PLC Industrial Training File

INDUSTRIAL TRAINING REPORT ON PROGRAMMABLE LOGIC CONTROLLER Submitted in the partial fulfillment of requirement for the award of the Diploma of

ELECTRICAL ENGINEERING

SUBMITTED BY

AMIT SHUKLA

191075209256

UNDER THE GUIDANCE OF ER. MANDEEP SINGH THAKUR

HOD (ELECTRICAL ENGINEERING)

DEPARTMENT OF ELECTRICAL ENGINEERING CHANDIGARH POLYTECHNIC COLLEGE, GHARUAN SEPTEMBER – 2021

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CERTIFICATE

Submitted by:

Submitted to:

AMIT SHUKLA

MANDEEP SINGH THAKUR

191075209256

Head of Department

Electrical Engineering

Electrical Engineering

Chandigarh Polytechnic College

Chandigarh Polytechnic College

Gharuan

Gharuan

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ACKNOWLEDGEMENT

The Industrial Training Report is a task which cannot be done by an individual in isolation. I have no exception to this rule and have gratefully accepted the helping hand offered by many. We express my deep gratitude and indebtedness to Dr. GURMEET SINGH SWAG (Principal Chandigarh Polytechnic College Gharuan) and Chandigarh University for providing us such a platform, infrastructure and learning environment.

We also grateful to “ER. MANDEEP SINGH THAKUR” (HOD “ELECTRICAL ENGINEERING”) and “ER. KAMALPREET SINGH” (Assist.

Professor,

Department

of

“ELECTRICAL

ENGINEERING”)

Chandigarh Polytechnic College, Gharuan for extending all possible help in formation and completion of Training and for his valuable guidance and constant encouragement at each and every step-in preparation of this Training.

AMIT SHUKLA

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ABSTRACT

The programmable Logic Controller (PLC) is the central controlling unit in the industry or a process. The effective operation of the process and safety considerations if programmed appropriately can meet the required objectives. The present technical paper briefly distinguishes the present automation systems and the past technologies to identify and explore the capabilities of PLCs for any process. The relay logic and contactor logics (RLC) were practiced in the olden days which include the human intervention and errors. The advent and application of microprocessors, microcontrollers and new specific tools such as PLCs, Supervisory control and data acquisition (SCADA) and Distributed control systems (DCS) have increased productivity, accuracy, precision and efficiency. These systems reduced human intervention and increased the flexibility in the process control. The keyword automation clearly state that the working of a process or repetition in an efficient manner by incorporating mechanisms and control sequences in the proper order several times with acceptable deviations in the output of the process.

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Table of Contents Contents

Page No.

Certificate_________________________________________________2 Acknowledgements__________________________________________3 Abstract__________________________________________________4 Table of Contents___________________________________________5 The Need for PLCs__________________________________________6 The first Programmable Logic Controller_________________________6 Advantages of PLC Control Systems____________________________7 PLC System________________________________________________9 Processor (CPU)___________________________________________12 Programming Device________________________________________15 Ladder Diagram____________________________________________16 Traffic Light Ladder Programming_____________________________18 PLCs Versus Personal Computers______________________________21

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The Need for PLCs  Hardwired panels were very time consuming to wire, debug and change.  GM identified the following requirements for computer controllers to replace hardwired panels.  Solid-state not mechanical  Easy to modify input and output devices  Easily programmed and maintained by plant electricians  Be able to function in an industrial environment

The First Programmable Logic Controllers (PLCs)  Introduced in the late 1960’s  Developed to offer the same functionality as the existing relay logic systems  Programmable, reusable and reliable  Could withstand a harsh industrial environment  They had no hard drive, they had battery backup  Could start in seconds  Used Ladder Logic for programming

Programmable Logic Controller  A programmable logic controller (PLC) is a specialized computer used to control machines and process.  It uses a programmable memory to store instructions and specific functions that include On/Off control, timing, counting, sequencing, arithmetic, and data handling

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Advantages of PLC Control Systems      

Flexible Faster response time Less and simpler wiring Solid-state - no moving parts Modular design - easy to repair and expand Handles much more complicated systems

 Sophisticated instruction sets available  Allows for diagnostics “easy to troubleshoot”  Less expensive

PLC Architecture

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PLC System

PLC Architecture  An open architecture design allows the system to be connected easily to devices and programs made by other manufacturers.  A closed architecture or proprietary system, is one whose design makes it more difficult to connect devices and programs made by other manufacturers. NOTE: When working with PLC systems that are proprietary in nature you must be sure that any generic hardware or software you use is compatible with your particular PLC.

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I/O Configurations Fixed I/O  Is typical of small PLCs  Come in one package, with no separate removable units.  The processor and I/O are packaged together.  Lower in cost -but lacks flexibility.

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Modular I/O  Is divided by compartments into which separate modules can be plugged.  This feature greatly increases your options and the unit’s flexibility. You can choose from all the modules available and mix them in any way you desire.

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Power Supply

 Supplies DC power to other modules that plug into the rack.  In large PLC systems, this power supply does not normally supply power to the field devices.  In small and micro PLC systems, the power supply is also used to power field devices.

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Processor (CPU)  Is the “brain” of the PLC.  Consists of a microprocessor for implementing the logic, and

controlling the communications among the modules.  Designed so the desired circuit can be entered in relay ladder logic form.  The processor accepts input data from various sensing devices, executes the stored user program, and sends appropriate output commands to control devices.

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I/O Section Consists of:  Input modules  Output modules.

Input Module

 Forms the interface by which input field devices are connected to the controller.  The terms “field” and “real world”are used to distinguish actual external devices that exist and must be physically wired into the system.

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Output Module  Forms the interface by which output field devices are connected to the controller.  PLCs employ an optical isolator which uses light to electrical- ly isolate the internal components from the input and output terminals.

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Programming Device  A personal computer (PC) is the most commonly used programming device.  The software allows users to create, edit, document, store and troubleshoot programs.  The personal computer communicates with the PLC processor via a serial or parallel data communications link.

 Hand-held programming devices are sometimes used to program small PLCs.  They are compact, inexpensive, and easy to use, but are not able to display as much logic on screen as a computer monitor.

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 Hand-held units are often used on the factory floor for troubleshooting, modifying programs, and transferring programs to multiple machines.

LADDER DIAGRAM  A ladder diagram (also called contact symbology) is a means of graphically representing the logic required in a relay logic system.

Ladder Representation

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PLC WIRING DIAGRAM

SCAN  A PLC resolves the logic of a ladder diagram (program) rung by rung, from the top to 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.

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Traffic Light Ladder Programming

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901 RTO

RUNG1 901

RUNG2 RUNG3

RUNG4

901

RUNG7 RUNG8

902

902 RTO 901

901

902 903

RUNG12

30

RST J. Green

903

66

RTO 901

902

903 904

RST

904 RTO 901

904

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904 905

20 M. Green

71

71

RUNG11

M. Red

66

RUNG9

RUNG10

RST 67

67

RUNG5 RUNG6

901

80

RST 70

40 M. Yellow

19

RUNG13

905 RTO

70 901

RUNG14 RUNG15

RUNG16 RUNG17 RUNG18

RUNG19

903

905 906

65

65 901 902

906 907

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906 RTO RST

J. Yellow

10

64

J. Red

907

64

RUNG 20

RST

10

RTO 901

907

RST

50

20

PLCs Versus Personal Computers

VS

PLC:    

Operates in the industrial environment. Is programmed in relay ladder logic. Has no keyboard, CD drive, monitor, or disk drive. Has communications ports, and terminals for input and output devices.

PC:  Capable of executing several programs simultaneously, in any order.  Some manufacturers have software and interface cards available so that a PC can do the work of a PLC.

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