ME 376 Control Engineering Sessional
Experiment No: 07
Name of Experiment: Introduction to PLC and Basic PLC programing
1. Objectives:
To understand the main components of the PLC
To familiarize the students with common industrial input and output devices
To Program a PLC using ladder diagram
To control and monitor a process using PLC
2. Introduction
A Programmable Logic Controller (PLC) is a specialized, robust digital computer designed to
perform automatic control operations in challenging industrial and commercial environments.
PLCs are central to modern mechatronics and automation, where precision, flexibility,
reliability, and real-time responsiveness are essential for safe and efficient operation.
PLCs were developed in the late 1960s to replace complex, hard-wired relay logic systems,
initially in the automotive industry. Over time, their application has expanded across
manufacturing, energy, infrastructure, food processing, building automation, robotics, and
other sectors requiring automated and intelligent control of machinery, processes, or production
lines. Programmable Logic Controllers are engineered for harsh environments, tolerating
extreme temperatures, humidity, vibration, and electrical noise. Their rugged design ensures
continuous, real-time operation for maximum uptime and process safety.
Figure: Block diagram of inputs and outputs in PLC
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A typical PLC system includes a central processing unit (CPU) to execute logic and arithmetic
operations, memory to store user programs and operational data, input/output (I/O) interfaces
for connecting to sensors, switches, actuators, motors, and valves, a power supply that converts
AC power to the DC voltages required by internal circuits, and communication modules for
integration with other control systems and networks. PLCs operate by receiving signals from
field devices such as sensors and switches, processing this data according to a user-defined
program, and then controlling output devices such as motors, valves, alarms, and lights to direct
machine or process behavior.
The key advantages of PLC include ruggedness to withstand mechanical, electrical, and
environmental stress; reliability for continuous real-time operation; flexible programming that
allows process changes through software rather than rewiring; and scalability to support
applications from single-machine control to complex, plant-wide automation with thousands
of I/O points.
Applications of PLC
PLCs are used in a wide range of industries and processes, such as:
Manufacturing production lines
Process control (chemical, food and beverage, water treatment)
Robotics and factory automation
Power generation and distribution
Commercial building automation (elevators, HVAC, lighting)
Glass, paper, steel, and other material processing industries
3. Apparatus: Siemens LOGO OBA 8
During this experiment you will be studying LOGO PLC kit. This trainer kit provided by
SIEMENS LOGO OBA8 which is programmed using LOGO Soft Comfort V3.
Every PLC has four main components:
1. Power supply
2. Processor
3. Input cards/terminals
4. Output cards/terminals
Figure 1, shows the Siemens LOGO OBA8 PLC. This PLC has the main four components as
any other PLC. It needs a dc power supply of 24 V. It has a processor and it can handle 8 inputs
and 4 outputs distributed between 2 I/O terminals.
ME 376 Control Engineering Sessional
Figure: Siemens LOGO OBA 8
2. Inputs
Since the human operator role is very limited in automated systems, sensors play a major role
in them. Most common inputs in PLC systems are Push Buttons, Limit Switches and Proximity
Sensors or Proximity Switches, temperature sensors/switches, pressure sensors/switches,
motions sensor etc.
3. Outputs
Mainly these types of output devices are widely used in process control; motors, heater, linear
cylinders and rotary cylinders.
4. Terminology
The important thing now is to familiarize you with the terminology for the inputs and outputs
used in LOGO Soft comfort software.
Normally open contacts are represented as follows:
On the other hand, normally closed contacts are represented as follows:
ME 376 Control Engineering Sessional
While the output coils are represented as follows:
Self-latch
Self-latch is the process where an output coil stays energized after the inputs (that caused it to
be energized) are no longer satisfied. Self-latch illustrated in Figure 2 is achieved by adding a
NO contact with the same address as the output in parallel with the input that will energize the
output. This NO contact will provide an alternative route when the inputs are no longer
satisfied. At least one contact must be outside the latch to ensure that the output can be de-
energized without the need to shut down the system power, otherwise; after one operation,
the output will stay active indefinitely.
Figure: Self-Latch Ladder Diagram Elements
Example 1:
If "Start" push button is pressed and LED light is on, then the LED will not be off until
"Stop" push button is pressed.
Solution:
The LED will be operated as long as current is flowing through the output "Q1". Since "Start"
should be pressed in order for the current to flow through it to the output and since "Start" is
a normally open push button, a normally open contact of it was used in the ladder diagram.
The signals from "Start" push button "I1" is momentary signals (i.e. once "Start" push button
is released or the piece leaves the beginning position, the signals from them will stop). For
this reason, a latch will be needed to maintain "Q1" operated until "Stop" is pressed.
ME 376 Control Engineering Sessional
The ladder diagram needed to perform the operation described above is shown in Figure 3.
Figure 3: Ladder diagram for Example
Exercises:
As per Instructor design.
