PLC2

PLC CONTROLLER
4.1Introduction:
The automatic control of repetitious mechanical or physical operations
is a common control problem, which abounds in great appliances, office
machines, the manufacturing industry, and industryin general.
Traditionally, this type of operation control was done with
electromechanical devices such as relays, timers, and sequencers. If the
control logic changes the circuit must be rewired, moreover General
Motors developed the specifications for a programmable electronic
controller that could change the hard-wired relay circuits. Based on those
specifications, the first Programmable Logic Controller (PLC) developed
by the Gould Modicon Company. [42]
PLCs are solid – state members of the computer family, using integrated
circuits instead of electromechanical devices to implement control
functions. In an automated system, the PLC is commonly regarded as the
heart of the control system. A simplified model of a PLC is designing to
be operating by engineers with perhap a limite knowledge of computer
and computing language.
This chapter provides the overview of the programmable logic controller
(PLC), hardware forms, internal architecture, and software forms which
were used in the current thesis.
4.2 fundamental of Programmable Logic Controller
(PLC):
A programmable logic controller (PLC) is a small, self-contained, rugged

computer designed to control operations and events in an industrial
environment that is to take over the task formerly done with relay logic
controllers. A PLC contains a microprocessor-based controller with
multiple inputs and outputs. The inputs give it information about the
process that it is controlling. These are switches and sensors connected to
an input module to provide the interface with PLC. The outputs are
connected directly or indirectly to actuator controls. Includes solenoids,
motors, motor contactors and warning lights.
Used special software provided by the PLC manufacturer to develope
the PLC program on a separate computer like a personal computer (PC).
[43] [44]
It contains a programmable memory to store instructions and to
implement functions like logic, sequencing, timing, counting and
arithmetic. In order to control machines and processes, It has a major
advantage of changed the PLC diagram after it had been built or worke,
which give a facility of used the same PLC unit for controlling different
systems after remove it each time. [45]
PLCs have the big advantage that the same basic controller can be use
with a formidable range of control systems. To modulated a control
system and the rules that are to be use, all that important is for an
operatoring to key in a different set of instructions. The controller then
monitors the inputs and outputs according to this program and carries out
the control rules for which it has been programmed. [46]
The PLC has many benefits enable us to choose it for controlling design
such as [47]:
1. Small size and durability.
2. Immunity against jamming.
3. Language:
 Easy to teach.
 Easy to use in control.
4. Input and output:
 Standard (Standard) which is in line with the sensors traded and
actuators in the market.
 Modular making it easier to change.
The PLC programmed control devices have some of defects:

 The cost is high relatively so it is not used in the hardware with a
productivity density.
 Relatively slow compared so it cannot be used in systems that
require high speeds in the implementation of programs.
4.3 PLC Components Hardware:
A PLC controller, consists of two basic sections: the central processing
unit and the input/output interface system.
The central processing unit (CPU) governs all PLC activities. The
following three components:[42]
• The processor.
• The memory system.
• The system power supply.
A typical PLC system shown in Figure (4.1) which contains the following
major components.[46]
1. processor unit or central processing unit (CPU): is the unit containing
the microprocessor and this interprets the input signal and carried out the
control actions, according to the program store in its memory,
communicated the decisions as action signal for the output.
2. Power supply unit: needed to converts the AC into DC voltages
necessary for the system and the circuits in the input and output
interfaces.
3. Programming device: utilizing to insert the user program in the
memory unit of the processor. The program is improve in a device and
then relocate to amemory unit of a PLC.
4. Program and data memory unit: The program is stocks that is to be
use for the control procedure to be utilize by the microprocessor and data
stocked from the input for process and for the output for outputtin.
5. input and output interface sections: The processor receive information
from external device and communications interface to external device.
The inputs might be from switches, with the automatic drill, or other
sensors such as photo-electric cells, temperature sensor, or flow sensors,
etc. The outputs might be to motor starter coils, solenoid valves, etc.
input and output devices canbe classified as giving signal which are
discrete, digital or analogue.
6. The communications interface: is used to receive and transmit data on
communication networks from or to other remote PLCs. As device
verification, data acquisition, synchronization between user applications
and connection management.
Figure(4.1) The PLC system[46]
4.4 PLC Software:

Programming languages specified by IEC is the international standard for
programmable controller programming languages:
Ladder diagram (LD): supply a programming style excerpted from
electronic and electrical circuits. LDs are unsuited for the complexity of
controllers and structured programming.
Sequential Function Charts (SFC):is used for structuring the internal
organization of PLC processing elements.
Structured Text (ST): it provides a useful means to handle the complexity
and modularity of modern programmable controllers.
Instruction List (IL): is well suited for solving small straightforward
problems and producing optimized code, but it does not support
structured programming
Function Block Diagram (FBD): a graphical language similar to
Structured Analysis controllers are modelled as signal and data flows
through processing elements.[48]

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PLC CONTROLLER

A programmable logic controller (PLC) is a small, self-contained, rugged

The PLC programmed control devices have some of defects:

Figure(4.1) The PLC system[46]

4.4 PLC Software:

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