Here is a detailed and structured explanation of **sequence control**, **PLCs**,
their **working specifications**, **types of I/O modules**, and a **comparison
between PLCs and PCs**:
---
### **1. Introduction to Sequence Control**
**Sequence control** refers to the automation of operations in a fixed, logical
order, usually based on time, events, or sensor inputs. It is widely used in
manufacturing, packaging, process control, and material handling systems. The goal
is to ensure that each step in a process is executed in the correct order, under
defined conditions.
Sequence control systems are commonly implemented using **Programmable Logic
Controllers (PLCs)** due to their reliability, ease of programming, and ability to
interface directly with industrial sensors and actuators.
---
### **2. Introduction to PLCs (Programmable Logic Controllers)**
A **PLC** is an industrial digital computer specifically designed for controlling
manufacturing processes or machinery. It monitors inputs, makes decisions based on
a programmed logic, and controls outputs to automate processes.
#### **Key Features:**
* Rugged and designed for harsh environments (temperature, humidity, vibration).
* Real-time operation and deterministic control.
* Easy to program using ladder logic, function block diagrams, or structured text.
---
### **3. Working Specifications of PLCs**
Some typical **technical specifications** of a PLC include:
| Specification | Typical Range / Description |
| ------------------- | ------------------------------------------------- |
| **Processor speed** | 1-100 MHz or more (depending on model) |
| **Memory** | 2 KB to several MB (RAM, ROM, Flash) |
| **Scan time** | 1-10 ms per cycle (varies by complexity) |
| **Input types** | Digital (24V DC, 120V AC), Analog (0-10V, 4-20mA) |
| **Output types** | Relay, Transistor (DC), or Triac (AC) |
| **Communication** | Ethernet, Modbus, Profibus, RS-232/485 |
| **Programming** | Ladder Logic, Function Block, Structured Text |
PLCs can be **modular** (expandable with additional cards) or **compact** (fixed
I/O capacity).
---
### **4. Onboard, Inline, and Remote I/O Modules**
#### **a. Onboard I/Os**
* Built directly into the PLC CPU module.
* Suitable for small applications.
* Limited flexibility in expanding I/O points.
#### **b. Inline (Local) I/Os**
* Connected directly beside the PLC in the same rack.
* Offer modular expansion within the control panel.
* Short communication path, high-speed data transfer.
#### **c. Remote I/Os**
* Located away from the main PLC, often in the field.
* Connected via communication protocols (e.g., Ethernet/IP, Profibus).
* Reduce wiring cost and complexity in large plants.
---
### **5. Comparison: PLCs vs. PCs**
| Feature | PLC |
PC |
| ------------------------- | ------------------------------------------------- |
-------------------------------------- |
| **Purpose** | Industrial control |
General-purpose computing |
| **Operating Environment** | Harsh (temperature, dust, vibration) |
Office or clean environments |
| **Reliability** | Very high (24/7 operation) |
Less reliable for continuous operation |
| **Real-time Control** | Yes, deterministic |
Limited without RTOS |
| **I/O Handling** | Direct connection to industrial sensors/actuators |
Requires interface cards |
| **Programming** | Ladder, FBD, ST |
C++, Python, etc. |
| **Cost** | Higher for small applications |
Lower initial cost |
| **Scalability** | Excellent with modular I/Os |
Limited in industrial settings |
| **Maintenance** | Easy with hot-swappable modules |
More complex troubleshooting |
---
### Summary
* **Sequence control** ensures processes run in a logical order.
* **PLCs** are purpose-built controllers ideal for real-time, industrial
automation.
* **Onboard, inline, and remote I/Os** offer scalability depending on system size
and location.
* **PLCs vs. PCs**: PLCs are optimized for reliability and control, while PCs are
better for computation but less suited to harsh industrial environments.
