CHAPTER -7 LOGIC Systems
Contents
Introduction
Types of switches
Relays
Counters
Timers
Ladder Diagram
Logic Gates
Introduction
Programmable Logic Controller (PLC)
Invented in 1968 as a substitute for hardwired relay panels.
"A digitally operating electronic apparatus which uses a programmable
memory for the internal storage of instructions by implementing specific
functions such as logic sequencing, timing, counting, and arithmetic to
control, through digital or analog input/output modules, various types of
machines or processes. The digital computer which is used to perform the
functions of a programmable controller is considered to be within this
scope. Excluded are drum and other similar mechanical sequencing
controllers."
National Electrical Manufacturing Association (NEMA)
VENDORS
•Rockwell
•GE/Fanuc
•Schnieder
Introduction
Programmable Logic Controller (PLC)
It is designed for high reliability and real-time performance in industrial environments.
PLCs are widely used in manufacturing, process control, energy systems, and many
other industries.
Components of a PLC:
1.Central Processing Unit (CPU):
• The brain of the PLC.
• Executes programs and processes input/output (I/O) data.
• Includes memory for storing programs and data.
2.Input/Output (I/O) Modules:
1. Input Modules: Receive signals from sensors, switches, or other input devices.
2. Output Modules: Send signals to actuators, motors, lights, or other output
devices.
3.Power Supply: Provides the necessary power for the PLC and its components.
4.Programming Device: Used to write, edit, and load programs into the PLC (e.g., via
a PC or handheld device).
5.Communication Interfaces: Allow the PLC to connect to other devices or networks
for data exchange.
What devices does a PLC interact with?
• INPUT RELAYS-(contacts) A relay is an electrical switch that opens and
closes under the control of another electrical circuit. In the original
form, the switch is operated by an electromagnet to open or close
one or many sets of contacts. They receive signals from switches,
sensors, etc.
• INTERNAL UTILITY RELAYS-(contacts) These do not receive signals
from the outside world nor do they physically exist. They are
simulated relays and are what enables a PLC to eliminate external
relays. There are also some special relays that are dedicated to
performing only one task. Some are always on while some are always
off. Some are on only once during power-on and are typically used for
initializing data that was stored.
• COUNTERS-These again do not physically exist. They are simulated
counters and they can be programmed to count pulses. Typically these
counters can count up, down or both up and down. Since they are
simulated they are limited in their counting speed. Some
manufacturers also include high-speed counters that are hardware
based. We can think of these as physically existing. Most times these
counters can count up, down or up and down.
Continued…
• TIMERS-These also do not physically exist. They come in many
varieties and increments. The most common type is an on-delay
type. Others include off-delay and both retentive and non-
retentive types. Increments vary from 1ms through 1s.
• OUTPUT RELAYS-(coils)These are connected to the outside world.
They physically exist and send on/off signals to solenoids, lights,
etc. They can be transistors, relays depending upon the model
chosen.
• DATA STORAGE-Typically there are registers assigned to simply
store data. They are usually used as temporary storage for math
or data manipulation. They can also typically be used to store data
when power is removed from the PLC. Upon power-up they will
still have the same contents as before power was removed.
NB: solenoid is an electromagnetic device that converts electrical energy into linear mechanical
motion. It consists of a coil of wire wound around a metal core, typically cylindrical in shape.
When an electric current passes through the coil, it creates a magnetic field, which either attracts
or repels the metal core, causing motion.
TYPES OF SWITCHES
Basic switch, operated by a mechanical level,
Push-button switch, Slide switch
Thumbwheel switch, Limit switch
Proximity switch Photoelectric switch
RATING: voltage, current
RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"
contact
coil
input
Relay coil Output contact
COUNTER
input
Register
Accumulator
reset
contact
output
TIMER
✓ A timer consists of an internal clock, a count value register,
and an accumulator. It is used for or some timing purpose.
✓ It counts time units, represented by the symbol below where
the number indicates that the following task will be performed
after timer counts that number of time units (usually seconds).
Clock
Accumulator
reset
Register
contact
Contact
output
PLC Programming
Programming languages of
PLC
• Ladder Logic (most
common)
• Function Block Diagram
(FBD)
• Structured Text (ST)
• Sequential Function Chart
(SFC)
• Instruction List (IL)
PLC Programming
PLC programming is based on the use of Ladder Diagrams. Using these, writing a
program is equivalent to drawing a switching circuit. The basic components in a ladder
logic program are the contact and the coil. The contact is the name given to a general
input device, while the coil is the name given to a general output device. Fig. shows
the standard symbols used in any ladder diagram.
The ladder diagram consists of 2 vertical lines
and circuits are connected as horizontal lines
i.e. the rungs of the ladder between these two
verticals. Fig. shows an example of a ladder
diagram.
LADDER DIAGRAM
• A ladder diagram (also called contact symbology) is a means of graphically
representing the logic required in a relay logic system.
• Each horizontal line i.e. rung on the ladder represents a line in the program
and the entire ladder can be translated into a program using a keyboard with
the graphic symbols for the ladder elements and then the program panel
translates these symbols into machine language that is then stored in the PLC
memory.
LOGIC STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize, etc.
AND GATE
OR GATE
NOR GATE
NAND GATE
Example on how to energize the PLC Circuit
PROGRAMMING EXAMPLE 1
Bar code reader
microswitch Stopper
Part Conveyor
Robot
Machine
id description state explanation
MSI microswitch 1 part arrive
R1 output to bar code reader 1 scan the part
C1 input from bar code reader 1 right part
R2 output robot 1 loading cycle
R3 output robot 1 unloading cycle
C2 input from robot 1 robot busy
R4 output to stopper 1 stopper up
C3 input from machine 1 machine busy
C4 input from machine 1 task complete
SOLUTION
Input
Output
MS1 R1
01 11
C1 02 12 R2
C2 R3
03 13
C3 R4
04 14
C4 Programmable
05 Controller 15
PLC
Rung 1. If part arrives and no
part is stopped, trigger the
bar code reader.
Rung 2. If it is a right part,
01 14 11 activate the stopper.
Rung 3. If the stopper is up, the
02 14 machine is not busy and the
robot is not busy, load the
12
part onto the machine.
14 04 03
Rung 4. If the task is completed
05 03 13
and the robot is not busy,
unload the machine.
Programming
Example 2
