Programmable Logic Controllers (PLCs) were invented by the American Richard (‘Dick’) Morley in 1969, to be used in the manufacture of cars. Prior to that date production lines had been controlled by a mass of hard-wired relays. Using programmable devices in their place meant that changes in production could be implemented much faster without the need to rewire control circuits.

The aim of this unit is to further develop students’ skills in the use of PLCs and their specific applications within engineering and manufacturing. Among the topics included in this unit are: device interface methods, PLC signal processing and communications with other devices, PLC programming methodology and alternative programmable control devices.

On successful completion of this unit students will be able to research the design, selection and use of PLCs as part of a larger system, programme a PLC to solve an industrial process problem for a given application and illustrate the alternative strategies for using other available types of programmable control devices.

PLC selection:
Common PLC industrial applications
Different PLC types, their features and PLC manufacturers
External input and output devices: analogue and digital
PLC operational characteristics: speed, current, voltages, memory
Alternative PLC modules available: Relay, Triac, Transistor, Analogue to Digital
PLC signal processing and communications with other devices
Communication links and standards
Networked bus systems
Supervisory Control and Data Acquisition (SCADA) systems and Human Machine
Interfaces (HMIs)

PLC programming methodology:
Fundamentals of logic–ladder diagrams and other programming structures
PLC programming methods used of PLCs in accordance with IEC 61131
Logic functions: AND, OR, NOT, EXOR
Number systems used by PLCs: Binary, Hexadecimal, Octal, BCD
System input and output allocation data
Advanced functions: registers, Analogue to Digital (AtoD), performing
Calculations, high-speed counters and timers
Program test and debug software functions
Fault-finding of systems using PLC software remotely
Software toolbox elements
Virtual PLC simulations

Alternative programmable control devices:
Programmable Logic Device (PLD)
Peripheral Interface Controller (PIC)
Microcontrollers
Industrial computers

Programmable device interface methods:
Relays and solid state relays
Opto couplers
Opto isolators
Motor driver interface integrated circuits

A 15 minute (plus Q&A) presentation on the selection of a PLC for an industrial application assessing learning outcomes 1 and 2, weighted at 50%.

A Report of 1500 words plus artifact (programme) on the design and analysis of a PLC programme for a given application, assessing learning outcomes 3 and 4, weighted at 50%.

Whole group lectures will be used to deliver new material and to consolidate previous material. Small-group tutorials, with activities designed to enhance the understanding of the material delivered in the lectures, will be used to apply the skills and knowledge learned. A mixture of classroom based and practical activities will take place supported by staff.

Discuss the selection of a specific PLC for a given industrial application.

Evaluate how PLCs exchange information and process signals with other devices.

Design a PLC programme to solve an industrial process problem for a given application.

Analyse alternative strategies using other types of programmable control devices in industrial applications.

PLC and robotics labs, microprocessor matrix kits
PCs with programming software.
Fanuc off-line programming units

BOLTON, W. (2015) Programmable Logic Controllers. 5th Ed. Newes.
KAMEL, K. and KAMEL, E. (2013) Programmable Logic Controllers: Industrial Control. McGraw-Hill Education.
MORTON, J. (2005) The PIC Microcontroller: Your Personal Introductory Course. 3rd Ed. Newnes.
PEREZ, E. (2012) Introduction to PLCs: A beginner's guide to Programmable Logic Controllers. Elvin Perez Adrover.

www.seipub.org/ Science and Engineering Publishing Company International Journal of Information and Computer Science (Journal)
http://www.airccse.org/ AIRCC Publishing Corporation International Journal of Computer Science, Engineering and Information Technology (IJCSEIT) (Journal)

Must be registered on HNC/D Electrical and Electronic Engineering provision at South Staffordshire College.

Programmable Logic Controllers (PLCs) were invented by the American Richard (‘Dick’) Morley in 1969, to be used in the manufacture of cars. Prior to that date production lines had been controlled by a mass of hard-wired relays. Using programmable devices in their place meant that changes in production could be implemented much faster without the need to rewire control circuits.

The aim of this unit is to further develop your skills in the use of PLCs and their specific applications within engineering and manufacturing. Among the topics included in this unit are: device interface methods, PLC signal processing and communications with other devices, PLC programming methodology and alternative programmable control devices.

On successful completion of this unit you will be able to research the design, selection and use of PLCs as part of a larger system, programme a PLC to solve an industrial process problem for a given application and illustrate the alternative strategies for using other available types of programmable control devices.