1. TRAINING On PLC PROGRAMMING - Kumar N

4. Our FOCUS Application Engineering Division The perfection in Application Engineering lies in understanding the application, understanding the product, its power, and its limitations. We also do develop the customized products for the various requirements of the customer. Panel Engineering Division With vast experience in the field, our engineers are talented creative professionals & technology developers, the excel had been proven in various industries, with compact non heating cost effective Panel designs. Product Sales Division The suggestion and selling of right product for right application with the best possible cost effectiveness, knowing the strengths and limitations of the products, has been always the high morale.

5. Our FOCUS Training Division At Hitech Electronics Research and Training Zone, HERTZ , A unit of VaShIST Tecnologies, we mobilize the engineering work force for corporate as well as individuals by providing advanced training in PLC’s, Field Sensors and Instruments, Process Control & Instrumentation, Panel engineering, Embedded Programming and Design, Motion Controllers, SCADA HMI DCS

7. Design, Engineering & Supply.

8. Software Development.

9. Total Staging / Factory acceptance test.

10. Supervision of erection and commissioning.

11. Training

13. PLC /SCADA System integration

14. Embedded Systems / Controllers

15. Servo/AC drives applications

16. Products / Components

17. Sensors and Switches marketing

18. Commissioning

20. Aerospace,

21. Avionics,

22. Telecommunications,

23. Automotive,

24. Semiconductor / electronics / electrical,

25. Machinery,

27. What happens if “man” works,Constantly and continuously ??? ERRORS !!!, ERRORS !!! , ERRORS !!! Why ?? Due to fatigue and over confidence

28. Automation In other words,Using technology in the placeswhere “human errors” are possible.And using “manpower” in “appropriate way”

29. How do you do ? Simplification through applying ideas of appropriate Branch of Engineering Electrical, Electronics, Mechanical, Instrumentation, Mechatronics, Optical, Almost You apply All branches of SCIENCE and ENGINEERING

30. Replace Human . . , What do you do ? If we Consider, Then, MAN : MACHINE EYE : Photo-Electric Sensors , Vision systems EAR : Ultrasonic, Sound ,Vibratory Sensors SKIN : Temperature, Magnetic, Tactile, Shock, Viscosity, Flow, Etc.. NOSE : Chemical Sensors, TONGUE : Bio sensors INPUTS HANDS : Grippers , Motion Controllers LEGS : Motion Controllers, MOUTH : Speakers, Indicators, Communication Devices, OUTPUTS CONTROL SYSTEM BRAIN : CONTROLLERS

31. 14 How Industrial Automation Helps? 1- You get product CONSISTENCY 2- PRODUCTION rate is maximised 3- You Save lot of POWER 4- Easy Maintenance 5- Prevention of Human accidents 6- Minimizing Wastages 7- Reducing Man Power 8- Saving Time 9- Easy & Systematic accounting

32. WHAT IS A PLC ? ? ?

33. PLC A device used to automate monitoring and control of industrial plant can be used stand-alone or in conjunction with a SCADA or other system. PROGRAMMABLE LOGIC CONTROLLER (IN OTHER WORDS..) The “logic” “controller” which is “programmable” DEFINITION:

34. PROGRAMMABLE LOGIC CONTROLLER Invented in 1968 as a substitute for hardwired relay panels. "A digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions such as logic sequencing, timing, counting, and arithmetic to control, through digital or analog input/output modules, various types of machines or processes. The digital computer which is used to perform the functions of a programmable controller is considered to be within this scope. Excluded are drum and other similar mechanical sequencing controllers."

35. Understanding PLC Understanding the Logic Understanding the Controller Understanding the Program.

36. LOGIC Meaningful things Electrically Meaningful – Electrical Logic True logic: It can be expressed in truth table Pseudo logic: It cannot be expressed in truth table

38. THE CONTROLLER HAS PRE-SPECIFIED, DEFINED, STRUCTURES FOR THE CONTROL.

39. IT JUST CHECKS IF THE FUNCTIONS ARE GOING AS PER THE DEFINED STRUCTURES.

40. YOU CAN PROGRAM THE REQUIRED LOGIC,

42. Definition of PLC PLC is a digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions such as logic sequencing, timing, counting, and arithmetic to control, through digital or analog input/output modules, various types of machines or processes. Modern PLC can be viewed as specialized computer Specialized in logic control Handle harsh and noisy environment

43. Structures

44. 5/17/2011 Input / Output module Analog inputs Flow sensors Humidity sensors Potentiometers Pressure sensors Temperature sensors Analog outputs Analog meters Analog valves and actuators DC and AC motor drives Digital input/output Bar code, encoder Display Special purpose I/O PID controller Fast input Network module

45. 5/17/2011 Memory ROM RAM PROM EPROM etc

46. Peripherals Operator console Printer Simulator EPROM loader Network communication PC based programming software

47. Functions of PLC Relay Timer and counter Program control Arithmetic Data manipulation Data transfer Others, such as sequencers

48. A Relay

49. A counter

50. Counter timing diagram (the count value is 5)

51. A timer

52. Timer timing diagram (the timing value is 5)

53. Logic control Control actions are taken by making decisions depending on the values associated with various inputs or variables and the control logic in the program. Decisions by attributes (go-nogo decision) Is the machine turned on? Is the gate to the work cell open? Has the AGV arrived at the docking station? Decision by variables How deep is the hole? What is the cutting speed? What is the required surface finish? How many parts are to be made?

54. Logic control Attribute decision can be represented by a logic variable (true or false) and its value can be determined by a logic expression Boolean algebra is used for logic expression

55. Logic network diagram and ladder diagram

56. Example 1 A robot is to be used to unload finished parts from a machine onto an AGV and to load raw parts from the AGV to the machine. Assume that there are sensors at the AGV's docking station to indicate the arrival of a vehicle and onboard sensors indicating whether the vehicle has brought a raw part to be processed as well as whether the AGV has space to carry away a finished part. Also assume there are sensors on the machine to indicate whether the machine is loaded with a part and also to signal completion of part processing. The robot is required to unload a processed part from the machine onto the AGV, pick up a new part for processing from the AGV, and load it onto the machine. The AGV is to be dispatched after completion of the cycle. Construct a ladder logic diagram for this task.

57. Identify I/Os 01 AGV has arrived 02 AGV is carrying a new part to be processed 03 AGV has space to store a processed part 04 Machine has a finished part to be unloaded 20 Unload old part from machine onto the AGV 21 Pick new part from the AGV and load onto the machine 22 Dispatch the AGV

58. The Ladder Diagram

59. Features of Ladder Diagram A ladder logic diagram is made up of inputs and outputs connected according to the appropriate logic. Each rung in the ladder represents a set of logical relationships between the inputs that leads to a particular output. The output from one rung of the ladder could be used as an input in another rung of the same ladder. Except when special provisions are made, it is considered that all rungs in a given ladder logic diagram are executed simultaneously, so the order of the rungs on the ladder in general does not matter.

60. PLC scan

61. Example 2

62. 5/17/2011 Identified I/Os

63. 5/17/2011 Program

64. Wiring diagram

65. Example 3 During the powder metallurgy process, a punch is used to press blended metal powder into a compact inside a die. A pushbutton is used to start the process. When the start button is pressed, the die is filled with powder. The punch is then advanced and it applies pressure to the powder for a duration of 10 s, after which it is retracted. The pressed compact is then ejected from the die and the cycle repeats. The cycle can be interrupted by pressing a stop button. If the stop button is pressed, the punch is required to retract (if it had been advanced) before the process is stopped. We are required to construct a ladder logic diagram for this task.

66. Identify I/Os

67. Ladder Diagram

68. Example 4 This example illustrates the use of both the timing and counting functions. Consider a production line in which parts requiring processing are brought to a machine by a conveyor. A robot is used to load parts from the conveyor onto the machine and, after the part has been processed, unload the part from the machine and place it on a pallet. The cycle time for processing each part is 10 min. The robot is to palletize the parts by placing 125 parts on each pallet. The parts are to be arranged on the pallet in five layers of 25 parts each. Once a pallet is complete, it is dispatched and a new pallet is started. An allowance of 30 s is to be made for pallet dispatching and presentation of a new pallet. Construct a ladder logic diagram to effect the required control.