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Industrial automation is the end of this century paradigm for automating manufacturing processes. The technology applied in this field, however, is present in our everyday life more than ever. In a process industry we have many non-electrical parameters like Temperature, pressure, humidity among others. Each parameter will have some set Point; if the value goes below the limit (set point) the micro controller will Automatically control the parameters such that it matches the set point. For example take a flow pipe having withstand capacity of 1000 bars, then The whole system will collapse; to overcome these kind of problems we use a Microcontroller, which controls the pressure and brings back to the set point. Also manual intervention is possible
CHAPTER 1
1.1 What Is Automation
INTRODUCTION TO AUTOMATON
Automation is the use of control systems such as computers to control industrial machinery and process, reducing the need for human intervention. Automation is basically the delegation of human control function to technical equipment for Processes and systems can also be automated.
Advantages Reduced space requirements. Energy saving. Less maintenance & greater reliability. Disadvantages Changes in control logic not possible. More project time.
CHAPTER 2
Flexibility: One single Programmable Logic Controller can easily run many machines.
Correcting Errors : In old days, with wired relay-type panels, any program alterations required time for rewiring of panels and devices. With PLC control any change in circuit design or sequence is as simple as retyping the logic. Correcting errors in PLC is extremely short and cost effective. Space Efficient: Today's Programmable Logic Control memory is getting bigger and bigger this means that we can generate more and more contacts, coils, timers, sequencers, counters and so on. We can have thousands of contact timers and counters in a single PLC. Imagine what it would be like to have so many things in one panel.
Low Cost: Prices of Programmable Logic Controllers vary from few hundreds to few thousands. This is nothing compared to the prices of the contact and coils and timers that you would pay to match the same things. Add to that the installation cost, the shipping cost and so on.
Testing : A Programmable Logic Control program can be tested and evaluated in a lab. The program can be tested, validated and corrected saving very valuable time. Visual Observation: When running a PLC program a visual operation can be seen on the screen. Hence troubleshooting a circuit is really quick, easy and simple. Some Other advantages of PLC:
Time Saving and Energy Saving. Have a long life. Can be troubleshooting through Software. Zero human error. Its Reprogrammable. Takes less time for download the program. Easier and faster to make changes. Applications can be performed faster and less expensively.
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This process is repetitive and called scan cycle. PII Process Image Input. PIQ Process Output Image. RLO Result of Logic Operator.
2.5 Communications
There are several methods to communicate between a PLC and a programmer or even between two PLCs. Communications between a PLC and a programmer (PC) are provided by a cable from your PC to the programming port on the PLC. This communication can be RS232 for PC and RS485 for PLC. There are many types of interface between PC and PLC like PPI, MPI, PROFIBUS, etc. The Mainly Used PPI and MPIs characteristics are-
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2.6.1 Ladder diagram (LD):Ladder logic is the main programming method used for PLC's. As mentioned before, ladder logic has been developed to mimic relay logic. The decision to use the relay logic diagrams was a strategic one. By selecting ladder logic as the main programming method, the amount of retraining needed for engineers and trades people was greatly reduced. This language uses electrical symbols to formulate the control task. Its easy to use. This language uses two coils mostly: 1. Normally Open 2. Normally Closed
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2.7.1
Normally Open Contact:This can be used to represent any input to the control logic - a switch or sensor, a contact from an output, or an internal output. When "solved" the referenced input is examined for an ON (logical 1) condition. If it is ON, the contact will close and allow power (logic) to flow from left to right. If the status is OFF (logical 0), the contact is Open, power (logic) will NOT flow from left to right.
2.7.2
Output Coil.
This can be used to represent any discrete output from the control logic. When "solved" if the logic to the left of the coil is TRUE, the referenced output is ON (logical 1).
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Fig 2.4 Single instruction Suppose a switch is wired to Input1, and a light bulb is wired through Output1 in such a way that the light is OFF when Output1 is OFF, and ON when Output1 is ON.
When Input1 is OFF (logical 0) the contact remains open and power cannot flow from left to right. Therefore, Output1 remains OFF (logical 0). When Input1 is ON (logical 1) then the contact closes, power flows from left to right, and Output1 becomes ON (the light turns ON)
Fig 2.5 The AND Gate Suppose a switch is wired to Switch1, a second switch is wired to Switch2, and a light bulb is wired through Light1 in such a way that the light is OFF when Light1 is OFF, and ON when Light1 is ON.
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In order for Light1 to turn ON, Switch1 must be ON, AND Switch2 must be ON.
If Switch1 is OFF, power (logic) flow from the left rail, but stops at Switch1. Light1 will be OFF regardless of the state of Switch2. If Switch1 is ON, power makes it to Switch2. If Switch2 is OFF, power cannot flow any further to the right, and Light1 is OFF.
If Switch1 is ON, AND Switch2 is ON - power flows to Light1 solving its state to ON.
Fig. 2.6 The OR Gate Suppose a switch is wired to Switch1, a second switch is wired to Switch2, and a light bulb is wired through Light1 in such a way that the light is OFF when Light1 is OFF, and ON when Light1 is ON. In this instance, we want to the light to turn ON if either Switch1 OR Switch2 is ON.
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If Switch2 is ON - power flows through the Switch2 contact, and up the rail to Light1 - turning it ON. If Switch1 AND Switch 2 are ON - Light1 is ON.
The only way Light1 is OFF is if Switch1 AND Switch2 are OFF. * Another set of basic contacts and coils that can be used in Ladder Logic are the Normally Closed Coil. This work just like their normally open counterparts - only in the opposite.
2.7.6
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Fig 2.7 View of CPU 224XP It has possible 9 devices. it has 256KB external memory We working with CPU 224XP in S7 200.
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2.8.1 TIMERS
Timers are used for 1. Count time Interval 2. Produce delay 3. Generate Pulses There are three types of timers 1. ON delay timer ( T on ) 2. OFF delay timer ( T off ) 3. ON delay timer Retentive ( T onR )
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2.8.1.2 Off-Delay Timer (Toff) This timer produced delay to get the off the
output.
Characteristics: 1) It starts working as the input switch is made OFF. 2) Output connected with this timer will get OFF after the preset value is over. 3) It doesnt keep continue counting after the preset time. 4) It can be reset by using RESET instruction or using NC. 5) OFF delay timer will be zero if the input switch is made ON during counting.
2.8.1.3
timer with one difference that it retain the time counting when the switch is made OFF. As the switch is made ON again, the timer starts counting from its previous value.
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Example: When input I0.0 is made ON, conveyer should start From 2 to 5 sec, filling of Bottle should be done. From 6 to 8 sec, capping of Bottle should be done. From 10 to 12 sec, packing of Bottle should be done.
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2.8.2 Counters
A counter simply counts the number of events that occur on an input. Means it counts the electric pulses. There are two basic types of counters 1. Up counter 2. Down counter 3. Up Down counter
2.8.2.1 Up Counter
It counts upwards whenever it gets pulse from 0 to 1. Counters can counts up to +32767 as the counters are integer. It doesnt counts negative. Output connected with up counter will get high when Preset Value (PV) will get over or equal. Counter can reset by using RESET (R) Pin.
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2.8.3
STEP
GENERATION-7-300
(SIEMENS
TECHNICAL
EDUCATION PROGRAMME Series 7): Its software name is SIMATIC Manager. Simulator in built. Mode rate is 187.5 kbps. It has 16 Input /16 outputs. In 300 Micro Memory Card (MMC) is necessary. It has 11 devices possible. This working with CPU 313-C-2-DP.
Version of 313 series Decentralized Process Compact Internal Battery backup 100 hours (2 standard capacitor). External Battery backup 200 hours.
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Simulator: simulator is a hardware/software device which helps us acknowledgment of the appropriate output then we have and incoming input. It is also judges the condition of memory bits and special memory bits.
The Main Modules In the s7-300 are 1. Power Supply 2. Central Processing Unit (CPU) 3. Interface Module 4. Signal Module 5. Function Module 6. Communication
2.8.4
It is faster than 200 due to frequency rang. It has inbuilt simulation. It is modular PLC (increase I/O) what should we want. We can design PLC dependent our requirements. 1024 input / 1024 output PLC-300.
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128 input / 128 output PLC-200. More communication source such as protocol, profinet. Mode rate of profibus is 12mbps. Provide inbuilt HMI services. S7-300 is used in experimentally harsh conditions. e.g. Chemical factory: dust, temperature handle. its allows malty tearing with one CPU 4 rack used in S7-300 but in S7-200 only one rack is used. The S7-300's range of CPUs provides the right solution for every application, and customers only pay for the performance actually required for a specific task. The S7-300 can be set up in a modular configuration without the need for slot rules for I/O modules.
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CHAPTER 3
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More and more manufacturing designers are recognizing the benefits of using Human Machine Interface to control and to operate their controls.
3.3 Functionality Representation of a plant in real time. Trending (Real-time / Historical) Alarms (Real-time / Historical) SPC (Statistical Process Control) Recipes Reports
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Lop Events Historical Data Logging and Browsing SQL Server 2000, Oracle, Sybase, ODBC support Networking and Redundancy Math and Logic
Fig. 3.1 HMI Component Its software name is SIMATIC winCC flexible. Tag: internal (data type) External (data type +address) connected with PLC. Alt+f4 used for exit from Run time.
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CHAPTER 4
Automation plays an increasingly important role in the global economy and in daily life. Engineers strive to combine automated devices with mathematical and organizational tools to create complex systems for expanding range of application and human activities. Industrial automation is very compulsory need of industries in todays scenario to meet market competition. Automation provides 100% accuracy all time. So the failure and mismatch in production completely eliminates. It makes the systems efficiency higher then manual as well as It controls wastages. So the overall savings increases. It Provides safety to the Human Being. By that Industry can achieves the safety majors ad ISO and OHSAS reputation. It makes the operation faster than manual which causes higher production by which the cost of each product decreases and industry profit decreases. It increase repeatability, so that the same kind of products can be manufacture easily at different stages without wasting times. It provides integration with business system. It can reduce labor costs, so the final profit Increases.
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REFERENCES
[1] Automation and HMI, http://www.automation.siemens.com [2] PLC, HMI, SCADA, http://www.wikipedia.com [3]Introduction to Automation, Author/Publisher: IATC Siemens,http://www.iatc.in [4] PLC & HMI : NOTES, Author: Ms. Shalja, Trainer at IATC Siemens [5] PLC & HMI , http://www.kronotech.com/
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