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Session 01
By Emamof
    Presented in 02-02-2009
PLC, by Mohamed Al-Emam, Session 1
TARGET TO 
   CONTROL SYS.
   Automatic Controller
   WHAT
   Origin of PLC
   History
   Sizes of PLC’s
    Cycle of Operation
    Which
   APPLICATIONS N REAL
   PLC H.W Components:
   INPUT TO PLC ,SENSING CONCEPTS
PLC, by Mohamed Al-Emam, Session 1
Open
         loop


Closed
 loop

           Control
           System
PLC, by Mohamed Al-Emam, Session 1
Analog



Digital

             Control
             System
Control
         system

Motion             Sequential
Batch Process
has a beginning and an end “complete
  product control process” , Some
  applications require that specific quantities
  of raw materials be combined in specific
  ways for particular durations to produce
  an intermediate or end result.
Example:
production of food and medicine.
Continuous Process
Often, a physical system is represented though
  variables that are smooth and uninterrupted in
  time.
Example :control of the water temperature in a
  heating jacket,
Discrete
It is Not independent, Most discrete
    manufacturing involves the production of
    discrete pieces of product
Examples :
 metal stamping.
 automotive production.
Hybrid
   Applications having elements of
    discrete, batch and continuous process
    control are often called hybrid
    applications.
Sequential Control
Control a process that is a series of tasks to be
  performed (sequence of operation ),each task
  is performed under :-
 Time driven . Common in open loop sys
 Event driven . Common in closed loop sys


Example washing machine
In PLC the SFC is powerful Lang for it .
Motion Control
Controlling motion in electromechanical sys
 Rotational or Linear by Servomotor.
 Digital by NC (Numerical Control).
 3 dimension by Robotic.
PLC, by Mohamed Al-Emam, Session 1
µC
  DCS                 PC


                           Mr.
CNC      CONTROLLER
                           PLC


 SCADA                PAC
          FPGA
Automatic controllers
  µC==Microcontroller.
  FPGA not FBGA.
  PC
  Mr. PLC
  DCS== Distributed Control System
  SCADA == Supervisory Control And Data Acquisition
  CNC == Computer Numerical Control
  PAC ==Programmable Automation Controller
SCADA
PLC, by Mohamed Al-Emam, Session 1
PLC, by Mohamed Al-Emam, Session 1
WHAT
 Programmable logic controllers, also called
  programmable controllers or PLCs, are
  solid-state members of the computer
  family, using integrated circuits instead of
  electromechanical devices to implement
  control functions.
 They are capable of storing
  instructions, such as
  sequencing, timing, counting, arithmetic, dat
  a manipulation, and communication, to
  control industrial machines and processes
PLC, by Mohamed Al-Emam, Session 1
Intro 2 Microprocessor and
Microcontroller world.
Microprocessor
 The block that will have a built in
 capability to Add “multiply, divide,
 subtract”, and move its contents from
 one memory location onto another is
 called "central processing unit" (CPU).
Characteristics differentiate
microprocessors
 Instruction set The set of instructions that
  the microprocessor can execute
 bandwidth The number of bits processed
  in a single instruction
 clock speed Given in megahertz MHz
  the clock speed determines how many
  instructions per second the processor can
  execute
Microcontroller
A microcontroller (also MCU or µC) is a
   functional computer system-on-a-chip.
It contains a processor core, memory, and
   programmable input/output peripherals.
Microcontroller Architecture
Why
 Coz we can say
 Microcontroller= Microprocessor +Memory
  +i/o Peripherals.
 PLC’s=Microcontroller +I/O Interfaces.
PLC, by Mohamed Al-Emam, Session 1
Dick Morley==Richard E. Morley
Founder of Modicon (now Schneider Automation, Inc)
History of PLCs

   The first Programmable Logic Controllers were
    designed and developed by Modicon as a relay
    replacer for GM and Landis
   The first PLC, model 084, was invented by Dick
    Morley in 1969
   The first commercial successful PLC, the 184, was
    designed by Michael Greenberg in 1973
PLC, by Mohamed Al-Emam, Session 1
Sizes of PLC’s
Single Board PLCs “ Open Frame
PLCs”.
PLC, by Mohamed Al-Emam, Session 1
PLC System With High-Density
I/O (64-point modules).
PLC market can
be segmented
into five groups:
1. micro
2. small
3. medium
4. large
5. very large
PLC, by Mohamed Al-Emam, Session 1
PLC, by Mohamed Al-Emam, Session 1
PLC, by Mohamed Al-Emam, Session 1
Cycle of operate PLC’s
               input                
                             scan
                                    
               execute
                     programme
                                    
                  degonistic and
                 commenucation
                           scan
                                    
               output scan
PLC, by Mohamed Al-Emam, Session 1
PLC conceptual application
diagram.
Sequence of PLC control
 When a process is controlled by a PLC it
  uses inputs from sensors to make
  decisions and update outputs to drive
  actuators
 The process is a real process that will
  change over time. Actuators will drive the
  system to new states (or modes of
  operation). This means that the controller is
  limited by the sensors available, if an input
  is not available, the controller will have no
  way to detect a condition “real time
  system “.
PLC, by Mohamed Al-Emam, Session 1
Number Of
               Scan       Special I/O
               Time        Modules

      Memory                            Communications


                                             Software
Number Of
                                            Availability
Logical I/O

                      Select
                       PLC                   Peripherals
  Type Of
 Controller
PLC, by Mohamed Al-Emam, Session 1
Packaging Machine
Pick And Place Robot Control
swimming pool
sewage/water treatment
Chemical processing plant
Food/Drugs Production
Petrochemical ,Petrol/Gas Plant
Amusement Park Control
Scientific Experiments CERN LHC




 CERN built LHC 27Klm …this experiment is controlled by PLC
Also
   Martial Handling            Plastic Machine
   Conveyor System             Semi Conductors/IC
   Pump Control                Manufacturing
   Paper And Pulp Industries   Air Condition Control "For
   Glass Manufacturing         Huge Sheller "
   Precast Concrete            Generator Control System
    Industries                  Lift Control System
   Cement Manufacture          Iron And Steel
                                Manufacturing
   Printing Industries
                                Traffic Light System
   Electro-plating Plants      Power Stations
   Machine Tools
BUT
there is NO horizon for the Applications !!
PLC, by Mohamed Al-Emam, Session 1
PLC H.W Components:
   CPU =ALU +CU
   System Busses
   Memory
   I/O Sections
   Power Supply Unit
   Programming Device
Programming Device
The programming device is used to enter
  the required program into the memory of
  the processor.
The program is DEVELOPED in the
  programming device and then
  TRANSFERRED TO MEMORY unit of
  the PLC.
CPU
Microprocessor based, allow arithmetic
  operations, logic operators, block memory
  moves, computer interface ,and local area
  network, functions,.. etc.
CPU makes a great number of CHECK-UPS of the
  PLC controller itself so eventual errors would be
  discovered early.
This is an intro to a point in next session
I/O Sections
Inputs monitor field devices, such as
  switches and sensors.
Outputs control other devices, such as
  motors, pumps, solenoid valves, and
  lights.
Power Supply Unit
Most PLC controllers work either at 24
  VDC or 220 VAC.
Some PLC controllers have electrical
  supply as a separate module, while
  small and medium series already
  contain the supply module.
Max current is 10mA.
Memory
System (ROM) to give permanent storage
  for the operating system and the fixed
  data used by the CPU.RAM for data.
  This is where information is stored on
  the status of input and output devices
  and the values of timers and counters
  and other internal devices. EPROM for
  ROM’s that can be programmed and
  then the program made permanent.
Cpu
Von Neumann
System Busses
The internal paths along which the digital
  signals flow within the PLC are called
  busses.
The system has four busses:
   The CPU uses the DATA BUS for sending data
    between the different elements,
   The ADDRESS BUS to send the addresses of
    locations for accessing stored data,
   The CONTROL BUS for signals relating to
    internal control actions,
   The SYSTEM BUS is used for communications
    between the I/O ports and the I/O unit.
PLC, by Mohamed Al-Emam, Session 1
Switches
PLC, by Mohamed Al-Emam, Session 1
PLC, by Mohamed Al-Emam, Session 1
PLC, by Mohamed Al-Emam, Session 1
Proximity
             switch



Inductive               Capacitive
PLC, by Mohamed Al-Emam, Session 1
Sensors
 Feed back elements which convert the
  physical quantity into electrical signals
 Now we introduce some sensors as
  refreshment ,Let me go ahead ☺
Useful Rule

If
U can measure it ,
U can control it
Obama say if the sun light is can measure it and emamof say this is the 1st exception is provide the truth of
                                                                                                  the rule 
1- Potentiometers
PLC, by Mohamed Al-Emam, Session 1
2- Encoders
Incremental encoder
3 -Tachometers
Tachometers
4- Linear Variable Differential
Transformers (LVDTs)
LVDTs
5 - Moire Fringes
$5 Moire Fringes




   These are used in high precision applications
    over long distances, often meters.
   They can be purchased from a number of
    suppliers, but the cost will be high. Typical
    applications include Coordinate Measuring
    Machines (CMMs).
$6 Accelerometers
PLC, by Mohamed Al-Emam, Session 1
6- Chemical pH
   The pH of an ionic fluid can be measured
    over the range from a strong base
    (alkaline) with pH=14, to a neutral value,
    pH=7, to a strong acid, pH=0. These
    measurements are normally made with
    electrodes that are in direct contact with
    the fluids.
PLC, by Mohamed Al-Emam, Session 1
7 -Thermocouples
PLC, by Mohamed Al-Emam, Session 1
8 -Resistive Temperature
Detectors (RTDs)
RTDs
9 -Venturi Valves
10-Photoelectric
OPPOSED
RETRO REFLECTIVE
REFLECTION
PLC, by Mohamed Al-Emam, Session 1
PLC, by Mohamed Al-Emam, Session 1
IR TEMP SENSORS
11- Pressure
PLC, by Mohamed Al-Emam, Session 1
Break




   Can u tell me which of sensors can use
    as position sensor in last example ?
   This is not all thing about sensors we
    can not talk about more, Coz the target
    is DONE ISA
KEY TERMS 
 DICK MORLY
 EMAMOF
 FDX CYCLE
 OPERATION CYCLE
 SELECTION of Ms. PLC
 TYPES, SIZE, INFRASTRUCTURE
 SENSING TECHNIQUES
PLC, by Mohamed Al-Emam, Session 1

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PLC, by Mohamed Al-Emam, Session 1

  • 1. Session 01 By Emamof Presented in 02-02-2009
  • 3. TARGET TO   CONTROL SYS.  Automatic Controller  WHAT  Origin of PLC  History  Sizes of PLC’s  Cycle of Operation  Which  APPLICATIONS N REAL  PLC H.W Components:  INPUT TO PLC ,SENSING CONCEPTS
  • 5. Open loop Closed loop Control System
  • 7. Analog Digital Control System
  • 8. Control system Motion Sequential
  • 9. Batch Process has a beginning and an end “complete product control process” , Some applications require that specific quantities of raw materials be combined in specific ways for particular durations to produce an intermediate or end result. Example: production of food and medicine.
  • 10. Continuous Process Often, a physical system is represented though variables that are smooth and uninterrupted in time. Example :control of the water temperature in a heating jacket,
  • 11. Discrete It is Not independent, Most discrete manufacturing involves the production of discrete pieces of product Examples :  metal stamping.  automotive production.
  • 12. Hybrid  Applications having elements of discrete, batch and continuous process control are often called hybrid applications.
  • 13. Sequential Control Control a process that is a series of tasks to be performed (sequence of operation ),each task is performed under :-  Time driven . Common in open loop sys  Event driven . Common in closed loop sys Example washing machine In PLC the SFC is powerful Lang for it .
  • 14. Motion Control Controlling motion in electromechanical sys  Rotational or Linear by Servomotor.  Digital by NC (Numerical Control).  3 dimension by Robotic.
  • 16. µC DCS PC Mr. CNC CONTROLLER PLC SCADA PAC FPGA
  • 17. Automatic controllers  µC==Microcontroller.  FPGA not FBGA.  PC  Mr. PLC  DCS== Distributed Control System  SCADA == Supervisory Control And Data Acquisition  CNC == Computer Numerical Control  PAC ==Programmable Automation Controller
  • 18. SCADA
  • 21. WHAT  Programmable logic controllers, also called programmable controllers or PLCs, are solid-state members of the computer family, using integrated circuits instead of electromechanical devices to implement control functions.  They are capable of storing instructions, such as sequencing, timing, counting, arithmetic, dat a manipulation, and communication, to control industrial machines and processes
  • 23. Intro 2 Microprocessor and Microcontroller world.
  • 24. Microprocessor The block that will have a built in capability to Add “multiply, divide, subtract”, and move its contents from one memory location onto another is called "central processing unit" (CPU).
  • 25. Characteristics differentiate microprocessors  Instruction set The set of instructions that the microprocessor can execute  bandwidth The number of bits processed in a single instruction  clock speed Given in megahertz MHz the clock speed determines how many instructions per second the processor can execute
  • 26. Microcontroller A microcontroller (also MCU or µC) is a functional computer system-on-a-chip. It contains a processor core, memory, and programmable input/output peripherals.
  • 28. Why  Coz we can say  Microcontroller= Microprocessor +Memory +i/o Peripherals.  PLC’s=Microcontroller +I/O Interfaces.
  • 30. Dick Morley==Richard E. Morley Founder of Modicon (now Schneider Automation, Inc)
  • 31. History of PLCs  The first Programmable Logic Controllers were designed and developed by Modicon as a relay replacer for GM and Landis  The first PLC, model 084, was invented by Dick Morley in 1969  The first commercial successful PLC, the 184, was designed by Michael Greenberg in 1973
  • 34. Single Board PLCs “ Open Frame PLCs”.
  • 36. PLC System With High-Density I/O (64-point modules).
  • 37. PLC market can be segmented into five groups: 1. micro 2. small 3. medium 4. large 5. very large
  • 41. Cycle of operate PLC’s input  scan  execute programme  degonistic and commenucation scan  output scan
  • 44. Sequence of PLC control  When a process is controlled by a PLC it uses inputs from sensors to make decisions and update outputs to drive actuators  The process is a real process that will change over time. Actuators will drive the system to new states (or modes of operation). This means that the controller is limited by the sensors available, if an input is not available, the controller will have no way to detect a condition “real time system “.
  • 46. Number Of Scan Special I/O Time Modules Memory Communications Software Number Of Availability Logical I/O Select PLC Peripherals Type Of Controller
  • 49. Pick And Place Robot Control
  • 56. Scientific Experiments CERN LHC CERN built LHC 27Klm …this experiment is controlled by PLC
  • 57. Also  Martial Handling Plastic Machine  Conveyor System Semi Conductors/IC  Pump Control Manufacturing  Paper And Pulp Industries Air Condition Control "For  Glass Manufacturing Huge Sheller "  Precast Concrete Generator Control System Industries Lift Control System  Cement Manufacture Iron And Steel Manufacturing  Printing Industries Traffic Light System  Electro-plating Plants Power Stations  Machine Tools
  • 58. BUT there is NO horizon for the Applications !!
  • 60. PLC H.W Components:  CPU =ALU +CU  System Busses  Memory  I/O Sections  Power Supply Unit  Programming Device
  • 61. Programming Device The programming device is used to enter the required program into the memory of the processor. The program is DEVELOPED in the programming device and then TRANSFERRED TO MEMORY unit of the PLC.
  • 62. CPU Microprocessor based, allow arithmetic operations, logic operators, block memory moves, computer interface ,and local area network, functions,.. etc. CPU makes a great number of CHECK-UPS of the PLC controller itself so eventual errors would be discovered early. This is an intro to a point in next session
  • 63. I/O Sections Inputs monitor field devices, such as switches and sensors. Outputs control other devices, such as motors, pumps, solenoid valves, and lights.
  • 64. Power Supply Unit Most PLC controllers work either at 24 VDC or 220 VAC. Some PLC controllers have electrical supply as a separate module, while small and medium series already contain the supply module. Max current is 10mA.
  • 65. Memory System (ROM) to give permanent storage for the operating system and the fixed data used by the CPU.RAM for data. This is where information is stored on the status of input and output devices and the values of timers and counters and other internal devices. EPROM for ROM’s that can be programmed and then the program made permanent.
  • 66. Cpu
  • 68. System Busses The internal paths along which the digital signals flow within the PLC are called busses. The system has four busses:  The CPU uses the DATA BUS for sending data between the different elements,  The ADDRESS BUS to send the addresses of locations for accessing stored data,  The CONTROL BUS for signals relating to internal control actions,  The SYSTEM BUS is used for communications between the I/O ports and the I/O unit.
  • 74. Proximity switch Inductive Capacitive
  • 76. Sensors  Feed back elements which convert the physical quantity into electrical signals  Now we introduce some sensors as refreshment ,Let me go ahead ☺
  • 77. Useful Rule If U can measure it , U can control it Obama say if the sun light is can measure it and emamof say this is the 1st exception is provide the truth of the rule 
  • 84. 4- Linear Variable Differential Transformers (LVDTs)
  • 85. LVDTs
  • 86. 5 - Moire Fringes
  • 87. $5 Moire Fringes  These are used in high precision applications over long distances, often meters.  They can be purchased from a number of suppliers, but the cost will be high. Typical applications include Coordinate Measuring Machines (CMMs).
  • 90. 6- Chemical pH  The pH of an ionic fluid can be measured over the range from a strong base (alkaline) with pH=14, to a neutral value, pH=7, to a strong acid, pH=0. These measurements are normally made with electrodes that are in direct contact with the fluids.
  • 95. RTDs
  • 106. Break  Can u tell me which of sensors can use as position sensor in last example ?
  • 107. This is not all thing about sensors we can not talk about more, Coz the target is DONE ISA
  • 108. KEY TERMS   DICK MORLY  EMAMOF  FDX CYCLE  OPERATION CYCLE  SELECTION of Ms. PLC  TYPES, SIZE, INFRASTRUCTURE  SENSING TECHNIQUES

Editor's Notes

  1. control systems may classify to open or closed loop, analog or digital. Yet we can classify control systems in other ways, which have to do with applications to. Process control Sequential control Motion control
  2. FPGA==can prog by VHDL or VerilogClosed sys contain sensorz
  3. PAC ==describes this new generation of industrial controllers that combines the functionality of a PLC and a PC.As the technological differences between PC and PLC wane, a new class of controllers is emerging for engineers who require higher loop rates, advanced control algorithms, more analog capabilities, and better integration with the enterprise network. The Programmable Automation Controller (PAC) describes this new generation of industrial controllers that combines the functionality of a PLC and a PC.
  4. Open Frame PLC(Triangle Research Inc., Pte. Ltd.)single printed circuit board as shown in Figure 2-1.They are sometimes called single board PLCs or open frame PLCs. These are totallyself contained (with the exception of a power supply) and, when installed in a system, theyare simply mounted inside a controls cabinet on threaded standoffs. Screw terminals onthe printed circuit board allow for the connection of the input, output, and power supplywires. These units are generally not expandable, meaning that extra inputs, outputs, andmemory cannot be added to the basic unit. However, some of the more sophisticatedmodels can be linked by cable to expansion boards that can provide extra I/O. Therefore,with few exceptions, when using this type of PLC, the system designer must take care tospecify a unit that has enough inputs, outputs, and programming capability to handle boththe present need of the system and any future modifications that may be required. Singleboard PLCs are very inexpensive (some less than $100), easy to program, small, andconsume little power, but, generally speaking, they do not have a large number of inputsand outputs, and have a somewhat limited instruction set. They are best suited to small,relatively simple control applications.
  5. (Omron Electronics) Modularized PLC
  6. usually based upon the required inputs, outputs and functions of the controller. The first decision is the type of controller; rack, mini, micro, or software based. This decision will depend on After the planning phase of the design, the equipment can be ordered. This deci-sion is usually based upon the required inputs, outputs and functions of the controller. The first decision is the type of controller; rack, mini, micro, or software based. This decision will depend upon the basic criteria listed below.• Number of logical inputs and outputs.• Memory - Often 1K and up. Need is dictated by size of ladder logic program. A ladder element will take only a few bytes, and will be specified in manufactur-ers documentation.• Number of special I/O modules - When doing some exotic applications, a large number of special add-on cards may be required.• Scan Time - Big programs or faster processes will require shorter scan times. And, the shorter the scan time, the higher the cost. Typical values for this are 1 microsecond per simple ladder instruction• Communications - Serial and networked connections allow the PLC to be pro-grammed and talk to other PLCs. The needs are determined by the application.• Software - Availability of programming software and other tools determines the programming and debugging ease.The process of selecting a PLC can be broken into the steps listed below.1. Understand the process to be controlled (Note: This is done using the design sheets in the previous chapter).• List the number and types of inputs and outputs.• Determine how the process is to be controlled.
  7. Tissue Packing Machine
  8. ammonia and ethylene processing
  9. سابك السعودية
  10. This is an intro to a point in next session Errors fatal or non
  11. Von Neumann architecture memory “memory-mapped I/O “accesses hardware by reading and writing to specific memory locations, using the same assembler language instructions that computer would normally use to access memory. 
  12. Omron E2K-X4ME2 Proximity Switch Capacitive 10 TO 30 Vdc Detecting Distance 4MM OMRON Inductive Proximity Switches
  13. Is a device used to detect the presence of an object by using a light transmitter, often infrared, and a photoelectric receiver. They are used extensively in industrial manufacturing. There are three different functional types, opposed, retro reflective, and proximity-sensing.