INDUSTRIAL AUTOMATION

Submitted By:- Mitali Choudhary

B-Tech , VII Sem.

Electronics And Communication

AUTOMATION

Making products under the control of computers and programmable controllers is known as “INDUSTRIAL AUTOMATION”.

Manufacturing assembly lines as well as stand alone machine tools (CNC machines) and robotic devices fall under this category.

Automation is delegation of human control

functions to technical equipments for increasing

productivity, better quality, increasing safety in

working conditions reducing manpower and cost

Different Components Used In Automation:-

Sensors for sensing the input parameters

Transmitters for transmitting the raw signal in electrical form

Control system which include PLC,DCS and PID controllers

Output devices such as actuators, drives, control valves, solenoid valves, coils, indicating lamps.

Different Control Systems Used In Automation:-

PID controller based controller system

PLC based control system

DCS based control system

PC based automation system

PROGRAMMABLE LOGIC CONTROLLER:-

INTRODUCTION:-

A PLC is a solid state/computerized industrial computer that performs discrete or sequential logic in a factory environment.

It was originally developed to replace mechanical relays, timers, counters and other such devices.

Photograph of PLC-

ARCHITECTURE OF A PLC:-

A typical PLC can be divided into four components:

Processor Unit Power Supply Input / Output Section The Programmable Device

Functional Diagram Of PLC:-

1)Input Discrete –On / Off TypePushbuttons

Switches

Limit Switches

Selector Switches

Proximity Sensors

Photo-electric Sensors

2)Input Devices-Analog

Resistance Temperature Detectors

Thermocouple

Input Module

The input module performs task electronically as:

Determines the presence or absence of input

Converts input signal to a DC level useable PLC

Provides electronic isolation between input signal and PLC

OUTPUTS:- PLC output devices can usually be:

Solenoids

Relays-AC or DC powered

Contactors

Motor-Stators

Indication Lights

Valves

Alarms

PROCESSOR,CONTROLLER OR C.P.U. :-

Stores the control program and data in its memory.

Reads the status of connected input devices.

Performs arithmetic and logical operations.

Executes the control program.

Commands connected to output to change state based on program execution.

WORKING OF PROCESSOR:-For any execution of program, processor has to scan the entire program. Scan cycle consists of-

1) Input Scan: Detects the state of all input devices that are connected to the PLC.

2) Program Scan: Executes the user created program logic.

3) Output Scan: Energizes or de-energizes all output devices that are connected to the PLC.

4) Housekeeping: This includes communications with programming terminals, internal diagnostics etc.

PLC SCAN-CYCLE

PLC PROGRAMMING-

APPLICATIONS OF PLC

PLC’s are used successfully to execute complicated control operations in a plant.

Its purpose is to monitor crucial process parameters and adjust process operations accordingly.

A sequence of instructions is programmed by the user to the PLC memory and when the program is executed ,the controller operates a system to the correct operating specifications.

In Brief:-

It is used for any application in industry that requires electrical control.

Packing – Bottling and Canning

Material Handling – Machining

Power Generation – HVAC / building

automation

Security Systems – Automated Assembly

Paint Lines _ Water Treatment

It could be used in various industries like:-

Cement Industry

Automation Industry

Chemicals Industry

Plastics Industry

Metals Industry

Paper Industry

Various Brands Of PLC:-

Allen Bradley USA

Siemens Germany

Modicon France

Mitshubishi Japan

GE Fanuc USA

Omron Japan

Advantages Of PLC:-PLC Saves - By

Material Cost : Reduced wiring and associated

Installation : Less SpaceTroubleshooting : No moving parts-

ruggedLabour Cost : Possibility of

reprogramming

Value Added Benefits:-Reliability

Flexibility

Advance Function

Communication

Speed

Diagnostics

SCADA-(SUPERVISORY CONTROL AND DATA ACQUISITIONO)

Supervisory Control:-