Ministry Of Education and Scientific Research
College Of Engineering
University Of Mustansiriyah
Electrical Engineering Department
Iraq
Implementation and simulation of PLC technology in automatic production
line
A Project Report Submitted Implementation and simulation of PLC
technology in automatic production line.
For The Award Of The Degree Of Bachelor In Electrical Engineering.
By Students:
Ali Hussain Khazal
Majd Aazz Faraj
Masarah Abdulkarim Ismael
Supervised By:
Asst. Prof. Dr. Amal Ibrahim Nasser
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)Acknowledgments(
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Dedication
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TABLE OF CONTENTS
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(Abstract(
This report presents the implementation and simulation of Programmable Logic
Controller (PLC) technology in an automatic production line. The objective of the
project was to design a robust and efficient control system that enhances the
automation process in manufacturing environments.
The project begins with a comprehensive overview of PLC technology, including its
architecture, programming languages, and application in industrial settings.
Subsequently, a detailed design of an automatic production line is outlined,
incorporating various components such as sensors, actuators, and conveyors.
Simulation was conducted using advanced software tools to model the behavior of the
production line under different operational scenarios. The results demonstrate
significant improvements in efficiency, reliability, and flexibility compared to traditional
control systems.
The findings indicate that integrating PLC technology can lead to reduced operational
costs and improved productivity. This project not only reinforces the theoretical
knowledge of automation systems but also provides practical insights into the
implementation challenges and solutions in real-world applications.
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CHAPTER ONE
INTRODUCTION TO PLC
1.1 Introduction
A Programmable Logic Controller (PLC) is a type of industrial computer
control system that's specifically designed to automate electromechanical
processes. It's essentially the "brain" that controls machinery in factories,
manufacturing plants, and other industrial settings.
Examples of these processes include controlling light fixtures, amusement
rides, and manufacturing assembly line machinery. It is required of PLCs
to operate faultlessly for years in industrial settings that pose a risk to the
microelectronic components that give contemporary PLCs their
exceptional precision and flexibility.
Before PLCs, contactor or relay controls were used to do many of these
control duties.
This is frequently called "hardwired control." Electrical components
needed to be specified and installed, circuit diagrams needed to be
drawn, and wire lists needed to be made. They would then wire the parts
required to do a certain task. If an error was made the wires had to be
reconnected correctly. A change in function or system expansion required
extensive component changes and rewiring.
1.2 History Of PLC
PLC Programming Then & Now: The History of PLC’s
The first PLC was introduced in the late 1960s. A programmable logic
controller is an industrial computer. It is designed to help in the control of
manufacturing processes.
The automobile sector was the first industry to deploy PLCs into its
operations. Their aim was to replace the hardwired relays and timers with
programmable and flexible controllers. Since then, PLCs have been
broadly adopted as the standard automation control system in discrete
manufacturing industries.
This part of the report will discuss the history of PLC programming and
how it has evolved over the years.
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The emergence of the first PLC in 1968 by (Dick Morley) meant large
banks of relays could be replaced by a single device that was easier to
maintain and could be programmed with the already accepted relay ladder
logic. In addition, the PLC was equipped with enough memory to retain
loaded programs in the event of power outages and was also designed to
operate in industrial environments where dirt, moisture, electromagnetism,
and vibration were often present.
Innovative Improvements
1970s
With inexpensive microprocessors becoming available in the late 1970s,
PLC manufacturers began developing graphical programming devices.
These devices enabled PLCs to be digitally programmed with graphical
representations for normally open and closed relay contacts, pushbuttons,
switches, relay coils, motor starters, valves, timers, and more.
Unfortunately, these programming devices were prohibitively expensive,
often costing more than the PLC they were designed to program. The
programming devices were also only compatible with a single
manufacturer’s controllers, further reducing their utility.
In the 1980s:
Third-party software packages that worked with multiple PLC hardware
platforms came available in the 1980s to alleviate the high cost of early
programming devices. These third-party software packages also offered
vastly improved documentation and reporting capabilities over the OEM
programming devices. This led PLC manufacturers to develop and market
their own competing programming packages, as well as purchase many of
the third-party software companies.
The 1980s also saw the introduction of the IEC 61131-3 Standard for
Programmable Controllers, which is the standard all PLC software is held
against. The IEC brings consistency to PLC software programs by
defining various standards for data types, naming conventions, program
flow, and other programming elements. More specifically, the standard
ensured functions and function blocks looked the same and had the same
defined inputs and outputs, making it easier for engineers or maintenance
personnel to understand the program. The IEC also established five PLC
compliant programming languages, consisting of LD, function block
diagrams (FBD), sequential function chart (SFC), structured text (ST), and
IL.
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In the 1990s:
In the 1990s, manufacturers began requesting for machinery to include
interactive terminals that allowed them to monitor their PLC software. In
addition, the terminals would allow operators to quickly see what was
wrong with their machines preventing them from having to spend hours
troubleshooting. This idea led to the development of the human-machine
interface (HMI).
Initially, HMIs were merely a digital replacement for physical pushbuttons
and were considered too expensive for applications that had less than 20
pushbuttons. However, with continued development and growing demand
for machine monitoring, HMIs gained the ability to translate the machine
data being recorded by PLCs and display it in the form of system status,
alarms, cycle times, reports, production counts, and more.
By the end of the 1990s, PLCs were becoming smaller, faster, more
powerful, and equipped with significantly more memory. As the world
moved into the twenty-first century, these advancements in PLC
technology would help pave the way for manufacturers to implement a
new era of internet connectivity, big data, and even forms of artificial
intelligence on the factory floor.
PLC today:
Today, PLCs maintain the same core functionality and simplicity that
originally made them so popular with manufacturers. However, thanks to
continued advancement in processor and memory technology, PLCs
continue to shrink in size while growing in power and speed. These
technological advancements have led to new capabilities, such as vision
system integration, motion control, and support for multiple
communication protocols. Modern PLCs also seamlessly integrate with
ERP and MES systems, as well as powerful machine monitoring
software and SCADA, providing new ways for manufacturers to drive
improvements to their operations’ efficiency and performance through
machine data analysis.
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1.3 Applications Of PLC
Applications of Programmable Logic Controllers (PLCs)
PLCs are versatile devices with a wide range of applications across
various industries. Here are some common applications:
Manufacturing:
Assembly Line Automation: Controlling robotic arms, conveyor belts,
and other machinery to automate assembly processes.
Machine Tool Control: Coordinating the operation of CNC machines,
lathes, and milling machines.
Quality Control: Monitoring product quality parameters and
triggering alarms or adjustments as needed.
Process Control: Regulating temperature, pressure, flow rates, and
other process variables.
Automotive Industry:
Vehicle Assembly: Controlling robotic arms and other equipment to
assemble vehicles.
Engine Testing: Automating engine testing processes, including fuel
injection timing and emissions testing.
Food and Beverage Industry:
Packaging and Bottling: Controlling packaging machines, labeling
machines, and filling machines.
Food Processing: Automating processes like mixing, blending, and
pasteurization.
Building Automation:
HVAC Control: Regulating heating, ventilation, and air conditioning
systems.
Lighting Control: Automating lighting systems based on occupancy
sensors or time schedules.
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Security Systems: Monitoring security systems, including alarms,
cameras, and access control.
Other Applications:
Water Treatment: Controlling pumps, valves, and chemical dosing
systems.
Power Generation: Monitoring and controlling power generation
processes.
Material Handling: Automating material handling systems, including
conveyors and cranes.
Robotics: Controlling robotic systems for various tasks, such as
welding, painting, and assembly.
1.4 Objectives of Using PLCs
Increase Productivity: Faster cycle times, higher throughput,
reduced labor costs
Improve Quality: Consistent performance, reduced defects,
enhanced product consistency
Enhance Safety: Hazard mitigation, reduced accidents
Increase Flexibility: Adaptability to change, new product
introduction, scalability
Reduce Costs: Predictive maintenance, remote monitoring
By automating processes, PLCs contribute to these objectives, leading to
increased efficiency, reduced costs, and improved overall operations.
Key Advantages of Using PLCs:
Flexibility: PLCs can be reprogrammed to adapt to changing
production requirements.
Reliability: PLCs are designed to operate reliably in harsh industrial
environments.
Efficiency: PLCs can improve productivity and reduce downtime.
Safety: PLCs can be used to implement safety interlocks and
emergency stop systems.
By understanding the diverse applications of PLCs, you can appreciate
their significant role in modern industrial automation.
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CHAPTER TWO
Programmable Logic Controllers: Hardware and Software
Insights
2.1 Exploring PLC Functionality
Before we delve into the specific components of PLC hardware and
software, it's essential to understand how a PLC operates and its
fundamental role in automation.
How Does a PLC work? The working of a PLC can be easily understood
as a cyclic scanning method known as the scan cycle.
Figure 2.1:Block diagram of PLC Functionality
A PLC Scan Process includes the following steps :
The operating system starts cycling and monitoring of time.
The CPU starts reading the data from the input module and checks
the status of all the inputs.
The CPU starts executing the user or application program written in
relay-ladder logic or any other PLC-programming language.
Next, the CPU performs all the internal diagnosis and
communication tasks.
According to the program results, it writes the data into the output
module so that all outputs are updated.
This process continues as long as the PLC is in run mode.
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2.2 PLC Hardware
Physical Structure of PLC The structure of a PLC is almost similar to a
computer’s architecture.
Figure 2.2:Block diagram of Physical Structure of PLC
Programmable Logic Controllers continuously monitors the input values from
various input sensing devices (e.g. accelerometer, weight scale, hardwired
signals, etc.) and produces corresponding output depending on the nature of
production and industry.
A typical block diagram of PLC consists of four parts namely:
Power Supply Module.
Central Processing Unit (CPU).
Input & Output Module.
Communication Interface Module.
2.2.1 Power Supply Module.
A PLC power supply is a device or module responsible for converting
high-voltage alternating current (AC) from the main power source into low-
voltage direct current (DC) suitable for a PLC system. It typically steps
down the voltage, rectifies it to DC, and stabilizes it for consistent delivery
to the PLC.
Most PLC power supplies provide a standard 24V DC output, which
powers not only the CPU but also other modules attached to the PLC
backplane. In addition, they may incorporate built-in features like
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overcurrent protection and battery backup to ensure reliability in critical
systems.
Figure 2.3:Block diagram of PLC Power Supply Module
2.2.2 Central Processing Unit (CPU).
The Central Processing Unit (CPU) of a Programmable Logic Controller (PLC) is
the brain of the system, responsible for executing control instructions and
processing input data from various sensors and devices. It operates using a
scan cycle, which involves reading inputs, processing logic, and updating
outputs, all in rapid succession. The CPU is designed for reliability and
robustness, often featuring real-time processing capabilities to ensure timely
responses to changes in the control environment. It can handle complex tasks
such as data manipulation, communication with other devices, and executing
control algorithms, making it essential for automation in industrial
applications. Additionally, modern PLC CPUs may incorporate advanced
features like networking capabilities, allowing for seamless integration into
larger control systems.
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Figure 2.4:Block diagram of PLC Central Processing Unit (CPU)
2.2.3 Input & Output Module.
2.2.4 Communication Interface Module.
2.3 PLC Software
PLC Software: The Brain Behind the Machine
PLC software, often referred to as PLC programming software or PLC
development environment, is the tool used to create, modify, and test the
control programs that govern the behavior of a PLC. This software serves
as the interface between the human programmer and the PLC hardware.
Software for programmable logic controllers governs the behavior of the
PLC and controls the automation process. The PLC software controls the
physical system by processing input signals, executing control algorithms,
and generating output signals.
Components of PLC Software:
1. Editor:
o Allows you to write and edit the PLC program using various
programming languages:
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Ladder Logic: A visual language resembling relay ladder
diagrams.
Function Block Diagram (FBD): A graphical language
using function blocks to represent operations.
Structured Text (ST): A text-based language similar to
high-level programming languages.
Instruction List (IL): A low-level language, often used for
advanced programming tasks.
2. Compiler/Interpreter:
o Translates the program written in a high-level language (like
Ladder Logic or ST) into machine code that the PLC can
understand.
3. Simulator:
o Allows you to test and debug the PLC program in a simulated
environment without needing the actual hardware.
4. Debugger:
o Helps identify and fix errors in the PLC program by providing
tools for step-by-step execution and variable monitoring.
5. Communication Interface:
o Enables communication between the software and the PLC,
allowing you to download the program to the PLC and monitor
its operation.
2.4 Ladder Logic: A Visual Programming Language for PLCs
Ladder Logic is a programming language widely used in PLCs to create
control programs. It's a visual language inspired by relay logic diagrams,
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making it intuitive for engineers and technicians familiar with electrical
control systems.
Basic Structure of a Ladder Logic Program
A Ladder Logic program consists of rungs, which are horizontal rows
representing a logical circuit. Each rung has two vertical rails, and
components are placed between these rails to form the logic.
Components in Ladder Logic:
2.5 Types of PLCs
PLCs come in various sizes and capabilities, each suited for different
applications. Here are the primary types:
1. Small-Scale PLCs: Compact and affordable, ideal for simple
applications.
2. Medium-Scale PLCs: More powerful, suitable for complex
applications with multiple machines and processes.
3. Large-Scale PLCs: High-performance, capable of handling large-
scale, complex systems.
4. Modular PLCs: Highly flexible, can be customized to specific
needs.
5. Safety PLCs: Designed to meet safety standards and regulations.
6. Embedded PLCs: Small, compact, integrated into machines or
devices.
When choosing a PLC, consider factors like I/O requirements, processing
power, communication capabilities, environmental conditions, safety
standards, and cost.
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