SWITCHE
S
Non-locking Locking
Normally Open Normally Closed
SPDT
P1
DPST
P2
Multiple Throw Multiple Pole
Break-before-make Make-before-break
TYPES OF
SWITCHES
1. Basic switch, operated by a mechanical level,
2. Push-button switch,
3. Slide switch,
4. Thumbwheel switch,
5. Limit switch,
6. Proximity switch, and
7. Photoelectric switch.
RATING: voltage, current
RELAY
A switch whose operation is activated by an electromagnet is called a "relay"
S
contact
coil
input
Relay coil Output contact
COUNTE
R
Digital counters output in the form of a relay contact when a
preassigned count value is reached.
input
Register 5
Accumulator
reset
contact
output
Input
Reset
Output
Count 0 12 3 4 5 0 1
TIME
A timer consists of an internal clock, a count value register, and
Ror some timing purpose.
an accumulator. It is used for
Clock
Accumulator
reset
Register
Clock
contact
Contact
Reset
output
Output
Count 0 1 2 3 4 5
Time 5 seconds.
AN EXAMPLE OF RELAY
seconds after a part touches a limitLOGIC
For process control, it is desired to have the process start (by turning on a motor) five
switch. The process is terminated automatically
when the finished part touches a second limit switch. An emergency switch will stop
the process any time when it is pushed.
L1
LS1 PB1 LS2 R1
R1
TIMER R2
R1 PB1
LS1 LS2
PR=5
TIMER
5
Motor
R2
R1
PLC
Programmable ARCHITECTURE
controllers replace most of the relay panel wiring
by software programming.
PC
Program
Loader
Switches
Printer
I/O
Processor
Modules Machines
Cassette
Loader
Power
EPROM Memory Supply
Loader
Peripherals External Devices
A typical PLC
PLC
1. Processor Microprocessor based, may allow arithmetic
COMPONENTS
operations, logic operators, block memory moves,
computer interface, local area network, functions, etc.
2. Memory Measured in words.
ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electronically Erasable Programmable
ROM),
EPROM (Erasable Programmable Read Only Memory),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.
PLC
3. I/O Modular plug-in periphery
COMPONENTS
AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g.., high speed timers,
Stepping motor controllers, etc. PID, Motion
4. Power supply AC power
5. Peripheral Hand held programmer (loader),
CRT programmer,
Operator console,
Printer,
Simulator,
EPROM loader,
Cassette loader,
Graphics processor, and
Network communication interface. MAP, LAN
LADDER
A ladder diagram (also called contact symbology) is a means of
DIAGRAM
graphically representing the logic required in a relay logic
system.
Rail
start emergency stop
PB1 PB2
R1
Rung R1
R1
A
Ladder Representation
PLC WIRING
DIAGRAM
Input PLC Output
01 01 02 20 11 A
12
02
20
03
20 11
External
switches
Stored program
SCA
A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to
N
the bottom. Usually, all the outputs are updated based on the status of the internal
registers. Then the input states are checked and the corresponding input registers are
updated. Only after the I/Os have been resolved, is the program then executed. This
process is run in a endless cycle. The time it takes to finish one cycle is called the
scan time.
Output
Input
begin
Idle
Scan cycle
Resolve
logic
PLC
1) Relay, INSTRUCTIONS
2) Timer and counter,
3) Program control,
4) Arithmetic,
5) Data manipulation,
6) Data transfer, and
7) Others, such as sequencers.
LOGIC
STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize,
etc.
Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.
(In the notes we use the symbol "~" to represent
negation. AND and OR are logic operators. )
AND and OR
LOGIC
PB1 PB2 R1
R1 = PB1.AND.PB2
AND PB3 PB4
R2
R2 = PB2.AND.~PB4
PB1 R1
R1 = PB1 .OR. PB2
OR PB2
COMBINED AND &
OR
R1 = PB1 .OR. (PB2 .AND. PB3)
PB1 R1
PB2 pb3
RELA
A Relay consists of two parts, the coil and the contact(s).
Y
Contacts:
a. Normally open -| |-
b. Normally closed -|/|-
c. Off-on transitional -||-
d. On-off transitional -| |-
()
Coil:
a. Energize Coil -( )-
b. De-energize -(/)-
c. Latch -(L)-
d. Unlatch -(U)-
TIMERS AND Input
COUNTERS
True False True
Timers: RTO counting stop counting
resume
a. Retentive on delay -(RTO)-RTF stop counting stop
b. Retentive off delay -(RTF)-
c. Reset -(RST)-
RTO reach PR value, output ON
RTF reach PR value, output OFF
Counter:
PR value in 0.1 second
a. Counter up -(CTU)-
b. Counter down -(CTD)-
c. Counter reset -(CTR)-
SEQUENCE
repeating operating cyclesR
Sequencers are used with machines or processes involving
which can be segmented into
steps.
Output
Step A B C Dwell time
1 ON OFF OFF 5 sec.
2 ON ON OFF 10 sec.
3 OFF OFF ON 3 sec.
4 OFF ON OFF 9 sec.
Rockwell/ Allen Bradley
PLC
I/O points are numbered, they correspond to the I/O slot on
the PLC.
For A-B controller used in our lab
I/O uses 1-32
Internal relays use 033 - 098
Internal timers/counters/sequencers use 901-932
Status 951-982
Programming a PLC
Oil is consumed
randomly. The
tank needs to be
refilled by turning
on a pump. Two
hydrostatic
switches are used
to detect a high
and low level.
Ladder Logic for Tank
Logic for Ladder Solution
How does it work?
PROGRAMMING EXAMPLE Bar code reader
1
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
Input
SOLUTIO
N
Output
MS1 R1
01 11
C1 R2
02 12
C2 R3
03 13
C3 R4
04 14
Programmable
C4 05 15
Controller
PLC
Rung 1. If part arrives and no
part is stopped, trigger the
bar code reader.
01 14 11 Rung 2. If it is a right part,
activate the stopper.
02 14 Rung 3. If the stopper is up, the
machine is not busy and the
12
robot is not busy, load the
14 04 03
part onto the machine.
05 03 13
Rung 4. If the task is completed
and the robot is not busy,
unload the machine.
EXAMPLE 2 TRAFFIC
LIGHTSMain street
Jefferson street
Cycle time
Street Red Yellow Green
Main 3 1 4
Jefferson 5 1 2
WIRING
input
DIAGRAM output
64 Jefferson Red
65 Jefferson Yellow
Programmable
Controller
66 Jefferson Green
67 Main Red
70 Main Yellow
71 Main Green
PROGRAM 901
(1)
RUNG1 RTO
80
901 901
RUNG2 RST
901 902
RUNG3 67 M. Red
902
RUNG4 67
RTO
30
RUNG5 901 902
RST
901 903
RUNG6 66 J. Green
903
RUNG7 66
RTO
901 903 20
RUNG8 RST
902 904 M. Green
RUNG9 71
904
71
RUNG10 RTO
901 904 40
RUNG11 RST
904 905
RUNG12 70 M. Yellow
PROGRAM
(2) 905
70
RUNG13 RTO
901 905 10
RUNG14 RST
903 906
RUNG15 65 J. Yellow
906
65
RUNG16 RTO
901 906 10
RUNG17 RST
902 907
RUNG18 64 J. Red
907
RUNG19 64
RTO
901 907 50
RUNG 20 RST
