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PLC : PROGRAMMEBLE LOGIC CONTROLLER

A programmable logic controller, PLC, or programmable controller is a digital computer used for automation of typically industrial electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many machines, in many industries. PLCs are designed for multiple arrangements of digital and analog inputs and outputs, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a "hard" real-time system since output results must be produced in response to input conditions within a limited time, otherwise unintended operation will result.

Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was mainly composed of relays, cam timers, drum sequencers, and dedicated closed-loop controllers. Since these could number in the hundreds or even thousands, the process for updating such facilities for the yearly model change-over was very time consuming and expensive, as electricians needed to individually rewire the relays to change their operational characteristics.

Digital computers, being general-purpose programmable devices, were soon applied to control industrial processes. Early computers required specialist programmers, and stringent operating environmental control for temperature, cleanliness, and power quality. Using a general-purpose computer for process control required protecting the computer from the plant floor conditions. An industrial control computer would have several attributes: it would tolerate the shop-floor environment, it would support discrete (bit-form) input and output in an easily extensible manner, it would not require years of training to use, and it would permit its operation to be monitored. The response time of any computer system must be fast enough to be useful for control; the required speed varying according to the nature of the process.[1] Since many industrial processes have timescales easily addressed by millisecond response times, modern (fast, small, reliable) electronics greatly facilitate building reliable controllers, especially because performance can be traded off for reliability.

Development[edit] Early PLCs were designed to replace relay logic systems. These PLCs were programmed in "ladder logic", which strongly resembles a schematic diagram of relay logic. This program notation was chosen to reduce training demands for the existing technicians. Other early PLCs used a form of instruction list programming, based on a stack-based logic solver. Modern PLCs can be programmed in a variety of ways, from the relay-derived ladder logic to programming languages such as specially adapted dialects of BASIC and C. Another method is state logic, a very high-level programming language designed to program PLCs based on state transition diagrams. Many early PLCs did not have accompanying programming terminals that were capable of graphical representation of the logic, and so the logic was instead represented as a series of logic expressions in some version of Boolean format, similar to Boolean algebra. As programming terminals evolved, it became more common for ladder logic to be used, for the aforementioned reasons and because it was a familiar format used for electromechanical control panels. Newer formats such as state logic and Function Block (which is similar to the way logic is depicted when using digital integrated logic circuits) exist, but they are still not as popular as ladder logic. A primary reason for this is that PLCs solve the logic in a predictable and repeating sequence, and ladder logic allows the programmer (the person writing the logic) to see any issues with the timing of the logic sequence more easily than would be possible in other formats.

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