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Introduction to Programmable Logic Controllers: Course Objectives and Industry Applications

This course provides an in-depth understanding of Programmable Logic Controllers (PLCs) and their applications in industrial automation. It encompasses course objectives aligned with ABET standards, emphasizing the development of PLC-based control and data acquisition systems. Participants will engage in two major projects: Hydro Automation for Winton Hydro and a power plant educational demo, along with automated data acquisition from the Medical School. Key skills include PLC programming, mechanical ability, and knowledge of internet protocols. This course equips students for fast-paced careers and real-world engineering challenges.

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Introduction to Programmable Logic Controllers: Course Objectives and Industry Applications

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  1. ECE 4951 Lecture 1: Programmable Logic Controllers

  2. Course Objectives • ABET OBJECTIVES • WORK WITH INDUSTRY TO DEVELOP: • Scope and Specification • Budget • Design • DELIVER WRITTEN AND ORAL REPORTS AT UMD

  3. PROJECTS • MP#1: Hydro Automation • Develop a PLC based control automation scheme for Winton Hydro (Ely, MN) • MP#2: Power Plant Educational Demo • Develop a PLC based control and data acquisition system for a model power plant • UMD#1: Automated Data Acquisition for Medical School • Develop hardware and software to broadcast metering data from Med. School to ethernet and collect for display and archiving

  4. Skill Sets • MP#1: • PLC programming • Ability to learn MP control Schemes • Ability to work a fast track job • MP#2: • PLC programming • Mechanical ability • Ability to visualize and implement an open-ended spec • UMD#1: • Internet protocols • Software development • Data base development

  5. PLC’s Are ... • Similar to a Microcontroller: • Microprocessor Based • Onboard Memory for Storing Programs • Special Programming Language: Ladder Logic • Input/Output Ports

  6. PLC’s Are... • Dissimilar to Microcontrollers: • Intended for Industrial Applications (High Power) • I/O Designed to interface with Control Relays • Emphasis on Maximum Reliability

  7. PLC’s • Widely Applied in Every Industry • Were Developed to Simplify the Implementation of Control Automation Systems in Plants and Assembly Lines • Designed to Minimize the Number of Control Relays in a Process and Maximize the Ways Relays can be Used • First Applied to Automobile Industry in the Late 1960’s • Flexible, Reliable and Low Cost

  8. PLC Components

  9. I/O Modules • Input Modules: Input Signals can be AC or DC, Analog or Digital • Output Modules: Outputs are either AC or DC Analog Signals (Although it is possible to ‘Construct’ Digital Outputs) • Modern PLC’s have Expansion Ports to Increase the Number of Available Inputs and Outputs

  10. Examples of I/O Signals • Inputs: • Pushbutton (Energizing or Grounding an Input) • Relay Contact Output • DC Voltage Level • Digital Logic Signal (+5V or 0 V, etc) • Outputs: • 24 V ac • 120 V ac • 120 Vdc • etcetera

  11. PLC’s Use Ladder Logic • Ladder Logic Diagrams Provide a Method to Symbolically Show How Relay Control Schemes are Implemented • Relay Contacts and Coils, Inputs and Outputs lie on “Rungs” Between the Positive and Ground Rails

  12. Example of Ladder Diagram

  13. Relays • In General, Relays Transform a Control Signal into a Control Action • Relays Provide: • Isolation Between Input and Output • Leverage (Small Signal Can Control Large Action) • Automation (Minimize Human Interaction with a Control Process)

  14. Relay Components

  15. Basic Relay Symbols

  16. Relay Applications • Relays can be Designed to Perform Many Functions • Detect Out of Limit Conditions on Voltages and Currents • Start Motors • Prevent Motors from Over Heating • Control Assembly Lines • Adjust Lighting

  17. References • Skvarenina/DeWitt, Electrical Power and Controls, Pearson-Prentice Hall, 2004

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