St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech
Student Handout Project #8 PLC:
Automation and Controls in Manufacturing
In this module you will be introduced to the
principles of Programmable Logic Controllers and
how they interface to automated processes. By
consulting and designing, you will automate a
process using basic instruction sets and control
knowledge.
Objectives
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Students will understand how automation controls
fit into a manufacturing environment
Students will understand the relationship between
the controller and the machine
Students will define various components and their
functions
Students will understand the importance and
flexibility of PLC’s
Students will describe the basic principles of Relay
Logic & numbering systems
Analyze and make appropriate changes to a PLC
automated system.
Students will present written and visual information
effectively
Students will research equipment, and present oral
reports discussing design recommendations.
Performance Expectations
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Students will be able to identify major components
of Programmable Logic Control System.
Students will create designs, make presentations,
and perform laboratory experiments.
Students learn to simplify their program and
problem solve in a team environment.
Students will learn numbering systems
Students will be able to do effective practical
research
©2005 STLCC at Florissant Valley
Problem Scenario for PLC
A small company is expanding its operations by
adding a new packaging line. The new packaging
line boxes smaller boxes of whiteout into bigger
ones. There are six small boxes of whiteout in every
big box. There are eight bottles of whiteout in each
small box. They can hire new employees to perform
the job, but they feel that installing an automated
control system will cut cost, provide reliability, and
speed. The packaging line is currently being put into
place. You have been brought in to help them with
the PLC portion of the project.
The company also wants:
 To be able to count how many bottles of
whiteout have gone through the system.
 To know how many boxes are packaged per
minute.
The company has provided a drawing that shows the
location of devices on the packaging system. Once
the design is complete present your results to the
plant representatives.
1. Using web links provided, gather some
background information on various input and
output sensing devices.
2. Using the drawing (figure 2) provided, add
any additional input and/or output devices.
Document your recommendations for the
necessary devices and describe how they are
used in the project. Also decide what type of
PLC will be used for the project.
3. Present your recommendations to your team
and collectively design a final project using
information from each team member.
4. Collectively as a team, prepare an oral and
visual presentation describing your
recommendations, cost, and how it works in
the process.
5. Draw your system using Ladder Logic format
(AutoCAD).
6. Download programs and make necessary
7. Document program accordingly.
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St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech
PLC Terminology
wwwdev.ab.com
Central Processing Unit (CPU) – The section of the
programmable controller that does the decision
making and data storage.
Chassis – A hardware assembly that houses PLC
devices such as adapter modules, power supplies, and
I/O modules.
Ladder Logic –A program written in a format similar
to ladders like diagrams used in electrical drawings.
Instructions–A mnemonic and data address defining
an operation to be performed by the controller.
Input Devices – Devices such as a pushbutton or a
switch that supplies input signals to the controller.
Output Devices – Devices such as a light or a motor
that is controlled by the controllers signal.
Programmable Logic Controller (PLC) – A solidstate control system used to implement specific
functions such as report generation, communication,
counting, arithmetic, and timing. See definition
below.
Storage Memory – The memory that stores the
instruction, input, and output status information.
User Memory – The memory that stores user
program or ladder logic.
Data Highway Plus (DH+) – A local area network
designed to provide simple communication between
PLCs, PC’s, and SLC 500.
Storage Memory – The memory that stores the
instruction, input, and output status information.
User Memory – The memory that stores user
program or ladder logic.
Data Highway Plus (DH+)-A local area network
designed to provide simple communication between
PLCs, PC’s, and SLC 500.
Addressing–A device that allows access to a PLC for
troubleshooting and programming.
Power Supply–Provides necessary voltage ranges to
devices.
Input and Output Modules – Input modules are
modules used to convert a input sensor voltage, or
current signals into digital data to be sent to the
PLC’s processor. While an output module sends an
output signal to control an output device. Modules
provide the necessary connections between sensors or
actuation devices.
Voltage – The amount of electrical pressure in a
circuit produced when electrons are freed from atoms.
Processor–the brains of the PLC that organizes data
and controls activity.
Programmable Logic Controllers
Originally designed to replace relay based control
systems in General Motors, Programmable Logic
©2005 STLCC at Florissant Valley
Controllers (PLC) have grown into a big part of the
control industry today. These industries include
packaging, pharmaceutical, automotive, and refinery, and
much more. PLCs provide faster production, more
reliability, and efficiency. They are also known for their
performance, reliability, tolerance to vibration dirty air
electrical noise and extreme temperatures. Like any other
electronic controls device, PLCs can be programmed to
perform a variety of tasks. The more knowledgeable a
person is on the PLC’s functions, the easier it is for
him/her to develop programs and to control complex
processes. Functions such as compare, compute, and
control instructions are used in almost every PLC. An
understanding on how the PLC works makes
troubleshooting time shorter and troubleshooting much
easier to perform.
PLC’s are broken into five parts, The CPU, Programming
device Memory, and I/O. It is common for PLC’s to
control more than one process at one time.
Logic Diagrams
Ladder Logic is the main programming language for the
SLC 500 PLC. By using ladder logic, the amount of
retraining required was greatly reduced. Engineers and
trades personnel such as electricians already being
familiar with ladder diagrams made the transition from
“Ladder Diagrams” to Ladder Logic much simpler.
Input and Output
Inputs and outputs modules for a PLC are used to monitor
and control processes. These modules provide an interface
that allows the controller to communicate with its
connected devices. Because not all input and output
modules are the same, it is important to understand their
differences to prevent damage or serious injury.
Inputs and Outputs (I/O) can be placed into two basic
categories: logical or continuous. A switch that turns on a
light bulb would be considered logical having only an on
and off state. If a dimmer were to be installed, the light
can then be dimmed to different levels. This would be
considered continuous control. Logical control is the most
common because of simplicity and accurate control. In
this example the switch would be the input device and the
light bulb would be the output device. Inputs detect and
measure outside variables while outputs control outside
devices such as motors, horns, etc.
Think of some devices you would consider input and
output devices. Using your design and materials
provided, develop and enter into a spreadsheet an I/O list.
The list will show all the necessary inputs and outputs
used in the program.
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St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech
Ladder Logic (PLC flow chart)
(figure 1) wwwdev.ab.com
Task Objectives: Students will
1. Students will individually research and summarize product data and cost needed for project.
2. Students will research the different types of PLC used in today’s industry.
3. Using a given description of the application, students must determine type and placement of equipment
that will be suitable for the plant application.
4. Students will perform calculations using the programmable Logic Controller.
5. Students will automate a process using basic instruction sets and control knowledge.
6. Students present their team recommendations through oral and/or written reports.
7. Participants will develop a drawing of the Logic that the controllers need to perform operations.
8. Students will present a working program.
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©2005 STLCC at Florissant Valley
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St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech
Drawing
(figure 2)
Research Links
http://www.frenchgerleman.com/frenchgerleman/CPort.aspx?tabindex=0&tabid=101263
http://wwwdev.ab.com/en/epub/catalogs/12762/2181376/2416247/1239758/
http://www.rockwell.com/
http://www.automationcontrols.com
©2005 STLCC at Florissant Valley
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St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech
PLC: PowerPoint Presentation Report
PREWRITING: Do your homework for the PLC lesson module. You must have background knowledge
about the subject you will be discussing. You will create an oral presentation using a powerful but easy-touse feature of the Microsoft PowerPoint application. You can use an already drafted outline or create one
from scratch, put it into slides, overhead transparencies, or even a webpage in order to present your ideas
to an audience. PowerPoint allows text, sound, clip art, graphics, animation, and movies to be integrated
into a presentation.
CONTENT:
Your research on the PLC equipment needed, the appropriate settings, and design recommendations.
Include all necessary visuals, drawings, and charts.
PREPARING A SLIDE SHOW OR PRESENTATION:
How to set up a PowerPoint Presentation using the Presentation Wizard:
1. Open PowerPoint from the Office Menu.
2. When the application opens, select AutoContent Wizard from the “Create a new presentation using:”
dialog box. Click OK.
3. When the next window opens, from the left side options, select the first square, “Presentation type.” On
the right side of the window you have a number of choices for types. Select one.
4. Go to the next square, “Output options, “ and unless you are making a webpage presentation, click the
first choice, “Presentations, etc.”
5. Select the next square, “Presentation style,” and click on the type of presentation you want to make, onscreen or overhead transparencies. Also you can click an option to make handouts for your audience.
6. At the last square, “Presentation options, “you can type in the title of your presentation, your name and
any other information you want to include in your presentation. Click the Finish button.
7. An outline of the presentation format will display. Now you can add your content.
For inserting an outline into the preformatted presentation:
1. From the Insert menu, select Slides from Outline. When the dialog box opens, select your file named
“outline.doc” or “outline.” Look in Drive A if you do not readily see your file listed.
2. Your outline content will fill into the presentation format. You can view the presentation in several ways
besides the outline. On the horizontal scroll bar in the lower left-hand corner of the window are several
view buttons: “Slide View,” “Slide Sorter View,” “Notes Page View,” and “Slide Show View.”
3. To change the order of the slides or pages, you can drag & drop or delete them in the “Slide Sorter
View.” To rearrange a page, do so just as you would in Word.
4. You can use the menu at the top of the PowerPoint window to add clip art, sounds (even your own
voice-overs), animation graphics, or even movie clips to enhance your presentation Save your file as
“slideshw.ppt” or “slideshow.”
EVALUATION:
©2005 STLCC at Florissant Valley
by teaching team according to student team-created rubric.
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St. Louis Community College at Florissant Valley: Gateway to Technology: An integrated study of Mathematics, English, Reading and Engineering/Tech
PLC: Presentation Evaluation Criteria
(Example: to be decided upon by student and teacher teams)
1 = Weak 2 = Moderately Weak 3 = Average 4 = Moderately Strong 5 = Strong
Problem Solving
1.
The student first determines the facts of a problem and what additional information is needed to
understand it.
1 2 3 4 5
2. The student does the necessary research to make appropriate design recommendations.
1 2 3 4 5
3. The student’s problem solving employs the appropriate and accurate calculations
1 2 3 4 5
4. The student’s problem solving shows an understanding of the concepts of PLC module.
1 2 3 4 5
Presentation
5.
The topic of the presentation meets the requirements of the assignments.
1 2 3 4 5
6. The presentation is well organized and cohesive.
1 2 3 4 5
7. The presentation indicates an understanding of Programmable Logic Controllers.
1 2 3 4 5
8. The presenter delivers ideas in a clear and concise fashion
1 2 3 4 5
9. The presenter speaks clearly and in a loud voice and maintains eye contact with the audience.
1 2 3 4 5
10. The presenter and the presentation use correct standard English sentence structure, mechanics,
grammar and spelling.
1 2 3 4 5
Additional Comments: ___________________________________________________________
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Total Points/Grade: __________
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