Chetan Prakash

INDUSTRIAL AUTOMATION EXPERT

chetanprakash02@gmail.com
What is Automation?
•As the name suggests ‘Automation’ means to
perform automatic operations by means of
different kinds of machines.
•Automation is the use of control systems and
information technologies to reduce the need for
human work in the production of goods and
services.
•It is used to reduce human interference and
efforts
 Why Automation required in industry

Productivity

Total Automation Manufacturing

Competitivenes
Plant Solution

Quality
Labour Cost
History of “Automation”
Programmable logic
controllers (PLC)

Electronic control
using logic Gates

Hard Wired Logic

control

Pneumatic control

Manual Control
Components used in
“Automation”
•Sensors
•Transmitters
•Control System
 PLC
 DCS (Distributed Control System)
 PID Controllers (Proportional,
Integral & Derivative)
•Output Devices
 Actuators
Drives
Control Valves
Solenoid Valves
Tools of “Automation”
PLC (Programmable Logic Controller)

SCADA (Supervisory Control and Data

Acquisition)

HMI (Human Machine Interface)

VFD (variable frequency drive)

 What is PLC?
•PLC-programmable logic controller
•A programmable Logic controller is simply a
solid state industrial computer that perform
discrete or sequential logic in a factory
environment.
Advantages of plc:-
Reliability and flexibility in operation.
Cost effective for controlling complex system
Small physical size, shorter project time
In-house simulation and testing of project
Security
 PLC v/s COMPUTER
PLC COMPUTER
• Executes simple program • Possibly complicated
in milliseconds, scan time program, often timing is
is much smaller than 1/60 not critical
seconds. • It may include floating
• Objective is to make point, arithmetic, manip-
yes/no,0/1 decisions. ulation of data
• Special purpose device, • General purpose,
same program is possibly different
repeated continuously. programs
• No peripherals. • Need peripherals
• Programmed using • Programmed using high-
ladder-logic level lang.
What constitute a PLC?
 Configuration of PLC
Built in display for I/O
Programming Terminal PC Connection
(in-rack, AS-i)

8 Analog Inputs 1
Analog Output

I/O Modules
Up/Down Fast
Counter

Up Counter TSX37-22

Unitelway Port for connection communications port

of up to 5 Slaves
memory expansion port
 TIMER

It is used for time delay generation

for the operation of different Machinery

Relay
Electromagnetic
switch PID Controller

COUNTER
It is used for counting
the no. of event
ELECTRICAL CONTROL
SYSTEM

RELAY
Electromagnetic Switches used
,basically for two purposes mainly in
industry
1) ON/OFF Switching
2) Interlinking two between Power
and control
Purpose of using Relay in Industry

•Electromagnetic Switch

•Signal Holding

•DOL Starter
Relay as
•Reverse and Forward Starter Electromagnetic Switch

•Interlocking Circuit Designing

•Star Delta Operation

•Control Panel Designing

Inputs and Outputs of PLC
 Power supply and memory of
PLC:-
A power supply of 24V DC is typically used to
drive the PLC, this power supply converts the 24v
DC in to voltage of 5v.

RAM (Random Access Memory ),a volatile

memory is used for program storage
ROM (Read only memory),a non–volatile
memory is used for data storage.
Executing any signal in PLC
 Programming in PLC:-
Languages used in PLC for the purpose of
programming are:-
•Ladder Language
•Functional block Diagram(FBD)
•Industrial list(IL)
•Sequential flow chart
•Structured text language
Out of all the above, Ladder Logic is the most commonly
used. The ladder logic language id defined as:-
Logical continuity in a ladder rung occurs when there is a
continuous path of TRUE conditions from the left power
to the output instructions. When there is a logical
continuity and the output being energised.
Showing NO and NC switches in PLC
A view of the PLC working screen
 SCADA(Supervisory control
and Data Acquisition)
•SCADA is real time industrial process control
systems used to centrally remote or local
industrial equipment such as motors, valves,
pumps, relays, etc
•It generally refers to an industrial system
(ICS).
•It is a production automation and control
system based on PCs.
 Supervisory Control and Data Acquisition
Supervisory means Monitoring
entire system through
GUI representation
of working Status ,of the
entire system
Data Acquisition
mean collecting
Control means Controlling data Information from
the entire System such as Different controller,
ON/OFF operation , Sensor , Drives ,
Speed controlling, Motor which are
temperature Controlling connected at distance
through wire ,
Ethernet , wireless
 Features of SCADA
Features of typical SCADA software:-

 Dynamic process graphic

 Real-time and Historical trending
 Alarms
 Recipe Management
 Security
 Device connectivity
 Script for logic development
 Database connectivity
Architecture OF SCADA
Trending in SCADA
Analogous symbols of general elements in SCADA
Requirements of SCADA
 Applications of SCADA
•Production department
•Quality department
•Maintenance department
•Enterprise information
•Engineering department
•Manufacturing department
Application of SCADA in various plants
VARIABLE FREQUENCY DRIVES
We can operate these
Drive through
Keypad , external Switch
and also through PLC
VFD
Induction Motor

Stepper Drive
Stepper Motor

Servo motor
Servo Drive
 HMI
Human Machine Interface

It have some major feature of SCADA ,HMI it is basically a

control display screen were operator can monitor and control
the machinery and it is portable and can easily installed on the
Machine itself

HMI It was
designed for the
specific task
operation on the
machine
and SCADA is for
entire Plant
operation
INDUSTRIAL SENSOR

It is basically are of two type

Digital Sensor
it has switching b/w ( 0,24V)

Analog Sensor
It is basically are of two type
Current type analog Sensor
(4mA—20mA)
Voltage type analog Sensor
(0—10V)
 SCOPE OF AUTOMATION

In Aeronautic and Space

Application, where large amount of
a Controlling unit are used for
connecting different device that are
working systematic manner
Smooth functioning of the Delhi Metro train
is a example of a motion control system .
@
INDUSTRIAL AUTOMATION LAB
THANKS