A typical PLC can be divided into parts, as illustrated in (Figure 2-2b) these are the central processing unit (CPU), the input/output (I/O) section, the power supply, and the programming device. The term architecture can refer to PLC hardware, to PLC software, or to a combination of both. An open architecture design allows the system to be connected easily to devices and programs made by other manufacturers. Open architectures use off-the shelf components that conform to approved standards. A system with a closed architecture is one whose design is proprietary, making it more difficult to connect to other systems. Most PLC systems are in fact proprietary, so you must be sure that any generic hardware or software you may use is compatible with your particular PLC.
Also, although the principal concepts are the same in all methods of programming, there might be slight differences in addressing, memory allocation, retrieval, and data handling for different models. Consequently, PLC programs cannot be interchanged among different PLC manufacturers.
There are two ways in which I/Os (Inputs/Outputs) are incorporated into the PLC: fixed and modular
TYPICAL PARTS OF MODULAR PLC.
The supplies DC power to other modules that plug into the rack. For large PLC systems, this power supply does not normally supply power to the field devices. With larger systems, power to field devices is provided by external alternating current (AC) or direct current (DC) supplies. For some small micro PLC systems, the power supply may be used to power field devices.
CPU is the “brain” of the PLC. A typical processor usually consists of a microprocessor for implementing the logic and controlling the communications among the modules. The processor requires memory for storing user program instructions, numerical values, and I/O devices status. The CPU controls all PLC activity and is designed so that the user can enter the desired program in relay ladder logic. The PLC program is executed as part of a repetitive process referred to as a scan. A typical PLC scan starts with the CPU reading the status of inputs. Then, the application program is executed. Once the program execution is completed, the status of all outputs is updated. Next, the CPU performs internal diagnostic and communication tasks. This process is repeated continuously as long as the PLC is in the run mode.
I/O system forms the interface by which field device are connected to the controller. The purpose of this interface is to condition the various signals received from or sent to external field devices. Input devices such as pushbuttons, limit switches, and sensors.
A programming device is used to enter the desired program into the memory of the processor. The program can be entered using relay ladder logic, which is one of the most popular programming languages. Instead of words ladder logic programming language uses graphic symbols that show their intended outcome. A program ladder logic is similar to a schematic for a relay control circuit. It is a special language written to make it easy for people familiar with relay logic control to program the PLC. Hand-held programming devices are sometimes used to program small PLCs because they are inexpensive and easy to use. Once plugged into the PLC, they can be used to enter and monitor programs. Both compact hand-held units and laptop computers are frequently used on the factory floor for troubleshooting equipment, modifying programs, and transferring programs to multiple machines.
A personal computer is the most commonly used programming device. Most brands of PLCs have software available so that a PC can be used as the programming device. This software allows users to create, edit, document, store, and troubleshoot ladder logic programs. The computer monitor is able to display more logic on the screen than can hand-held types, thus simplifying the interpretation of the program. The personal computer communicates with the PLC processor via a serial or parallel data communications link, or Ethernet. If the programming unit is not in use, it may be unplugged and removed. Removing the programming unit will not affect the operation of the user program.
A program is a user-developed series of instructions that directs the PLC to execute actions. A programming language provides rules for combining the instructions so that they produce the desired actions. Relay ladder logic (RLL) is the standard programming language used with PLCs. Its origin is based on electromechanical relay control. The relay ladder logic program graphically represents rungs of contacts, coils, and special instruction blocks. RLL was originally designed for easy use and understanding for its users and has been modified to keep up with the increasing demands of industry’s control needs.