Programmable Logic Controllers

Vocational Training

at IATC

in Industrial Automation

(PROGRAMMABLE

LOGIC CONTROLLERS)

Submitted By:Anchit Walia (C08507)

Manik Jain (C08531)

INDEX

• Company Profile

• Implementation Environment

• Introduction to Automation

• Configuration of PLC

• Hardware Configuration

• Language Used

• Applications Of PLC

• Our Project : “TOTAL TRAFFIC SECURITY & MANAGEMENT SYSTEM”

• Conclusion

Industrial Automation

Training Centre

(IATC) - Panchkula

Where the maxim of training is

“Learning by Doing” “Translating Skills into Success”

Partners in Promotion

IAG Automation Private Limited

(Private Partner)

German Technical Cooperation (GTZ)

(Executive Organization)

SIEMENS

(Supporting Multinational Company)

Implementation Environment

Software Used1. MicroWin version 4.0

2. Simatic Manager 5.4

3. PLC Simulator

Hardware Used1. Operating System i.e. Computer with windows XP

professionals sp2

2. PLC trainer kit

3. PLC ( S7-200/300)

4. PROFIBUS

5. MPI/PPI

6. Expansion Modules

Laboratory at IATC

Automation

AC / DC Drives

Switchgears

Industrial Hydraulics/Pneumatics

CNC Centre

Computer Centre

Machine Shop

Automation Lab

PLC Hardware Configuration

PLC Program development

S7 300 PLC training kits

S7 200 PLC training kits

Industrial Automation

Automation is encompassing virtually every

walk of life.

Automation solutions are required right from

agricultural to space technology.

Plant Automation is the necessity for the

manufacturing industry to survive in today’s

globally competitive market

What is Automation ?

Automation is basically the delegation of human control

function to technical equipment for

•Increasing Productivity

• Increasing Quality

• Reducing Cost

• Increasing Safety in working conditions

History of Automation

Pneumatic Control

Hard wired logic Control

Electronic Control using Logic Gates

Programmable Logic Controller

Manual Control

Manual Control

All the actions related to process control are taken by the operators

Drawbacks

Likely human errors and consequently its effect on quality of final product

The production, safety, energy consumption and usage of raw material are all subject to the correctness and accuracy of human action.

Pneumatic ControlIndustrial automation, with its machine and process control, had its origin in the 1920s with the advent of "Pneumatic Controllers".

Actions were controlled by a simple manipulation of pneumatic valves, which in turn were controlled by relays and switches.

Drawbacks

• Bulky and Complex System• Involves lot of rework to implement control logic• Longer project time

Hard wired logic control

The contactor and Relays together with hardware timers and counters were used in achieving the desired level of automation

Drawbacks

• Bulky panels• Complex wiring• Longer project time• Difficult maintenance and troubleshooting

Electronic Control using Logic Gates

In 1960s with the advent of electronics, the logic gates started replacing the relays and auxiliary contactors in the control circuits.

The hardware timers & counters were replaced by electronic timers

Advantages

Drawbacks

•Reduced space requirements•Energy saving•Less maintenance & greater reliability

•Changes in control logic not possible•More project time

Programmable Logic Controllers

In 1970s with the coming of microprocessors and associated peripheral chips, the whole process of control and automation underwent a radical change.

Instead of achieving the desired control or automation through physical

wiring of control devices, in PLC it is achieved through a program or say

software.

The programmable controllers have in recent years experienced an

unprecedented growth as universal element in Industrial Automation.

It can be effectively used in applications ranging from simple control like replacing small number of relays to complex automation problems

Advantages of PLCs

Reduced space Energy saving Ease of maintenance Economical Greater life & reliability Tremendous flexibility Shorter project time Easier storage, archiving and documentationFast and Less time consumingMore accurateAbility to pass heritageReduces complexity of tasks

CPU

External Power

Supply

I/O Modules

The PLC is programmed interface between the field I/p element like limit switches, sensors, push button and the final control elements like actuator, solenoid/control valves, drives, hooters etc

PLC consist of :

Input Module

CPU with Processor and Program memory

Output module

Bus System

Power Supply

Power

Supply

Input Module CPU

Program Memory

Output Module

Field Inputs Control Elements

PROCESS/MACHINE

CONSTITUENTS OF PLC & WORKING

Central Processing Unit It is a micro-controller based circuitry. The CPU consists of

following blocks :Arithmetic Logic Unit (ALU)Process image memory (Internal memory of CPU)Internal timers and countersProgram memory

CPU performs the task necessary to fulfill the PLC functions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device communication, special functions or data handling execution and self diagnostics.


Input moduleThese 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 VEx : 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


Output moduleThese 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 VEx : 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


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.


Bus System

It is path for the transmission of the signal . Bus system is responsible for the signal exchange between processor and I/O modules

The bus system comprise of several single line i.e. wires / tracks


PLC Cycle

Outputs

Machine

or

Process

Programmable

controller

Inputs

Sense the Input

Process the Logic

Give Output

PPI Connection

Mode SelectorMemory Card

Status Indicators

S7-200: CPU Design

Q0.0 .1 .2 .3 .4 .5 .6 .7

Q1.0 .1

I0

.0 .1 .2 .3 .4 .5 .6 .7

I1

.0 .1 .2 .3 .4 .5

CPU 224

SIEMENS

SF

RUNSTOP

Potentiometer

Status Indicators for integrated DO

Status indicators for integreted DI

S7-300: Modules

PS(optional)

CPU IM(optional)

SM:DI

SM:DO

SM:AI

SM:AO

FM:- Couting- Positioning- Closed-loop

control

CP:- Point-to-Point- PROFIBUS- Industrial Ethernet

Difference b/w S7- 200 & 300FIELDs S7-200 S7- 300

No. of I/Os 16 byte i.e. 128 128 bytes i.e. 1024

No. of Expansion / signal Modules

7 Modules 32- 4x Modules

Racking & Mounting Not Available Available up to 8 racks i.e. 0 to 7

Internal Memory 32 byte 128 byte

Scope less range of operation Medium Scale of operation

Scan time 3 ms 2 us

Simulator Not Available Available as PLCSim

Software Used MicroWin Simatic Manager

1. Simatic s7-300 is easy to use.

2. S7-300 is fast and powerful.

3. S7-300 is multi faceted and flexible.

4. S7-300 has fast and powerful CPU’s.

5. Simatic configuration and programming software is very easy.

6. S7-300 use in extremely harsh environment.

7. Its Baud rate is much higher i.e. 192.6 kbps

8. It uses MPI for its Data transfer.

1. Ladder Language (LAD)

2. Function Block Diagram (FBD)

3. Statement List (STL)

• In Industry, there are many production tasks which are of highly repetitive nature.

• Eliminating the possibilities of human error.

• Some of the capabilities of PLC are as follow:* logic control * timing,counting,comparison* analog value processing and PID control* real time clock* coordination and communication

• In short, wherever sequential logic control and automation is desired ,the PLCs are best suited to meet the task.

• Few examples of industries : Tyre industry,steel plant, brick molding, dairy automation, Printing industry etc.

OUR PROJECT WORK:

TOTAL TRAFFIC SECURITY AND MANAGEMENT SYSTEM

Instruction Set used in the TTSM System

TTSM

STANDARD CONTACTS

STANDARD OUTPUTS

TIMER

COMPARE BYTE INSTRUCTIONS

CONSTRAINTS OF THE PROJECT

1. SHOULD PROVIDE TRAFFIC MANAGEMENT TO THE CITY FROM

ONE CONTROL ROOM.

2. SHOULD PROVIDE COORDINATED TRAFFIC LIGHTS .

3. THE CAMERAS CONNECTED MUST NOT ONLY BE USED FOR

TRAFFIC MANAGEMENT BUT ALSO FOR SECURITY PURPOSES.

4. THE TRAFFIC CONTROLLER MUST BE ABLE TO GIVE PASS TO

EMERGENCY VEHICLES EVEN IF THEY GET RED LEGHT AT THE

TRAFFIC LIGHTS WITHOUT DISTURBING THE COORDINATED

SYSTEM.

5. MAINTENANCE OF THE WHOLE SYSTEM SHOULD BE EASY.

For First 15 seconds and next 15 secs

For next 15 seconds

For next 15 seconds

../Desktop

Thank You.

Any Queries???

Engineering

Programmable Logic Controllers