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A modern controller device used extensively for sequence control today in transfer
lines, robotics, process control, and many other automated systems is the
Programmable Logic Controller (PLC). A PLC (i.e. Programmable Logic
Controller) is a device that was invented to replace the necessary sequential relay
circuits for machine control. The PLC works by looking at its inputs and depending
upon their state, turning on/off its outputs. The user enters a program, usually via
software, that gives the desired results. In essence, a PLC is a special purpose
industrial microprocessor based real-time computing system, which performs the
following functions in the context of industrial operations
.
• Monitor Input/Sensors
• Execute logic, sequencing, timing, counting functions for Control/Diagnostics
• Drives Actuators/Indicators
• Communicates with other computers
PLC Example :
• Let's assume that when a switch turns on we want to turn a solenoid on for 5
seconds and then turn it off regardless of how long the switch is on for.
• We can do this with a simple external timer. But what if the process included 10
switches and solenoids? We would need 10 external timers. What if the process
also needed to count how many times the switches individually turned on? We
need a lot of external counters.
PLC - need :
Disadvantages:
The major activities that define the manufacturing enterprise in direct relation to
the manufacturing of products include (i) Production Management, and (iii)
Manufacturing. The first function is incorporated in Level 3 automation while the
second one refers to Level 1 and Level 2 functions of a hierarchical Industrial
Automation System.
Level 3 Automation:
Production Management
The role of production management is to plan and control effectively the physical
and operational resources of the manufacturing plant such as, materials, tools,
fixtures, machines, storage space, material handling equipment, and manpower, so
as to meet the production requirements. Production management is also referred to
as Production Planning and Control. As the name implies, it comprises two
functions, namely, Production Planning and Production Control.
Production planning is concerned with: (1) deciding on the set of products to be
manufactured, along with their production volumes, over a certain duration which
is called the planning horizon; (2) scheduling, i.e., determining the sequence of
production of the set of parts and products over the time duration and (3) allocation
of the necessary manpower, raw material and equipment resources needed to
accomplish the production plan.
Functionality at Basic Level (Level 1): The Basic Level shall cover control of all
equipment, sequencing, interlocking micro-tracking of strip for specific functions,
dedicated technological functions, storage of rolling schedules and look-up tables,
fault and event logging etc. Some of these are mentioned below.
♦ All interlocking and sequencing control of the machinery such as for entry and
exit handling of strips, shear control etc. Interlocking, sequencing, switching
controls of the machines. This shall also cover automatic coil handling at the
entry and exit sides, automatic sequencial operation of welding machine and
strip threading sequence control as well as for acid regeneration plant.
♦ Calculation of coil diameter and width at the entry pay-off reels.
♦ Position control of coil ears for centrally placing of coils on the mandrels.
♦ Generation of master speed references for the line depending on operator's input
and line conditions and down loading to drive control systems.
♦ Speed synchronising control of the drives, as required.