Elements of Industrial Automation 20ME44P

WEEK -5

Programmable logic controller (PLC): It is a digital electronic device that uses a

programmable memory to store instructions and to implement functions such as logic,
sequencing, timing, counting and arithmetic in order to control machines and processes.
Different PLC Programming Languages:
1. Ladder Diagram (LD)
2. Sequential Function Charts (SFC)
3. Function Block Diagram (FBD)
4. Structured Text (ST)
5. Instruction List (IL)

Ladder diagrams: The diagram shows the circuit for switching on or off an electric motor.
This diagram in a different way, using two vertical lines to represent the input power railsand
stringing the rest of the circuit between them. Figure (b) shows the result. Both circuits have
the switch in series with the motor and supplied with electrical power when the switch is
closed. The circuit shown in Figure (b) is termed a ladder diagram.

With such a diagram the power supply for the circuits is always shown as two vertical lines
with the rest of the circuit as horizontal lines. The power lines, or rails as they are often
termed, are like the vertical sides of a ladder with the horizontal circuit lines like the rungs of
the ladder. The horizontal rungs show only the control portion of the circuit.

PLC ladder programming: A very commonly used method of programming PLCs is based on
the use of ladder diagrams. Writing a program is then equivalent to drawing a switching
circuit. The ladder diagram consists of two vertical lines representing the power rails. Circuits
are connected as horizontal lines, i.e. the rungs of the ladder, between these two verticals.

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Elements of Industrial Automation 20ME44P

In drawing a ladder diagram, certain conventions are adopted:

1. The vertical lines of the diagram represent the power rails between which circuits are
connected. The power flow is taken to be from the left-hand vertical across a rung.

2. Each rung on the ladder defines one operation in the control process.

3. A ladder diagram is read from left to right and from top to bottom.

4. Each rung must start with an input or inputs and must end with at least one output.

5. Electrical devices are shown in their normal condition. Thus a switch which is normally
open until some object closes it, is shown as open on the ladder diagram. A switch that is
normally closed is shown closed.

6. A particular device can appear in more than one rung of a ladder.

7. The inputs and outputs are all identified by their addresses, the notation used depending on
the PLC manufacturer.

Standard IEC 1131-3 /Symbols used for I/O Devices: IEC 1131-3 symbols that are used for
input and output devices. Some slight variations occur between the symbols when used in
semi-graphic form and when in full graphic. Note that inputs are represented by different
symbols representing normally open or normally closed contacts. The action of the input is
equivalent to opening or closing a switch. Output coils are represented by just one form of
symbol.

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Elements of Industrial Automation 20ME44P

Logic functions:
1.NOT
Figure (a) shows an electrical circuit controlled by a switch that is normally closed. When
there is an input to the switch, it opens and there is then no current in the circuit. This
illustrates a NOT gate in that there is an output when there is no input and no output when
there is an input (Figure (c)). The gate is sometimes referred to as an inverter.
The truth table is:

(a) NOT circuit, (b) NOT logic with a ladder rung, (c) high output when no input to A

Figure (b) shows a NOT gate system on a ladder diagram. The input A contacts are shown as
being normally closed. This is in series with the output ( ). With no input to input A, the
contacts are closed and so there is an output. When there is an input to input A, it opens and
there is then no output.
Example of a NOT gate control system is a light that comes on when it becomes dark, i.e.
when there is no light input to the light sensor there is an output.

2.OR
Figure (a) shows an electrical circuit where an output is energized when switch A or B, both
normally open, are closed. This describes an OR logic gate (Figure(b)) in that input A or
input B must be on for there to be an output. The truth table is:

(a) OR electrical circuit, (b) OR logic gate

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Elements of Industrial Automation 20ME44P

Figure (a) shows an OR logic gate system on a ladder diagram, Figure (b) showing an
equivalent alternative way of drawing the same diagram. The ladder diagram starts with | |,
normally open contacts labelled input A, to represent switch A and in parallel with it | |,
normally open contacts labelled input B, to represent switch B. Either input A or input B have
to be closed for the output to be energised (Figure (c)). The line then terminates with O to
represent the output.

Example of an OR gate control system is a conveyor belt transporting bottled products to

packaging where a deflector plate is activated to deflect bottles into a reject bin if either the
weight is not within certain tolerances or there is no cap on the bottle.
3.AND
Figure (a) shows a situation where an output is not energised unless two, normally open,
switches are both closed. Switch A and switch B have both to be closed, which thus gives an
AND logic situation. This is representing a control system with two inputs A and B (Figure
(b)). Only when A and B are both on is there an output. Thus if we use 1 to indicate an on
signal and 0 to represent an off signal, then for there to be a 1 output must have A and B both
1. Such an operation is said to be controlled by a logic gate and the relationship between the
inputs to a logic gate and the outputs is tabulated in a form known as a truth table.

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Elements of Industrial Automation 20ME44P

Figure (a) shows an AND gate system on a ladder diagram. The ladder diagram starts with | |,
a normally open set of contacts labeled input A, to represent switch A and in series with it | |,
another normally open set of contacts labelled input B, to represent switch B. The line then
terminates with O to represent the output. For there to be an output, both input A and input B
have to occur, i.e. input A and input B contacts have to be closed (Figure (b))

Example of an AND gate is an interlock control system for a machine tool so that it can only
be operated when the safety guard is in position and the power switched on.

4.NOR
The consequence of having the NOT gate is to invert the outputs of the OR gate. The
combination of OR and NOT gates is termed a NOR gate. There is an output when neither
input A or input B is 1.The following is the resulting truth table:

Figure shows a ladder diagram of a NOR system. When input A and input B are both not
activated, there is a 1 output.

5.NAND
The consequence of having the NOT gate is to invert all the outputs from the AND gate. Both
the inputs A and B have to be 0 for there to be a 1 output. There is an output when input A
and input B are not 1. The combination of these gates is termed a NAND gate.

The same truth table occurs

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Elements of Industrial Automation 20ME44P

Figure shows a ladder diagram which gives a NAND gate. When the inputs to input A and
input B are both 0 then the output is 1. When the inputs to input A and input B are both 1, or
one is 0 and the other 1, then the output is 0.

Example of a NAND gate control system is a warning light that comes on if, with a machine
tool, the safety guard switch has not been activated and the limit switch signalling the presenc
of the workpiece has not been activated.

6. Exclusive OR (XOR)
The OR gate gives an output when either or both of the inputs are 1. Sometimes there is,
however, a need for a gate that gives an output when either of the inputs is 1 but not when
both are 1, i.e. has the truth table:

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Elements of Industrial Automation 20ME44P

Figure Shows a ladder diagram for an XOR gate system. When input A and input B are not
activated then there is 0 output. When just input A is activated, then the upper branch results
in the output being 1. When just input B is activated, then the lower branch results in the
output being 1. When both input A and input B are activated, there is no output.

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