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0 - Intro - PLC Fundamentals Essentials For Control Systems

The document provides an introduction to programmable logic controllers (PLCs), including their history, basics, applications, advantages over other systems, major manufacturers, and differences between PLCs and distributed control systems. Specific topics covered include the inventor of the PLC, getting started with PLCs, a bottle filling process example, interpreting PLC symbols, and introductions to common PLC models from manufacturers like Allen-Bradley and ABB.

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Minh Nguyen Hoang
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11 views

0 - Intro - PLC Fundamentals Essentials For Control Systems

The document provides an introduction to programmable logic controllers (PLCs), including their history, basics, applications, advantages over other systems, major manufacturers, and differences between PLCs and distributed control systems. Specific topics covered include the inventor of the PLC, getting started with PLCs, a bottle filling process example, interpreting PLC symbols, and introductions to common PLC models from manufacturers like Allen-Bradley and ABB.

Uploaded by

Minh Nguyen Hoang
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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PLC Fundamentals: Essentials for Control Systems

Introduction to PLCs
1.1 What is a PLC?

Let's see what exactly a PLC or Programmable Logic Control is in simple


terms!

1.2 PLC Basics | Programmable Logic Controller

In this lesson, we are going to talk about the basics of a PLC, the workhorse
of industrial automation. The programmable logic controller, or PLC, is a
special purpose computer. It has no display, no keyboard, no printer, no
hard drive, and hides in the control panel out on the factory floor, but it is
still a computer. Initially, the PLC was a replacement for panels of relays,
devices that turn on and off. Making a machine run using relays as logic was
time-consuming and challenging, and making a change in the logic or the
operation of the machine was almost as complicated as starting over.

1.3 Who is the Father of the PLC?

Ever wondered about the inventor of the PLC? Meet Richard “Dick” Morley,
known as the "Father" of the PLC.

Morley had a clear vision for the controller: He wanted it to have no


interrupts for processing, enable direct memory mapping, eliminate
software handling of repetitive tasks, initially operate slowly (a decision he'd
later regret), feature a rugged industrial design, and use a proprietary
language. This language eventually led to the development of ladder logic—
a universal language for technicians and engineers.

Getting Started with PLCs


2.1 Low Cost PLC for Beginners | How to Get Started with Your
Own PLC!

Low-cost PLCs, such as Siemens S7-1200, are designed for skill development
and exploration. They offer affordable access to fully licensed components,
making them ideal for programmers looking to enhance their PLC
programming skills. These kits come with everything you need to quickly
create and test PLC programs and are available in various configurations,
including options with Human-Machine Interface (HMI) panels and safety
PLC Fundamentals: Essentials for Control Systems

PLCs. They provide a cost-effective way to gain hands-on experience in


automation and control systems.

2.2 Applying an ABB PLC to a Small Process

In the automation industry, ABB is a major PLC manufacturer. We'll


configure an ABB AC500 PLC system with CPU, interfaces, and remote I/O
cards using Automation Builder software. This hardware setup allows for
project-specific programming and control through the PLC and Control
Panel.

2.3 Bottle Filling Process PLC Program _ Part 1

There is a bottle filling machine that fills the empty bottles on a conveyor
belt with liquid from this tank. In this and the next lessons you’re going to
learn how this machine works and how to write a professional PLC program
that fully controls this machine. This filling machine has three operation
modes which are off, manual and automatic. These modes are determined
by the three position selector switch.

Advantages and Applications of PLCs


3.1 What Are the Advantages PLCs Have over Relay Systems?
PLC systems offer several advantages over relay systems:

Reliability: PLCs use solid-state internal relay systems, eliminating


mechanical components for improved reliability.
Ease of Troubleshooting: Troubleshooting in a PLC system is
straightforward, as technicians can examine the programming to identify
issues quickly.
Easy Expandability: PLCs are highly versatile and easily expandable.
Adding functions like timers is as simple as modifying the program.
Smaller Size: PLC systems have significantly smaller physical requirements
compared to relay logic circuitry. Most components are contained within
the PLC itself.
PLC versus Other Systems
4.1 PLC vs PC: Which is Better for Industrial Automation?

In this lesson, we will explore the benefits of using a Programmable Logic


Controller (PLC) over a Personal Computer (PC) in industrial control
systems.
PLC Fundamentals: Essentials for Control Systems

Specifically, we will discuss how PLCs were originally designed to replace


hard-wired relays and timers with user-created software programs, and
how they execute programs differently from PCs.

Additionally, we will compare the susceptibility of PLCs and PCs to viruses


and cyber attacks.

We will also look at the ease of expansion for PLCs versus PCs, and
introduce the concept of Industrial PCs and their advantages over
traditional PCs.

Finally, we will delve into the advantages of the programming capabilities of


Industrial PCs over PLCs.

4.2 What is the Difference Between PLC and DCS?

In a nutshell, a PLC or programmable logic controller is a ruggedized


computer used for automating processes. A DCS or distributed control
system is similar to a PLC in that is has rugged computer controllers
however the DCS contains multiple autonomous controllers that are
distributed throughout a system, also used for automating processes. As
you can tell, there are likely advantages and disadvantages in both systems.

The take away is that with today’s technologies, either system can control
an entire plant. Which system is chosen will likely take the advantages and
disadvantages into account as well as system costs. In summation, the DCS
has autonomous controllers dispersed throughout the entire plant. If a
controller fails, the entire plant doesn’t necessarily get impacted. It also has
the onboard monitoring and control that saves development time. A single
PLC is a single point of failure. You surely wouldn’t want to control an entire
plant with a single PLC, however; a connected PLC system can have nearly
the same security and robustness as a DCS.

4.3 How to Interpret DCS and PLC Symbols on a P&ID

This video explains how to interpret PLC and DCS symbols on a P&ID, a
critical skill for Instrumentation & Control Engineers, technicians, and
maintenance personnel working with industrial plant control systems.

P&IDs serve as a roadmap, detailing the instruments, their locations, and


interactions within the plant. Originally designed before PLCs and DCSs,
PLC Fundamentals: Essentials for Control Systems

P&ID symbols were adapted to accommodate these modern control


systems.

In the past, stand-alone instruments were represented by circles with tag


numbers. A horizontal bar across the circle signified a physical instrument
accessible from the main control panel. Drawing a box around the circle
indicated integration into a shared display and control system within a DCS.

PLC symbols, less common on P&IDs, are depicted as diamonds within


boxes, representing software instructions for plant functions.

PLC Manufacturers and Specific Models


5.1 What are the Major PLC Manufacturers?

Today we will discuss several of the top PLC manufacturers from around
the world. There are quite a few, and hopefully, this video will clear up
some of the differences between the major brands. As technicians,
engineers, and programmers, we have several choices when it comes to
choosing a brand of PLC. Depending on where you work, you may have to
familiarize yourself with many different PLC brands. Some places use more
than one manufacturer in a single facility. So let’s break some of the major
brands down so we can see the difference.

5.2 An Introduction to Allen Bradley PLCs and the Evolution of


Rockwell Automation PACs

Allen-Bradley, now part of Rockwell Automation, is a leading manufacturer


of factory automation equipment. Established in 1903, they offer a range of
products, including PLCs, HMI interfaces, sensors, and software. Their
history includes contributions to PLC development and various product
lines like PLC-5, SLC500, MicroLogix, ControlLogix, and CompactLogix, each
catering to specific needs. Communication with their PLCs is managed using
Rslinx software.

5.3 An Introduction to ABB AC500 PLCs

ABB is a prominent manufacturer in the automation industry, known for its


PLC controllers. Their AC500 PLC lineup offers scalability for various
automation systems, with models catering to small to large applications.
These PLCs support diverse I/O modules and communication interfaces,
making them versatile choices for industrial settings. ABB provides
PLC Fundamentals: Essentials for Control Systems

programming and configuration capabilities through the "ABB Automation


Builder" software, offering flexibility and compatibility with multiple
programming languages.

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