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Summary
Summary
This book is designed to help readers develop a good general working knowledge of programmable controllers with concentration on relay ladder logic techniques and how PLC is connected to external components in an operating control system. The book uses real world programming problems that readers can solve on any available programmable controller or PLC simulator. Later chapters relate to more advanced subjects in machine controls making this a welcome addition to a personal technical reference library. KEY TOPCIS: The authors examine ladder diagram fundamentals, the programmable logic controller, fundamental PLC programming, advanced programming techniques, mnemonic programming code, wiring techniques, analog I/O, discrete position sensors, encoders, transducers, and advanced sensors, closed loop and PID control, motor controls, and system integrity and safety. For those involved in Electrical, Automation, Control, and Process Engineering.
Excerpts
Excerpts
Most textbooks related to programmable logic controllers (PLCs) start with the basics of ladder logic, Boolean algebra, contacts, coils, and all the other aspects of learning to program PLCs. However, once they get more deeply into the subject, these books generally narrow the field of view to one particular manufacturer's unit (usually one of the more popular brands and models) and concentrate on programming that device with its capabilities and peculiarities. This is worthwhile if the desire is simply to learn to program that particular unit. However, after finishing the PLC course, most students will likely be employed designing, programming, and maintaining systems using PLCs of another brand or model or various machines with different PLC brands and models. We believe that it is more advantageous to approach the study of PLCs using a general language that provides a thorough knowledge of programming concepts which can be adapted to all controllers. This language would be based on a collection of different manufacturer types with generally the same programming technique and capability. Although it would be impossible to teach one programming language and technique that would be applicable to each and every programmable controller on the market, students can be given a thorough insight into programming methods with this general approach that will allow them to easily adapt to any PLC situation encountered. The goal of this text is to help the reader develop a good general working knowledge of programmable controllers while concentrating on relay ladder logic techniques and how the PLC is connected to external components in an operating control system. The text presents real-world programming problems that can be solved on any available programmable controller or PLC simulator. Later chapters relate to more advanced subjects that are more suitable for an advanced course in machine controls. Readers should have a thorough understanding of fundamental ac and do circuits, electronic devices (including thyristors) and a knowledge of basic logic gates, flip flops, Boolean algebra, and college algebra and trigonometry. Although a knowledge of calculus will enhance the understanding of closedloop controls, it is not required. We also hope that this text will serve as a technical reference for students and professionals. Excerpted from Programmable Logic Controllers: Programming Methods and Applications by John R. Hackworth, Frederick D. Hackworth All rights reserved by the original copyright owners. Excerpts are provided for display purposes only and may not be reproduced, reprinted or distributed without the written permission of the publisher.Table of Contents
Chapter 1 Ladder Diagram Fundamentals | p. 1 |
Objectives | p. 1 |
Introduction | p. 1 |
1-1 Basic Components and Their Symbols | p. 2 |
1-2 Fundamentals of Ladder Diagrams | p. 13 |
1-3 Machine Control Terminology | p. 31 |
Summary | p. 33 |
Chapter 2 The Programmable Logic Controller | p. 35 |
Objectives | p. 35 |
Introduction | p. 35 |
2-1 A Brief History | p. 36 |
2-2 PLC Configurations | p. 37 |
2-3 System Block Diagram | p. 42 |
2-4 Update-Solve the Ladder-Update | p. 43 |
2-5 Update | p. 44 |
2-6 Solve the Ladder | p. 45 |
Summary | p. 48 |
Chapter 3 Fundamental PLC Programming | p. 50 |
Objectives | p. 50 |
Introduction | p. 50 |
3-1 Physical Components vs. Program Components | p. 51 |
3-2 Example Problem--Lighting Control | p. 56 |
3-3 Internal Relays | p. 58 |
3-4 Disagreement Circuit | p. 59 |
3-5 Majority Circuit | p. 59 |
3-6 Oscillator | p. 62 |
3-7 Holding (also called Sealed, or Latched) Contacts | p. 64 |
3-8 Always-ON and Always-OFF Contacts | p. 65 |
3-9 Ladder Diagrams Having More Than One Rung | p. 67 |
Summary | p. 69 |
Chapter 4 Advanced Programming Techniques | p. 72 |
Objectives | p. 72 |
Introduction | p. 72 |
4-1 Ladder Program Execution Sequence | p. 73 |
4-2 Flip Flops | p. 73 |
4-3 R-S Flip Flop | p. 73 |
4-4 One Shot | p. 74 |
4-5 D Flip Flop | p. 77 |
4-6 T Flip Flop | p. 79 |
4-7 J-K Flip Flop | p. 81 |
4-8 Counters | p. 83 |
4-9 Sequencers | p. 85 |
4-10 Timers | p. 87 |
4-11 Master Control Relays and Control Zones | p. 96 |
Summary | p. 98 |
Chapter 5 Mnemonic Programming Code | p. 103 |
Objectives | p. 103 |
Introduction | p. 103 |
5-1 AND Ladder Rung | p. 104 |
5-2 Entering Normally Closed Contacts | p. 105 |
5-3 OR Ladder Rung | p. 106 |
5-4 Simple Branches | p. 107 |
5-5 Complex Branches | p. 110 |
Summary | p. 112 |
Chapter 6 Wiring Techniques | p. 115 |
Objectives | p. 115 |
Introduction | p. 115 |
6-1 PLC Power Connection | p. 116 |
6-2 Input Wiring | p. 119 |
6-3 Inputs Having a Single Common | p. 121 |
6-4 Isolated Inputs | p. 124 |
6-5 Output Wiring | p. 126 |
6-6 Relay Outputs | p. 127 |
6-7 Solid State Outputs | p. 131 |
Summary | p. 137 |
Chapter 7 Analog I/O | p. 139 |
Objectives | p. 139 |
Introduction | p. 139 |
7-1 Analog (A/D) Input | p. 110 |
7-2 Analog (D/A) Output | p. 144 |
7-3 Analog Data Handling | p. 145 |
7-4 Analog Input Potential Problems | p. 146 |
Summary | p. 147 |
Chapter 8 Discrete Position Sensors | p. 150 |
Objectives | p. 150 |
Introduction | p. 150 |
8-1 Sensor Output Classification | p. 151 |
8-2 Connecting Discrete Sensors to PLC Inputs | p. 154 |
8-3 Proximity Sensors | p. 156 |
8-4 Inductive Proximity Sensors | p. 156 |
8-5 Capacitive Proximity Sensors | p. 159 |
8-6 Ultrasonic Proximity Sensors | p. 161 |
8-7 Optical Proximity Sensors | p. 163 |
Summary | p. 167 |
Chapter 9 Encoders, Transducers, and Advanced Sensors | p. 169 |
Objectives | p. 169 |
Introduction | p. 169 |
9-1 Temperature | p. 170 |
9-2 Liquid Level | p. 175 |
9-3 Force | p. 177 |
9-4 Pressure/Vacuum | p. 181 |
9-5 Flow | p. 186 |
9-6 Inclination | p. 192 |
9-7 Acceleration | p. 193 |
9-8 Angle Position Sensors | p. 194 |
9-9 Linear Displacement | p. 204 |
Summary | p. 209 |
Chapter 10 Closed-Loop and PID Control | p. 212 |
Objectives | p. 212 |
Introduction | p. 212 |
10-1 Simple Closed-Loop Systems | p. 212 |
10-2 Problems with Simple Closed-Loop Systems | p. 214 |
10-3 Closed-Loop Systems Using Proportional, Integral, Derivative (PID) | p. 218 |
10-4 Derivative Function | p. 220 |
10-5 Integral Function | p. 225 |
10-6 The PID in Programmable Logic Controllers | p. 228 |
10-7 Tuning the PID | p. 229 |
10-8 The "Adjust and Observe" Tuning Method | p. 231 |
10-9 The Ziegler-Nichols Tuning Method | p. 233 |
10-10 Autotuning PID Systems | p. 239 |
Summary | p. 240 |
Chapter 11 Motor Controls | p. 242 |
Objectives | p. 242 |
Introduction | p. 242 |
11-1 AC Motor Starter | p. 243 |
11-2 AC Motor Overload Protection | p. 245 |
11-3 Specifying a Motor Starter | p. 247 |
11-4 DC Motor Controller | p. 248 |
11-5 Variable Speed (Variable Frequency) AC Motor Drive | p. 255 |
Summary | p. 258 |
Chapter 12 System Integrity and Safety | p. 260 |
Objectives | p. 260 |
Introduction | p. 260 |
12-1 System Integrity | p. 260 |
12-2 Equipment Temperature Considerations | p. 263 |
12-3 Fail Safe Wiring and Programming | p. 264 |
12-4 Safety Interlocks | p. 268 |
Summary | p. 272 |
Appendix A Logic Symbols | p. 274 |
Appendix B Industrial Electrical Symbols | p. 276 |
Bibliography | p. 281 |
Glossary | p. 283 |
Index | p. 297 |