DEVELOPMENT OF TUNING ALGORTHM OF PID CONTROLLER USING PLC
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INTRODUCTION TO PLC
1. Programmable Logic Controller

A Programmable Logic Controller, or PLC for short, is simply a special computer device used for industrial control systems. They are used in many industries such as oil refineries, manufacturing lines, conveyor systems and so on. Where ever there is a need to control devices the PLC provides a flexible way to "software" the components together.
The basic units have a CPU (a computer processor) that is dedicated to run one program that monitors a series of different inputs and logically manipulates the outputs for the desired control. They are meant to be very flexible in how they can be programmed while also providing the advantages of high reliability (no program crashes or mechanical failures), compact and economical over traditional control systems.
1.1 A Simple Example
Consider something as simple as a switch that turns on a light. In this system with a flick of the switch the light would turn on or off. Beyond that though there is no more control. If your boss came along and said I want that light to turn on thirty seconds after the switch has been flipped, then you would need to buy a timer and do some rewiring. So it is time, labor and money for any little change.
1.2 A PLC Saves the Day
Now consider the same device with a PLC in the middle. The switch is fed as an input into the PLC and the light is controlled by a PLC output. Implementing a delay in this system is easy since all that needs to be changed is the program in the PLC to use a delay timer.
This is a rather simple example but in a larger system with many switches and lights (and a host of other devices) all interacting with each other this kind of flexibility is not only nice but imperative. Hopefully a light bulb has now turned on over your head.
1.3 OTHER DEFINATION’S TO PLC
1. A PLC (Programmable Logic Controllers) is an industrial computer used to monitor inputs, and depending upon their state make decisions based on its program or logic, to control (turn on/off) its outputs to automate a machine or a process.
2. A digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions such as logic sequencing, timing, counting, and arithmetic to control, through digital or analog input/output modules, various types of machines or processes.
2. BLOCK DIAGRAM OF PLC
3. WORKING OF PLC

A programmable logic controller is a specialized computer used to control machines and processes. It therefore shares common terms with typical PCs like central processing unit, memory, software and communications. Unlike a personal computer though the PLC is designed to survive in a rugged industrial atmosphere and to be very flexible in how it interfaces with inputs and outputs to the real world.
The components that make a PLC work can be divided into three core areas.
• The power supply and rack
• The central processing unit (CPU)
• The input/output (I/O) section
PLCs come in many shapes and sizes. They can be so small as to fit in your shirt pocket while more involved controls systems require large PLC racks. Smaller PLCs (a.k.a. “bricks”) are typically designed with fixed I/O points. For our consideration, we’ll look at the more modular rack based systems. It’s called “modular” because the rack can accept many different types of I/O modules that simply slide into the rack and plug in.
3.1 The Power Supply and Rack
So let’s start off by removing all our modules which leaves us with a naked PLC with only the power supply and the rack.
The rack is the component that holds everything together. Depending on the needs of the control system it can be ordered in different sizes to hold more modules. Like a human spine the rack has a backplane at the rear which allows the cards to communicate with the CPU. The power supply plugs into the rack as well and supplies a regulated DC power to other modules that plug into the rack. The most popular power supplies work with 120 VAC or 24 VDC sources.
3.2 The CPU
The brain of the whole PLC is the CPU module. This module typically lives in the slot beside the power supply. Manufacturers offer different types of CPUs based on the complexity needed for the system.
The CPU consists of a microprocessor, memory chip and other integrated circuits to control logic, monitoring and communications. The CPU has different operating modes. In programming mode it accepts the downloaded logic from a PC. The CPU is then placed in run mode so that it can execute the program and operate the process
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