Download - Programmable Logic Controllers
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Vocational Training
at IATC
in Industrial Automation
(PROGRAMMABLE
LOGIC CONTROLLERS)
Submitted By:Anchit Walia (C08507)
Manik Jain (C08531)
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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
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Industrial Automation
Training Centre
(IATC) - Panchkula
Where the maxim of training is
“Learning by Doing” “Translating Skills into Success”
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Partners in Promotion
IAG Automation Private Limited
(Private Partner)
German Technical Cooperation (GTZ)
(Executive Organization)
SIEMENS
(Supporting Multinational Company)
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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
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Laboratory at IATC
Automation
AC / DC Drives
Switchgears
Industrial Hydraulics/Pneumatics
CNC Centre
Computer Centre
Machine Shop
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Automation Lab
PLC Hardware Configuration
PLC Program development
S7 300 PLC training kits
S7 200 PLC training kits
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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
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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
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History of Automation
Pneumatic Control
Hard wired logic Control
Electronic Control using Logic Gates
Programmable Logic Controller
Manual Control
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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.
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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
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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
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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
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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
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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
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CPU
External Power
Supply
I/O Modules
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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
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Power
Supply
Input Module CPU
Program Memory
Output Module
Field Inputs Control Elements
PROCESS/MACHINE
CONSTITUENTS OF PLC & WORKING
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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.
Programmable Logic Controllers
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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
Programmable Logic Controllers
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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
Programmable Logic Controllers
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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.
Programmable Logic Controllers
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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
Programmable Logic Controllers
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PLC Cycle
Outputs
Machine
or
Process
Programmable
controller
Inputs
Sense the Input
Process the Logic
Give Output
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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
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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
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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
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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.
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1. Ladder Language (LAD)
2. Function Block Diagram (FBD)
3. Statement List (STL)
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• 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.
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OUR PROJECT WORK:
TOTAL TRAFFIC SECURITY AND MANAGEMENT SYSTEM
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Instruction Set used in the TTSM System
TTSM
STANDARD CONTACTS
STANDARD OUTPUTS
TIMER
COMPARE BYTE INSTRUCTIONS
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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.
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For First 15 seconds and next 15 secs
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For next 15 seconds
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Thank You.
Any Queries???