis/Backplane. All PLCs need some

method of communicating between the controller,
I/O and communications modules. Here are three
ways used to accomplish this communications
between the various components that make up the
PLC system.

• Modules are installed in the same

chassis as the PLC and communicate
over the chassis backplane.
• Modules are designed to “plug” into Fig 1.3: PLC program
each other. The interconnecting plugs 1.1.6. Network Interface. Most PLCs have the
form a backplane. There is no chassis. ability to communicate with other devices. These
devices include computers running programming

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software, or collecting data about the PLC architecture design can be an open
manufacturing process, a terminal that lets an architecture design or a closed architecture design.
operator enter commands into the PLC, or I/O that An open architecture design allows the system to
is located in a remote location from the PLC. The be connected easily to any device and also to
PLC will communicate to the other devices through programs developed by other manufacturers. A
a network interface. closed architecture which is also known as
proprietary system is one whose design makes it
more difficult to connect with other devices or
programs developed by other manufacturers. When
working on a proprietary PLC system, all hardware
and software that is used should be compatible
with the PLC.

2.1 Programming in PLCs

Early PLCs, up to the mid-1980s, were

Fig 1.4: Network connecting other devices programmed using proprietary programming panels
or special-purpose programming terminals, which
often had dedicated function keys representing the
various logical elements of PLC programs.
2. PLC Architecture
Programs were stored on cassette tape cartridges.
Facilities for printing and documentation were very
minimal due to lack of memory capacity.PLC
programs are typically written in a special
application on a personal computer, then
downloaded by a direct-connection cable or over a

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network to the PLC. The very oldest PLCs used
non-volatile magnetic core memory but now the
program is stored in the PLC either in battery-
backed-up RAM or some other non-volatile flash
memory. Early PLCs were designed to replace
relay logic systems. These PLCs were programmed
in "ladder logic", which strongly resembles a
schematic diagram of relay logic. Modern PLCs
can be programmed in a variety of ways, from
ladder logic to more traditional programming
languages such as BASIC and C. Another method
is State Logic, a Very High Level Programming
Language designed to program PLCs based on
Fig 2.1: PLC architecture State Transition Diagrams. The International
standard IEC 61131-3 defines five programming
The PLC architecture is divided into three parts: languages for programmable control systems: FBD
a. CPU : It is the brain of PLC system .It (Function block diagram), LD (Ladder diagram),
consists of the microcontroller, Memory ST (Structured text, similar to the Pascal
IC and necessary circuit to store and programming language), IL (Instruction list) and
retrieve information from the memory. SFC (Sequential function chart). These techniques
The Job of CPU is to monitor status or emphasize logical organization of operations.
state of input device, scan and solve the While the fundamental concepts of PLC
logic of a user program and control ON programming are common to all manufacturers,
or OFF state of output device. differences in I/O addressing, memory organization
b. Memory: The type of RAM (Random and instruction sets mean that PLC programs are
Access Memory) normally used is CMOS never perfectly interchangeable between different
(Complementary Metal Oxide makers. Even within the same product line of a
Semiconductor) to store the program. single manufacturer, different models may not be
c. Input/output: Input is the one through directly compatible.
which signal is send and result is observed 2.2. User Interface
at the Output.
PLCs may need to interact with people for the
purpose of configuration, alarm reporting or

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everyday control. A Human-Machine Interface continuity of each rung by referring to the input
(HMI) is employed for this purpose. HMI's are also image table to see if the input conditions are met. If
referred to as MMI's (Man Machine Interface) and the conditions controlling an output are met, the
GUI (Graphical User Interface).A simple system processor immediately writes a 1 in its memory
may use buttons and lights to interact with the user. location, indicating that the output will be turned
Text displays are available as well as graphical ON; conversely, if the conditions are not met a 0
touch screens. Most modern PLCs can indicating that the device will be turned OFF is
communicate over a network to some other system, written into its memory location. And the final
such as a computer running a SCADA (Supervisory step of the scan process is to update the actual
Control And Data Acquisition) system or web states of the output devices by transferring the
browser. output table results to the output module, thereby
switching the connected output devices ON (1) or
2.3. PLC Software OFF (0).

The PLC software is manufacturer dependent and

even when the manufacturer is the same, it may
vary for the different models of the same brand.
For, instance for a manufacturer like Allen Bradley
the software may vary for its PICO Controller
models and other models. For example, the
software used for these controllers is PICO Soft
whereas for its higher models it is RSLogix.
Moreover, the HMI Interface may also vary for the
different controllers.

2.4. Program Scan

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When a PLC executes a program, it must know in
real time when external devices controlling a
process are changing. During each operating cycle,
the processor reads all the inputs, takes these Fig 2.3 Scan process applied to a multiple rung
values, and energizes or de-energizes the outputs program.
according to the user program. This process is
known as a program scan cycle. Figure 2.2
illustrates a single PLC operating cycle consisting
of the input scan, program scan, output scan.

2.5. Ladder programs

Ladder programs process inputs at the beginning of

a scan and outputs at the end of a scan, as
illustrated in Figure 2.3 . For each rung executed,
the PLC processor will perform the following
steps: The first step is to update the input image
table by sensing the voltage of the input terminals. Fig 2.4: Typical micro PLC.
Based on the absence or presence of a voltage, a 0
or a 1 is stored into the memory bit location
designated for a particular input terminal. The
second step is to solve the ladder logic in order to
determine logical continuity. The processor scans
the ladder program and evaluates the logical

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2.6. Latching Relays

Electromagnetic latching relays are designed to The Figure 3.1 illustrates a bottle-filling motion
hold the relay closed after power has been removed control process. This application requires two axes
from the coil. Latching relays are used where it is of motion: the motor operating the bottle filler
necessary for contacts to stay open and/or closed mechanism and the motor controlling the conveyor
even though the coil is energized only speed. The role of each control component can be
momentarily. summarized as follows:

2.7 Ladder Logic 3.1. Programmable Logic Controller

Before a PLC can perform any control task, it must • The controller stores and executes the user
be programmed to do so. The most popular program that controls the process.
language used to program a PLC is ladder logic. It • This program includes motion instructions that
is a graphical, problem oriented programming control axis movements.
language which replicates electronic switching • When the controller encounters a motion
blueprints or circuits. In a conveyor system, we instruction it calculates the motion commands for
have several “requirements” to accomplish; for the axis.
example, timing and counting parts on the • A motion command represents the desired
conveyor. Each of these requirements must be position, velocity, or torque of the servo motor at
programmed into the PLC so that it knows how to the particular time the calculations take place.
respond to different events. The programmer
develops the program, and connects their personal 3.2. Motion Module
computer to the PLC through a network or cable
and then downloads the program to the PLC. The motion module receives motion commands
Ladder logic rungs are basically IF-THEN

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from the controller and transforms them into a
statements. Each individual rung is executed from compatible form the servo drive can understand. In
the left to the right. addition it updates the controller with motor and
drive information used to monitor drive and motor
performance.

3.3. Servo Drive

The servo drive receives the signal provided by the

motion module and translates this signal into motor
drive commands. These commands can include
motor position, velocity, and/or torque. The servo
drive provides power to the servo motors in
response to the motion commands.

Fig 2.5: Example of Ladder Logic diagram 3.4. Servo Motor

3. Block diagram of conveyor Controller • The servo motors represent the axis being
controlled.
• The servo motors receive electrical power from
their servo drive which determines the motor shaft
velocity and position.
• The filler motor must accelerate the filler
mechanism in the direction the bottles are moving,
match their speed, and track the bottles.
• After the bottles have been filled, the filler motor
has to stop and reverse direction to return the filler
mechanism to the starting position to begin the
process again.

Fig 3.1: Bottle filling control process

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4. Programming PLC for Conveyor

The figure 4.2 shows the program for the conveyor:
The first line of code turns on the motor and the
light when a box is detected by photoeye1.
Likewise, the motor and light are turned off when
photoeye2 detects the box in the second line of
code.

Fig 4.1: Example of conveyor

The simulation is done using omron which ensures

that the program can be successfully implemented
in PLC. Today delta PLC is available in market
which helps in easier implementation of the above
required purpose. It uses simple omron motion
language for programming. A PLC program
consists of rules that make logic relation between Fig 4.3: Relay ladder logic
inputs and outputs of the controller. Basically it
uses logic operands: AND, OR, negation. The The third line begins a timer when the box passes
structure of the rules is IF…THEN…ELSE. The by photoeye1, and if the box does not pass by

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PLC reads all field input devices via the input photoeye2 in 30 seconds (the timer counts in
interfaces. Executes the user program stored in milliseconds), the motor and light are shut off by
application memory, then, based on whatever line 4. This is the indication of a jam condition.
control scheme has been programmed by the user.
Turn the field output devices on or off, or perform 4.1. The control system
whatever control is necessary for the process
application. The PLC resolves the program rule by A complete control system is made up of a
rule (sequential execution). The PLC operates in a combination of PLCs, networks, I/O, terminals and
synchronous way i.e. inputs does not change under software. All the components work together to
a scan cycle. And the figure 4.1 shows that when a form a complete control system. The control
box is placed on the conveyor in front of system is the system that is responsible for the
Photoeye 1, Light 1, and Motor 1 will turn on, control of the process. This is the system that
causing the box to move down the conveyor to the includes the PLC, all of the I/O and any Human
left. When the box passes in front of Photoeye 2, Machine Interfaces (HMI).
Motor 1 and Light 1 will turn off, stopping the
conveyor.

Fig 4.2: Relay Ladder Logic Example Fig 4.4: The complete control system

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4.2. Data Acquisition System 6. PLC Applications

• Automotive Industry
• Beverage Industry
• Marine Industry
• Packaging Industry
• Intelligent Motor Control
• Motor Control Applications

7. Conclusion

PLCs are well-adapted to a range of automation

Fig 4.5 : Data acquisition system tasks. These are typically useful in industrial
processes in manufacturing where the cost of
The Data Acquisition system is generally developing and maintaining the automation system
responsible for collecting data about the control is high relative to the total cost of the automation,
system, and storing it on master computers or and where changes to the system would be
servers, or displaying it on terminals. The data is expected during its operational life. PLCs contain
often used later for reporting or charting purposes. input and output devices compatible with industrial
They are made up of devices and networks which pilot devices and controls; little electrical design is
are responsible for acquiring data about the process required, and the design problem centers on
but are not responsible for direct control of the expressing the desired sequence of operations in
process. The network used for data acquisition is ladder logic (or function chart) notation. PLC
often Ethernet. While data acquisition devices can applications are typically highly customized
exist directly on the control network, a gateway is systems so the cost of a packaged PLC is low

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often used to separate network traffic between the compared to the cost of a specific custom-built
data acquisition system and the control system. controller design. On the other hand, in the case of
mass-produced goods, customized control systems
are economic due to the lower cost of the
components, which can be optimally chosen
instead of a "generic" solution, and where the non-
recurring engineering charges are spread over
thousands of places.

8. References
[1] Guo, L., Pecen, R., “Design Projects in a
Programmable Logic Controller (PLC) Course in
Electrical Engineering Technology”, ASEE Annual
Conference & Exposition, 2008
[2] Johnson, C. D., Process Control Instrumentation
Technology, Prentice Hall, 2006
[3] Petruzella, F. D., Programmable Logic Controllers,
McGraw Hill, 2005
Fig 4.6: Omron PLC with modbus-RTU [4] Yang, G., Rasis, Y., “Teaching PLC in Automation –
network A Case Study”, ASEE Annual Conference &
Exposition, 2003
5. Advantages of PLC [5] URL: http://read-out.net/signpost/oid.html; Education
and Research in the area of Measurement, Control and
• Cost effective for controlling complex Automation.
system. [6] URL: http://www.plcs.net; Your Personal PLC Tutor
• Flexible and can be reapplied to control Site - The BEST Place to Learn PLC Programming.
other system quickly and easily. [7] URL: http://www.me.ua.edu/ME360/plc; ME 360 -
• Computational abilities allow more Programmable Logic Controller Module.
sophisticated control.
• Trouble shooting aids make programming
easier and reduce downtime.
• Reliable components make these likely to
operate for longer life.

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