UNIT 1

PROGRAMMABLE CONTROLLERS IN AUTOMATION

I. Industrial Automation

As the global marketplace demands higher quality goods and lower costs, factory floor automation
has been changing from separate machines with simple hardware-based controls, if any, to an
integrated manufacturing enterprise with linked and sophisticated control and data systems. For many
organizations the transformation has been gradual, starting with the introduction of programmable
logic controllers and personal computers to machines and processes. However, for others the change
has been rapid and is still accelerating.

There are two ways to achieve high yields in manufacturing. The simplest, yet most expensive way
is to increase the number of production lines. An alternative and more desirable way is to increase the
rate of production in the existing production lines. It is possible to increase the production rate by
reducing the cycle time needed to produce a single part or product. There are also two ways to reduce
cycle time. The first approach is to improve the manufacturing process. The second approach is to
automate the manufacturing process by using re-programmable and automatically controlled
equipment.

I.1. Definition of an Industrial Automation

Automation refers to a technology which is based on the usage of mechanical, electronic and
computer system in handling process and manufacturing process control. The usage of automation
technology started when work done by labor / worker started being replaced by machines.
Technology development process continuously improved until humans started introducing the usage
of robotic, CAD/CAM, Flexible manufacturing system and others technology to increase human
quality of life and increase productivity in the industrial.

In a general sense the term “Industry” is defined as follows Systematic Economic Activity that could
be related to Manufacture/Service/ Trade.

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The word ‘Automation’ is derived from Greek words “Auto” (self) and “Matos” (moving).
Automation therefore is the mechanism for systems that “move by itself”. However, apart from this
original sense of the word, automated systems also achieve significantly superior performance than
what is possible with manual systems, in terms of power, precision and speed of operation.

Definition: Automation is a set of technologies that results in operation of

machines and systems without significant human intervention and achieves performance
superior to manual operation

Industrial Automation is a process of operating machines and other industrial equipment with
the help of digital logical programming and reducing human intervention in decision making
and manual command process with the help of mechanized equipment.

Industrial automation is a set of technologies that uses control systems and devices, such as
computer software and robotics, to enable automatic operation of industrial processes and
machinery without the need for human operators.

NB1:

Automatic control can be defined as the continuous control of a physical analog variable through the
utilization of any kind of actuators, while industrial automation refers to the sequential or digital ON-
OFF control of the two-state devices. ( George Nikolakopoulos, 2018)

Control is a set of technologies that achieves desired patterns of variations

of operational parameters and sequences for machines and systems by providing the
input signals necessary.

It is important at this stage to understand some of the differences in the senses that these two
terms are generally interpreted in technical contexts and specifically in this course. These are
given below.

1. Automation Systems may include Control Systems but the reverse is not true. Control
Systems may be parts of Automation Systems.

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2. The main function of control systems is to ensure that outputs follow the set points.
However, Automation Systems may have much more functionality, such as computing set points for
control systems, monitoring system performance, plant startup or shutdown,
job and equipment scheduling etc.

Refelction1:

i. Why does an automated system achieve superior performance compared to a manual

one?
ii. Is the definition applicable to open-loop as well as closed loop control?
iii. Can you give an example of an automated system, which contains a control system as a
part of it?
I.2. Advantages for Automation

Companies undertake projects in manufacturing automation and computer integrated

manufacturing for a variety of good reasons. Some of the reasons used to justify automated are the
following
1. To increase labor productivity. Automating a manufacturing operation usually increases production
rateand labor productivity. This means greater output per hour of labor input.
2. To reduce labor cost. Ever-increasing tabor cost has been and continues to be the trend in the world's
industrialized societies. Consequently, higher investment in automation has become economically
justifiable to replace manual operations.

3. To migrate the effects of labor shortages. There is a general shortage of labor in many advanced
nations and this has stimulated the development of automated operations as a substitute tor labor.
4. To reduce or eliminate routine manual and clerical tasks. An argument can be put forth that there
is social value in automating operations that are routine, boring, fatiguing, and possibly irksome.
Automating such tasks serves a purpose of improving the general level of working conditions.
5. To improve worker safety. By automating a given operation and transferring the worker from active
participation in the process to a supervisory role, the work is made safer. The safety and physical well-
being of the worker has become a national objective with the' enactment of the Occupational Safety
and Health Act (OSHA) in 1970. This has provided an impetus for automation.
6. To improve product quality. Automation not only results in higher production rates than manual

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operations; it also performs the manufacturing process with greater uniform and conformity to quality
specifications. Reduction attraction defect rate is one of the chief benefits of automation.
7. To reduce manufacturing lead lime. Automation helps to reduce the elapsed time between
customer order and product delivery, providing a competitive advantage 10 the manufacturer for future
orders. By reducing manufacturing lead time, the manufacturer also reduces work-in-process
inventory.
8. To accomplish processes that cannot be done manually. Certain operations cannot be
accomplished without the aid of a machine. These processes have requirements for precision,
miniaturization or complexity of geometry that cannot be achieved manually.
Examples include certain integrated circuit fabrication operations, rapid prototyping processes based
on computer graphics (CAD) models, and the machining of complex, mathematically defined surfaces
using computer numerical control. These processes can only be realized by computer-controlled
systems.
9. To avoid the high cost of not automating. There is a significant competitive advantage gained in
automating a manufacturing plant. The advantage cannot easily be demonstrated on a company's
project authorization form. The benefits of automation often show up in unexpected and intangible
ways, such as in improved quality, higher sales, better labor relations, and better company image.
Companies that do not automate are likely to find themselves at a competitive disadvantage with their
customers, their employees, and the general public.

I.3. Disadvantages of Automation

Aside from these advantages, it is also important for us to discuss about the disadvantages of using
and implementing automation in the industrial.

1. Higher Start-up cost and the cost of operation. Automated equipment includes the high capital
expenditure required to invest in automation. An automated system can cost millions of FCFA to
design, fabricate and install machine. These include buying electromechanical devices such as
electromechanically valve, sensory devices, and smart devices. Cost of spare parts for automation
system may consider higher compare to the manual operate.

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3. Obsolescence/Depreciation Cost. Obsolescence and depreciation is a gradual reduction in the value
of physical assets. This phenomenon is characteristic of all physical assets in the form of equipment
and machinery. It was something that was inevitable due to technology development. Obsolescence
or depreciation can be classified into two parts, namely:

I. Physical Depreciation - occurred as a result of physical damage of equipment or robots. It describes

a form that can be seen clearly as damage, wear and corrosion.

ii. Depreciation of the functions - it existed from changes in demand for services may be provided.
Depreciation caused by changes in the need for an equipment service discovery of new equipment
or a robot system inability to meet demand

4. Unemployment. A disadvantage often associated with automation, is worker displacement. Due to

the fact that manual laborers are being replaced by robots or other automated machineries, this results
to mass lay-off. A lot of people are losing their jobs especially those who work in the manufacturing
industry such as a car factory.

5. Not economically justifiable for small scale production.

I.4. Types of Automation System

Automated manufacturing systems can be classified into three basic types:

i. Fixed automation.

ii. Programmable automation, and

iii. Flexible automation

I.4.1. Fixed Automation

Fixed automation is a system in which the sequence of processing (or assembly) operations is fixed
by the equipment configuration. Each of the operations is the sequence is usually simple, involving
perhaps a plain linear or rotational motion or an uncomplicated combination of the two; for example,
the feeding of a rotating spindle. It is the integration and coordination of many such operations into

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one piece of equipment that makes the system complex. Typical features of fixed automation are:
i. high initial investment for custom-engineered equipment

ii. high production rates

iii. relatively inflexible in accommodating product variety

The economic justification for fixed automation is found in products that are produced in very large
quantities and at high production rates. The high initial cost of the equipment can be spread over a
very large number of units, thus making the unit cost attractive compared with alternative methods of
production. Examples of fixed automation include machining transfer lines, automated assembly
machines, distillation process, conveyors and paint shops.

I.4.2. Programmable Automation

In programmable automation, the production equipment is designed with the capability to change
the sequence of operations to accommodate different product configuration. The operation sequence
is controlled by a program, which is a set of instructions coded so that they can be read and interpreted
by the system. New programs can be prepared and entered into the equipment to produce new products.
Some of the features that characterize programmable automation include:

i. high investment in general purpose equipment

ii. lower production rates than fixed automation

iii. flexibility to deal with variations and changes in product configuration

iv. most suitable for batch production Programmable automated production systems are used in low-
and medium-volume production. The parts or products are typically made in batches. To produce each
new batch of a different product, the system must be reprogrammed with the set of machine
instructions that correspond to the new product.

The physical setup of the machine must also be changed. Tools must be loaded, fixtures must be
attached to the machine table and the required machine setting must be entered. This changeover
procedure takes time. Consequently, the typical cycle for a given product includes a period during

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which the setup and reprogramming takes place, followed by a period in which the batch is produced.
Examples of programmable automation include numerically controlled (NC) machine tools, industrial
robots, programmable logic controller, steel rolling Mills and paper mills.

I.4.3. Flexible Automation

Flexible automation is an extension of programmable automation. A flexible automated system is

capable of producing a variety of parts (or products) with virtually no time lost for changeovers from
one part style to the next. There is no lost production time while reprogramming the system and
altering the physical setup (tooling, fixtures, machine settings). Consequently, the system can produce
various combinations and schedules of parts or products instead of requiring that they be made in
batches. What makes flexible automation possible is that the differences between parts processed by
the system are not significant. It is a case of soft variety.so that the amount of changeover required
between styles is minimal.

The features of flexible automation can be summarized as follows:

i. high investment for a custom-engineered system

ii. continuous production of variable mixtures of products

iii. medium production rate

iv. flexibility to deal with product design variations

Examples of flexible automation are the flexible manufacturing systems for performing machining
operations that date back to the late 1960s. The relative positions of the three types of automation for
different production volumes and product varieties are depicted in Figure 1.4. For low production
quantities
and new product introduction manual production is competitive with programmable automation, as
indicated in the figure.

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 variety
Programmable
Automation

Flexible
Automation

Fixed
Automation

Quantity

Figure 1. 1:Three types of automation relative to production quantity and product variety.
Reflection2:

i. During a technical visit to an industry how can you identify the type of automation
prevailing there from among the above types?
ii. For what kind of a factory would you recommend computer integrated manufacturing
and why?
iii. What kind of automation would you recommend for manufacturing?
(a) Light bulbs (b)garments (c)textiles (d) Cement (e) Printing (f) Pharmaceuticals (g) Toys
I.5. Automation in Production System

A production system is a collection of people, equipment, and procedures organized to perform the
manufacturing operations of an organization. A production system consists of facilities and
manufacturing support systems (Figure 1.2):

i. Facilities—the factory, the equipment in the factory, and the way the equipment is organized
around the shop floor.

ii. Manufacturing support systems—the set of procedures used to manage production and to solve
technical and logistics problems met in manufacturing processes. These systems include product
design, planning and control, logistics and other business functions.

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Figure 1. 2:Production System consists of facilities and manufacturing support systems
A manufacturing system is a logical grouping of equipment in the factory and the workers who
operate it. Examples include worker-machine systems, production lines, and machine cells. A
production
system is a larger system that includes a collection of manufacturing systems and the support systems
used to manage them. A manufacturing system is a subset of the production system. Portions of
production systems tend to be automated and/or computerized, while other parts may be operated by
manual labor. The overall operation of the production system is controlled by people, including direct
labor staff for facility operation, and professional staff with responsibilities over the manufacturing
support systems. Facilities include the factory, production machines and tooling, material handling
equipment, inspection equipment, and computer systems that control the manufacturing operations.
Facilities can also include the plant layout—that is, the physical arrangement of the equipment in the
factory, which is usually organized into logical groupings called manufacturing systems

Manufacturing systems consist of groups of machines and associated workers. Typically, the
manufacturing system comes in direct physical contact with the product or parts to be made. Three
types
may be identified, as outlined in Table 1.1.

Table 1.1: Three categories of manufacturing systems

Category Description

Manual Work
One (or more) workers performing one (or more) tasks without powered tools.
System
Typical example is the material handling task. In production tasks the use of hand

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 tools is pre-dominant, sometimes with optional work-holder. Examples include:
filing milled parts; checking quality of parts with micrometer; moving cartons
using a dolly; and, assembling machinery using hand tools.

A human worker operates powered equipment, in various combinations of one (or

Worker- more) workers, and one (or more) pieces of equipment. Relative strengths of
Machine humans and machines are combined. Examples include: machinist operating
Systems engine lathe; a fitter working with an industrial robot; a crew of workers operating
a rolling mill; and personnel performing work on a mechanized conveyor.

Process is performed by machine without the direct participation of a human

worker. Automation uses a programmed of instructions and a control system for
implementation; there are two sub-categories: semi-automated, and fully
automated. Semi-automation implies only part of the work cycle is completely
Automated automated, with other work done by a human worker. A fully automated machine,
Systems on the other hand, has the capacity to operate for extended periods of
time (longer than one work cycle) with no human interaction. However, although
fully automated, human monitoring may still be used. Examples include: injection
moulding machines; and automated processes in oil refineries and nuclear power
plants.

Manufacturing Support Systems are used by a company to manage its production operations. Most
support systems do not directly contact the product, but they plan and control its progress through the
factory. Manufacturing Support Systems use a four-function information-processing cycle that is
explained
in Table 1.2. This list of functions is activated by customers’ orders, which propels the system into
action, and operates by deploying the facilities detailed above.

Table 1.2: Information-processing cycle for Manufacturing Support Systems

Function Description

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 First and last phase. The principle means of communicating with the customer,
includes sales and marketing, sales forecasting, order entry, cost accounting, and
customer billing. Product originates from customer order, and after sales and
Business marketing, proceeds to become a production order. Production order is in the form
Function of one of the following: a manufacturing order against customer specifications; a
customer order to buy one or more of manufacturer’s proprietary products; or, an
internal company order based on future-demand
Forecasts.

Second phase. If product is manufactured by customer design, then design supplied

by customer. If there are customer specifications, then manufacturer’s design
Product
department may be contracted to create a design on this basis, as well as to
Design
manufacture the product also. For a proprietary product, the manufacturing firm is
responsible for its development and design.

Third phase. Upon completion of product design, the associated information is given
to the manufacturing planning function. Process planning, master scheduling,
requirements planning, and capacity planning are performed here. Process planning
determines the process and assembly steps, and the order of the steps, needed to
Manufact produce the product. The master production schedule lists products to be made,
uring when they are to be made, and the quantities of each to be produced. Based upon
Planning the master production schedule, requirements planning are performed—that is, the
individual components, sub-assemblies, raw materials etc. required are purchased,
created, and scheduled to be available when needed. Capacity planning is concerned
with planning the manpower and machine resources to carry out the manufacturing
function.

Manufact Fourth phase. Concerned with managing and controlling the physical operations in

uring the factory to implement the manufacturing plans. Shop floor control, inventory

Control control, and quality control are performed here. Shop floor control monitors the
product as it moves about the shop floor; as the product is a work-in-process

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 inventory as it proceeds across the shop floor, shop-floor control is related to
inventory control also. Inventory control tries to maintain the correct amount of
inventory in the manufacturing system, and avoid overloading or starving the
system. Quality control tries to ensure correct product and component quality, as
per the specified design. It uses inspection activities on the shop-floor, and at the
point of entry of outsourced components, to do this.

I.6. Basic Components of an Automated system

An automated system consists of three basic elements: (1) power to accomplish the process and
operate the system, (2) as program of instructions to direct the process, and (3) a control system to
actuate the instructions. The relationship amongst these elements is illustrated in Figure 1.2. All
systems that qualify as being automated include these three basic elements in one form or another.

Figure 1. 3:Elements of automated system: (1) power, (2) program of instruction and (3) control
system

1. Power to Accomplish the Automated Process

A. Power for the process
▪ To drive the process itself
▪ To load and unload the work unit
▪ To transport between operations

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 B. Power for Automation
▪ Controller Unit
▪ Power to actuate the control signals
▪ Data acquisition and information processing
2. Program of Instructions

The actions performed by an automated process are defined by a program of instructions. Set of
commands that specify the sequence of steps in the work cycle and the details of each step. ork Cycle
Programs. In the simplest automated processes, the work cycle consists of essentially
one step, which is to maintain a single process parameter at a defined level, for example, maintain the
temperature of a furnace at a designated value for the duration of a heat treatment cycle, other examples
Axis position in a positioning system, motor ON or OFF

3. Control System

The control element of the automated system executes the program of instructions. The control
system causes the process to accomplish its defined function, which for our purpose is to carry out
some manufacturing operation. They are of two types

i. An open loop control system-operates without feedback, simpler and less expensive, risk that
the actuator will not have intended effect

Figure 1. 4: An open loop System

ii. A closed loop control system-A system in which the output variable is compared with an input
parameter, and any difference between the two is used to drive the output into agreement with
the input.

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Figure 1. 5:closed loop control system
I.7. Automation Examples: car painting, car manufacturing, soldering and brazing machine
A. Car painting

B. Car manufacturing

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 C. Bottle filling system

II. Programmable Controllers

Programmable controllers were originally designed to replace relay-based control systems and solid-
state, hard-wired logic control panels. However, the modern programmable controllers’ system is far
more complex and powerful.

The most basic function performed by programmable controllers is to examine the status of inputs and
in response, control some process or machine through outputs. The logical combinations of inputs to
produce an output or outputs are called control logic. Several logic combinations are usually required
to carry out a control plan or program. This control plan is stored in memory using a programming
device to input the program into the system. The processor, usually a high-speed microprocessor, in a
predetermined sequential order, periodically scans the control plan in memory. The period required to
examine the inputs and outputs, perform the control logic, and execute the outputs is called the “scan
time.” A simplified block diagram of a programmable controller is shown in Figure 1-1. In this
diagram, a level switch and panel-mounted pushbutton are wired to input circuits, and the output
circuits are connected to an electric solenoid valve and a panel-mounted indicator light. The output
devices are controlled by the control program in the logic unit. This figure shows a typical
configuration of the early programmable controller applications, which were intended to replace relay
or hardwired logic control systems. The input circuits are used to convert the various field voltages
and currents to the low voltage signals [normally 0- to 5-V direct current (DC)] used by the logic unit.
The output circuits convert the logic signals to a level that will drive the field devices. For example,

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in Figure below, 120-VAC power is connected to the field input devices, so the input circuits are used
to convert the 120 VAC to the 0- to 5-V logic signals used by the control unit.

Figure 1. 6: Block diagram of a PLC system

III. Microprocessor and Microcontroller controlled Systems

The digital integrated circuit called a microprocessor has ushered in a whole new era for control
systems electronics. This revolution has occurred because the microprocessor brings the flexibility of
program control and the computational power to bear on any problem. Automatic control applications
are particularly well suited to take advantage of this technology, and microprocessor based systems
are rapidly replacing many older control systems based on analog circuits or electromagnetic relays.
One of the first microprocessor based controllers made specifically for control applications was the
programmable logic controller, which is discussed later in this chapter. . A microprocessor by itself
is not a computer; additional components such as memory and input/output circuits are required to
make it operational. a close relative of the microprocessor, does contain all the computer functions on
a single IC, Microcontrollers lack some of the power and speed of newer microprocessors but their
compactness is ideal for many controlled applications. Most so-called microprocessor devices such
as vending machines are really using microcontrollers. Some specific reasons for using a digital
microprocessor design in control systems are the following:

• Low level signals from sensors, once converted to digital, can be transmitted long distances
without errors
• A microprocessor can easily handle complex calculations and control registers

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• Long term memory is available to keep track of parameters is slow-moving systems
• Changing the control strategy is easy by loading a new program. No hardware changes are required
• Microprocessor based controllers are more easily connected to the computer network withi an
organisation. This allows designers to enter program changes and read current system status from
their desk terminals.

Microprocessors are employed for high speed applications such as desktop and laptop computers
where as the microcontrollers are employed in automation and control applications such as microwave
ovens, automatic washing machines, dish washers, engine management systems.Microcontrollers are
embedded inside some other device (often a consumer product) so that they can control the features
or actions of the product. Therefore, it is also called as embedded controller. Because of its relatively
low cost, it is a natural choice for design. It performs many of the functions traditionally done by
simple logic circuitry, sequential control circuits, timers or a small microcomputer.

Figure 1. 7: Microprocessor and microcontroller

Instead of hardwiring each control circuit for each control situation, we can use the same
basic system for all situations if we use a microprocessor-based system and write a
program to instruct the microprocessor how to react to each input signal from, say, switches and give
the required outputs to, say, motors and valves. Thus we might have a
program of the form:

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If switch A closes

Output to motor circuit

If switch B closes

Output to valve circuit

By changing the instructions in the program, we can use the same microprocessor system to control a
wide variety of situations. As an illustration, the modern domestic washing machine uses a
microprocessor system .Inputs to it arise from the dials used to select the required wash cycle, a switch
to determine that the machine door is closed, a temperature sensor to determine the temperature of the
water, and a switch to detect the level of the water. On the basis of these inputs the
microprocessor is programmed to give outputs that switch on the drum motor and control its
speed, open or close cold and hot water valves, switch on the drain pump, control the water
heater, and control the door lock so that the machine cannot be opened until the washing
cycle is completed.

Figure 1. 8:microprocessor based system

What are the elements of microprocessor-based controllers or microcontrollers? A

microcontroller generally has the main CPU core, ROM/ EPROM / RAM and some accessory
functions (like timers, pulse width modulator, A/D convertor and I/O controllers) all integrated into

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one chip. Microcontroller is a computer on a chip that is programmed to perform almost any control,
sequencing, monitoring and display function.

IV. Programmable Logic Controllers.

A programmable logic controller (PLC) is a special form of microprocessor-based controller

that uses programmable memory to store instructions and to implement functions such as
logic, sequencing, timing, counting, and arithmetic in order to control machines and
processes (Figure 1.9). It is designed to be operated by engineers with perhaps a limited
knowledge of computers and computing languages. They are not designed so that only
computer programmers can set up or change the programs. Thus, the designers of the PLC
have preprogrammed it so that the control program can be entered using a simple, rather
intuitive form of language (see Chapter 4). The term logic is used because programming is
primarily concerned with implementing logic and switching operations; for example, if A or
B occurs, switch on C; if A and B occurs, switch on D. Input devices (that is, sensors such as

Figure 1. 9:A programmable logic controller

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switches) and output devices (motors, valves, etc.) in the system being controlled are
connected to the PLC. The operator then enters a sequence of instructions, a program, into
the memory of the PLC. The controller then monitors the inputs and outputs according to this
program and carries out the control rules for which it has been programmed.
PLCs have the great advantage that the same basic controller can be used with a wide range
of control systems. To modify a control system and the rules that are to be used, all that is
necessary is for an operator to key in a different set of instructions. There is no need to
rewire. The result is a flexible, cost-effective system that can be used with control systems,
which vary quite widely in their nature and complexity. When compared with relay systems,
PLCs:
• Can easily implement changes as changes are implemented in software rather
than more complex hardware modifications that would be the case with a relay
system
• Can be readily expanded by adding new modules to the PLC whereas hardware changes are necessary

with relay systems

• Are more robust and reliable than relay systems with their large number of mechanical
components

• Require less maintenance than relay systems

• Can operate faster than relay systems. PLCs are similar to computers, but whereas computers are
optimized for calculation and display tasks, PLCs are optimized for control tasks and the industrial
environment. Thus when compared to computers, PLCs:

• Are rugged and designed to withstand vibrations, temperature, humidity, and noise.
The common personal computer is not designed for harsh environments.

• Have interfacing for inputs and outputs already inside the controller. PLCs in a rack
format are easy to expand to tackle a larger number of inputs/outputs.

• Are easily programmed and have an easily understood programming language that is
primarily concerned with logic and switching operations. As a consequence, they are
more user friendly.
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• They are not so good at long term data storage and analysis as personal computers.
• Personal computers are more liable to crash than PLCs that have greater reliability.

IV.1. TYPES OF PLC

There are three types of PLC, which are shown below:

Figure 1. 10: Types of PLC

1. Modular PLC

In modular PLC, modular means adding modules. It allows us to expand the structure of PLC. It is
useful when there are a large number of inputs and outputs. We can add more input and outputs by
adding the modules in the PLC. It also has more memory and capability to store information. The
example includes control processing lines in the manufacturing industry.

Figure 1. 11:Modular PLC

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 2. Rack PLC

The modules in the rack type PLC are arranged in the rows. The racks are placed inside the cabinets.
The slots in the rack PLC communicate with each other connected by the standard network or bus.

Figure 1. 12: Rack PLC

3. Compact PLC

The Input / Output (I/O) modules in the compact PLC are determined by the manufacturer of that PLC.
It means that the I/O is fixed. But, the compact PLCs are used for small scale applications.

Figure 1. 13: Compact PLC

IV.2. How PLC Works

In simple words, PLC takes the input from the input devices, processes it based on the logic in the
CPU, and controls the output devices based on that logic. PLC is lightweight and can operate without
any electrical filtering or air conditioning.

The devices such as pushbutton, sensors are connected as the input devices, which can detect a change
in the input signals in the PLC. The input signal passes through the barrier that converts the voltage
into low voltage, such as 5V. The CPU monitors the state of the input. Based on the specified logic,
CPU processes and produces the output signal. The barrier present at the output terminal prevents the

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PLC from external noise and converts the low voltage to high voltage to drive output devices. The
output signal controls the output devices, such as motor, controllers, pilot lights, etc.

Figure 1. 14: physical structure of a PLC

Source;javapoit.com

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