A TECHNICAL SEMINAR ON INDUSTRIAL AUTOMATION USING PLC

SHAIK MAJEED RIZWANB.TECH IV YEAR II SEMESTER

HT.NO:-09RT1A0201

CONTENTSCONTENTS

1.INTRODUCTION1.INTRODUCTION

2.WHAT IS AUTOMATION2.WHAT IS AUTOMATION

3.CONCEPT OF AUTOMATION3.CONCEPT OF AUTOMATION

4.AUTOMATION HISTORY4.AUTOMATION HISTORY

5.AUTOMATION TOOLS5.AUTOMATION TOOLS

6.PLC6.PLC

7.ADVANTAGES7.ADVANTAGES

8.DISADVANTAGES8.DISADVANTAGES

9.APPLICATIONS9.APPLICATIONS

PLC is a solid state device or industrial computer that performs discrete logic in factory environment.

It was originally developed to replace mechanical timers,counters,relays etc.

PLC’s are used successfully to execute complicated control functions in the plant.

Instruction is programmed by the user in the plc memory then program is executed.

PLC operates the system according to the correct operating specifications.

PLC operation is a sequential process.

INTRODUCTIONINTRODUCTION

A Shaft manufacturing in processA Shaft manufacturing in process

1. What sort of accuracies are expected?1. What sort of accuracies are expected? 2. What is the production rate?2. What is the production rate? 3. To produce more units per given time, compromise on 3. To produce more units per given time, compromise on

tolerances? tolerances?

End result: End result:

No two shafts will be identical and performance of No two shafts will be identical and performance of machines using these, will not be same!!!machines using these, will not be same!!!

•If many shafts are to be produced...

How to produce more such units with How to produce more such units with better tolerancesbetter tolerances??

Automation is the solution!!

What is automation?What is automation?

The use of modern techniques to produce multiple units of the same product with high and same degree of accuracy

This will result in overall performance and end product quality

With the advent of automation, highly precise and complex products can be produced

Automation Automation examplesexamplesAutomation is basically a delegation of human control function to control technical

equipment.

Automation is the use of control systems and information technologies reducing the need for human intervention.

Example ContinuedExample Continued

• 1.MANUAL CONTROL

Automation HistoryAutomation History

5.PLC

2.PNEUMATIC CONTROL 3.HARD WIRE LOGIC CONTROL

4.ELECTRONIC CONTROL USING GATES

Automation ToolsAutomation ToolsDifferent types of automation tools exist:

ANN - Artificial neural network

DCS - Distributed Control System

HMI - Human Machine Interface

SCADA - Supervisory Control and Data Acquisition

PLC - Programmable Logic Controller

PAC - Programmable automation controller

Instrumentation

Motion control

Robotics

PLCPLC• What does ‘PLC’ mean?• 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.

1313

Programmable Logic ControllersProgrammable Logic Controllers( Definition according to NEMA standard ICS3-1978)( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic apparatus which uses a A digitally operating electronic apparatus which uses a programming memory for the internal storage of programming memory for the internal storage of

instructions for implementing specific functions such as instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to logic, sequencing, timing, counting and arithmetic to

control through digital or analog modules, various types control through digital or analog modules, various types of machines or process.of machines or process.

Major Components of a Common Major Components of a Common

PLCPLC

PROCESSORPROCESSOR

POWERPOWER

SUPPLYSUPPLY

I MI M

N O N O

P D P D

U UU U

T LT L

E E

O M O M

U OU O

T DT D

P UP U

U LU L

T ET E

PROGRAMMING PROGRAMMING

DEVICEDEVICE

From From

SENSORSSENSORS

Pushbuttons,Pushbuttons,

contacts,contacts,

limit switches,limit switches,

etc.etc.

ToTo

OUTPUTOUTPUTSolenoids, Solenoids,

contactors, contactors,

alarmsalarms

etc.etc.

1515

PLCPLC

INPUTSINPUTS

OUTPUTSOUTPUTS

MOTORMOTOR

LAMPLAMPCONTACTORCONTACTOR

PUSHBUTTONSPUSHBUTTONS

PLC DevicePLC DevicePLCs are compact, powerful, flexible, modular and

intelligent units.

1717

Leading Brands Of PLCLeading Brands Of PLCAMERICANAMERICAN 1. Allen Bradley 1. Allen Bradley

2. Gould Modicon2. Gould Modicon 3. Texas Instruments 3. Texas Instruments 4. General Electric4. General Electric 5. Westinghouse5. Westinghouse 6. Cutter Hammer6. Cutter Hammer

7. Square D7. Square D

EUROPEANEUROPEAN 1. Siemens 1. Siemens 2. Klockner & Mouller2. Klockner & Mouller

3. Festo 3. Festo 4. Telemechanique4. Telemechanique

PLC PLC

PLCs are available in different sizes to suit different applications. They offer cost effective solutions.

PLCs being microprocessor based, offer changes to the logic very easily.

PLCs also offer number crunching capability PLCs can be programmed from a PC

SelectingSelecting a PLCa PLC

CriteriaCriteria • • Number of logical inputs and Number of logical inputs and outputs.outputs.•• MemoryMemory•• Number of special I/O modulesNumber of special I/O modules•• Scan TimeScan Time•• CommunicationsCommunications•• SoftwareSoftware

Examples of PLC Programming Software:Examples of PLC Programming Software:

1. Allen-Bradley – 1. Allen-Bradley – Rockwell Software RSLogix500Rockwell Software RSLogix5002. Modicon - 2. Modicon - ModsoftModsoft3. Omron - 3. Omron - SyswinSyswin4. GE-Fanuc Series 6 – 4. GE-Fanuc Series 6 – LogicMaster6LogicMaster65. Square D- 5. Square D- PowerLogicPowerLogic6. Texas Instruments – 6. Texas Instruments – SimaticSimatic6. Telemecanique – 6. Telemecanique – Modicon TSX MicroModicon TSX Micro

ADVANTAGESADVANTAGES Accurate and consistent information Faster fault identification

Improved availability of system

Increased Production

ADVANTAGESADVANTAGESReduced Cost Maintenance of Quality & Quantity

Improved Safety Conditions

Reliable in operation.Flexibility in programming and reprogramming in the plant.Online/offline modifications.Cost effective for controlling complex systems.Small physical size, shorter project time.Speed of operation.Ability to communicate with computer systems in the plant.Ease of maintenance /troubleshooting. Documentation.Security.

ADVANTAGES :ADVANTAGES :

DisadvantagesDisadvantages The main disadvantages of automation are:

Technology limits: Current technology is unable to automate all the desired tasks.

Initial costs are relatively high: The automation of a new product required a huge initial investment in comparison with the unit cost of the product, although the cost of automation is spread in many product batches

Newer Technology.

APPLICATIONSAPPLICATIONS1. Automated Video surveillance

2.Automated Highway Systems

APPLICATIONSAPPLICATIONS3.Automated manufacturing

4.Home Automation

THANK YOUTHANK YOU

ANY QUERIES ?ANY QUERIES ?