83
Automation Basics By Raj Nayak (Technical Analyst)

Automation basics by raj nayak

Embed Size (px)

DESCRIPTION

This slides contains all the basic description of Industrial Automation and its components.

Citation preview

Page 1: Automation basics by raj nayak

Automation Basics

ByRaj Nayak

(Technical Analyst)

Page 2: Automation basics by raj nayak

Objectives:

• To get overview about automation .• To know about basic elements involved in the

automation process• To know how automation has been working in

the domestic and industrial spheres.• To understand how communication has helped

in automation of many things.• To understand advantages and limitations of

automation

Page 3: Automation basics by raj nayak

What one will learn ?

• What are the basic elements of Automation ?• Why automation is necessary ?• What are the different technologies available for

the automation.?• Where automation exists ?• What are the different controllers ?• What is SCADA and DCS ?• How communication is playing a vital role in the

process of Automation ? • What are the different protocols used in

Automation?

Page 4: Automation basics by raj nayak

Contents:• What is Automation…Role of Automation in the different industries• Why Automation ? ( Advantages)• Basic elements of Automaton … Sensors LVDT,Thermostat,Thermistor ,pressure CT,PT, Limit switches,Magntic Pick Up,Capacitive sensors etc Controllers and controller based systems Actuators Relays. Solenoids. • Types of Controllers Proportional,PI ,PID, Categories of controllers• DCS & SCADA… What is SCADA • How communication has enhanced automation. Common Protocols CAN ,MODBUS,PROPHI, Substation automation

protocol 61850 • When to go for Automation ?• Design of Automation system• Limitations / Disadvantages of Automation• Automation Myths… Impact of Automation How automation affects economics ?• Queries

Page 5: Automation basics by raj nayak

What is Automation ?

• The dictionary defines automation as “The technique of making an apparatus, a process, or a system operate automatically.”

• Automation federation define automation as 

“ The creation and application of technology to monitor and control the production and delivery of products and services.”

• Automation means use of Available technologies to reduce the need of Human work.

• Automation is a step beyond   mechanization. Mechanization provides human

operators machinery to assist themselves with the muscular requirements of work……

WhileAutomation greatly decreases the need

for human sensory and mental requirements as well. .

Page 6: Automation basics by raj nayak

Quality

Productivity

Manpower CostPlant

Total Automation Manufacturing Competitiveness Solution

Automation: Automation is basically the delegation of human control function to technical equipment for

Page 7: Automation basics by raj nayak

Automation cycleSense the Inputs

Process the Logic

Give the Outputs

Outputs

Machineor

Process

Controller

Inputs

Page 8: Automation basics by raj nayak

History of Automation

Manual control

Pnumatic control

Hard wired Logic Control

Electronic control using Logic gates

Programmable logic controller

Microcontrller based embedded controllers

Cluster of controllers and Master controller at Remote end.

Modern world

Ancient world

Page 9: Automation basics by raj nayak

Major Mile stones in Technologies

• Ancient world ( 8000BC to 330 )• The middle age through 1599• The age of scientific

revolutions 1600-1790• The industrial Revolution 1700-1920• The electrical age 1891 to 1934• The atomic and electronic age

1935 – into 21st century out of which last 20 years belong to COMMUNICATION and INFORMATION ERA

• Invention of Wheel• Discoveries of various metals • Invention of Glass• Discovery of Electricity• Invention of Telegraphy

/Telephone• Invention of Electric Motor• Invention of Transistor 1948• Invention of Microprocessor• Invention of Mobile

Technology• Invention of Internet

Technology

Page 10: Automation basics by raj nayak

Range of Technologies involved in AUTOMATION

Automation involves a very broad range of technologies including 1. Robotics 2. Expert systems(an expert system is a computer system that emulates the decision-

making ability of a human expert )3 Telemetry and communications4 Electro-optics Electro-optics is a branch of  technology involving components,

devices and systems which operate by modification of the optical properties of a material by an  electric field.

5 Cyber security, ( protecting your personal information or any form of digital asset

stored in your computer or in any digital memory device) 6 Process measurement and control,7 Sensors, 8 wireless applications, systems integration, test measurement, and

many, many more.

Page 11: Automation basics by raj nayak

ROBOTICS

Page 12: Automation basics by raj nayak

Where Automation exists ?

Automation encompasses many vital elements, systems, and job functions.

• Manufacturing , including food and pharmaceutical, chemical and petroleum, pulp and paper

• Transportation , including automotive, aerospace, and rail• Utilities , including water and waste water, oil and gas, electric

power, and telecommunications• Defense• Facility operations , including security, environmental control,

energy management, safety, and other building automation• …..And many others

Page 13: Automation basics by raj nayak

AUTOMATION IS EVERYWHERE

Automation is in all functions and places

• Aerospace• Automotive• Chemical and Petroleum• Computer Technology• Construction and Design• Electro-Optics• Environmental• Food and Pharmaceutical• Glass and Ceramics• Management• Marketing and Sales• Mining and Metals

• Mining and Metals• Nuclear• Power Distribution• Process Measurement and

Control• Pulp and Paper• Robotics and Expert Systems• Safety• Sensor Technology• Systems Integration• Telemetry and

Communications• Test Measurement• Textiles• Water and Waste water• Wireless Application• .

Page 14: Automation basics by raj nayak

Impact of Automation:

• Automation has a significant impact in the wide range of industries including Manufacturing industries

•  Automation has been responsible for the shift in the world economy from industrial jobs to service jobs in the 20th and 21st centuries.

• Once omnipresent telephone operators have seized to exist as telephone exchanges are automated.

• ATM have reduced the need for bank visits to obtain cash and carry out transactions.

Page 15: Automation basics by raj nayak

Impact of Automation:

• As a result of increase in Automation and (which is ever increasing almost every field as a result of ease in use of new Technologies)

the nature of jobs is getting affected .

• Telephone operators• Stock market agents• Railroad brake signal and

switch operators• Shoe and leather workers• Photographic process

workers and processing machine operators

• Model makers and pattern makers

Page 16: Automation basics by raj nayak

How much Automation ?

• Automation represents one of the major trends of 20th century as in many cases automation has provided extended system functionality well beyond existing human capabilities.

• Contrary to the implication of the term “Automated” humans have remained a critical part of most automated systems as most automation has been piece meal covering certain functions but not all functions.Human beings have remained in the system as integrators…monitoring the automation for some functions and performing others themselves

• Full automation of the task may be technically possible but it maynot be desirable if the performance of the joint human- machine system is to be optimized.Intermediate levels of Automation may be preferable for certain tasks in order to keep human operators’ situation awareness at a higher level and allow them to perform critical functions

Page 17: Automation basics by raj nayak

Level of Control

• One way to minimize the negative effect of Automation is to devise implementation schemes that keep human beings actively involved in the decision making loop while simultaneously reducing the load associated with doing everything manually

Page 18: Automation basics by raj nayak

Levels of control and Automation: (adapted from Endsley and kiris,1995)

LEVEL OF AUTOMATIONROLE

HUMAN SYSTEM

NONE 1 Decide Act ---

Decision support 2 Decide Act Suggest

Consensual Artificial intelligence (AI) 3 Concur Decide Act

Monitored AI 4 Veto Decide Act

Full automation 5 --- Decide Act

1 Manual system

5 Fully automatic system

Page 19: Automation basics by raj nayak

EXAMPLES OF AUTOMATION

Page 20: Automation basics by raj nayak

Common Examples of AutomationDay to Day life• ATM• Starting of the vehicle • Automatic washing

Machine• Electrically driven Pump• UPS, Canopy (power

supply Back up

Industry

• Painting Robots in the automobile mfg industry

• Soldering Machines• DCS Distributed

Control Systems• SCADA• AMF Generators

Page 21: Automation basics by raj nayak

Technologies involved in the working of ATM

• Computer and Electronics (HMI )• Communication using TCP/IP ( Communication with server at

remte end)• Sensors (magnetic sensor to read data from the card) Camera ,Timer

• Electromechanical solenoids and actuators (for counting currency accurately , and giving the same to user.)• Printer … Printing technology

Page 22: Automation basics by raj nayak

• Home Automation

Page 23: Automation basics by raj nayak

Subsystems of Home Automation:

• Hot water systems. • Appliances. Systems • Home office, home entertainment and other electronic

equipments. • Lighting. • Heating and cooling/air conditioning systems. • Fans and air pumps/heat shifters. • Powered window blinds, shutters and awnings. • Powered vents and window openings. • Water pumps, pool pumps . • Garage doors. • Security systems.

Page 24: Automation basics by raj nayak

Why Automation is required ?

• Increase in comfort

• More safety

• Improve the quality and precision.

• To do the job for which human beings will not have the capacity.

• To avoid monotonous work

Page 25: Automation basics by raj nayak

•Sensors•Controllers•Actuators• HMI• Display & alarm•Communication Protocol

Basic Elements of Automation

Page 26: Automation basics by raj nayak

•Sensors

•Controllers

•Actuators

• HMI

• Display & alarm

Basic Elements of Automation

Page 27: Automation basics by raj nayak

Sensors

• What is a sensor ?• Sensor is a device which measures a physical

quantity .

Temperature sensor (Input to thermometer /Temperature indicator)

Level sensor input to Fuel gauge

Proximity sensor, Pressure sensor

Photoelectric sensor LDR / opto coupler / photodiode

On/Off sensor push buttons / Relays /

Page 28: Automation basics by raj nayak

Sensors:

• sensors are used in a wide range of control systems that makes lives for people

easier, safer and more productive both at work and at home.

• Sensors extend the reach of human capabilities so that we can save energy, make faster decisions and perform tasks with greater precision.

• Sensors take on highly repetitive tasks

– leaving us free to apply our intellectual and creative abilities to further improve our lives.

• How we wash our clothes and refrigerate our food OR how we drive our cars and generate energy sensors help us.

Page 29: Automation basics by raj nayak

Different types of sensors

Page 30: Automation basics by raj nayak

Common usage of sensors:

• Transport and case Refrigeration Systems:

Temperature sensors are used to measure the supply of air to temperature controlled compartments while immersion probes measure refrigerant temperature. Rugged sensors designed specifically for measuring refrigerant pressure are used in conjunction with variable speed compressors to improve system efficiency.

• Traffic /smart Highway

Piezoelectric axle detectors are used to collect traffic data on highways, classify vehicles for automated toll booths, as well as provide timing mechanism for speed and red light cameras.

Page 31: Automation basics by raj nayak

Common usage of sensors:

• Petrol Pump

A rugged, hermetically sealed electromagnetic rotary encoder coupled to the fuel flow meter in gas pumps is used to accurately convert rotational pulses into gallons or liters dispensed.

• Printers : The drying process of ink jet printers is improved by monitoring air and paper humidity content. Measuring air and toner humidity guarantees print quality

in laser printers/copiers.

Page 32: Automation basics by raj nayak

Common usage of sensors:

• Cooking System: Long life, high-temperature oven probes operate up to

300°C. The high accuracy optimizes cooking control while protecting users.

• Washer/Dryer: Low cost/low power vibration sensors measure load

imbalance to avoid "walking." Humidity or thermopile sensors are used in dryers to automatically shut off when clothes are dry, extending the life of clothes and improving efficiency.

Page 33: Automation basics by raj nayak

Construction of C.T.

• C.T. has a primary coil of one or more turns of thick wire connected in series with the line whose current is to be measured.

• The secondary consist of large number of turns of fine wire, is connected across the ammeter terminals.

Page 34: Automation basics by raj nayak

Working

• If a current transformer has primary to secondary current ratio of 100:5 then it step up the voltage 20 times and step down the current 1/20 times of its actual value.

• If we know the current ratio I1/I2 and the reading of a.c. ammeter, the current can be calculated.

• Current = ratio × ammeter reading

Page 35: Automation basics by raj nayak
Page 36: Automation basics by raj nayak

Potential transformer

• A PT is a step down transformer having many primary turns but few secondary turns.

• In step down the voltage decreases and current increases, thus voltage can be easily measured by using low range voltmeter.

• The voltage is stepped down in known ratio called voltage ratio.

Page 37: Automation basics by raj nayak

Construction and working of P.T.

Construction• A potential transformer has many primary windings but

few number of secondary windings that makes it step down transformer.

• Voltmeter is connected to secondary winding usually voltmeter of 150 v is suitable.

Working• Primary terminals are connected across the line to which

the voltage is to be measured.• The voltmeter gives the transformed value of voltage at

secondary.• The deflection of voltmeter when divided by transformed

ratio gives the actual voltage at primary.

• Line voltage = deflection / trasf. Ratio

Where transformation ratio = V2/V1

Page 38: Automation basics by raj nayak

Types of P.T.

• Some types of p.t. are

1. Shell type

2. Dry type

3. Oil type

Rating Type

below 5000 v Shell type

5000-13800 v Dry type and oil type

above 13800 v only oil type

Page 39: Automation basics by raj nayak
Page 40: Automation basics by raj nayak

Precaution for For CT & PT

• Utmost care should be taken to ensure that CT secondary is never opens.

• For safety purpose the secondary should be completely insulated from the high voltage primary and should be in addition grounded.

Page 41: Automation basics by raj nayak

Automation and electricity demand

• In the near future, home automation systems may be linked to the electricity utility in a number of ways. The utility may communicate variations in electricity prices to a ‘smart’ electricity meter, that will interface with the home automation controller.

• Householders can then program appliances to reduce power or switch off altogether during high price periods.

• Alternatively householders could enter a supply contract that allows the electricity supplier to signal equipment controlled by the home automation system (such as air conditioners) to turn off certain equipment for short periods.

• The householder may choose to participate and obtain lower electricity prices or other financial incentives.

Page 42: Automation basics by raj nayak

Desirable Sensor attributes

• Reliability

• Accuracy and Repeatability • Good response time.

• Withstanding capability.

• Long Life

• Less expensive

Page 43: Automation basics by raj nayak

Repeatability and accuracy

Not repeatableNot accurate

Not repeatableAccurate

RepeatableNot accurate

RepeatableAccurate

Page 44: Automation basics by raj nayak

What is difference between sensor and a transducer?

• SENSOR and TRANSDUCER both are actually sensors, but:

TRANSDUCER: convert one form of energy into ELECTRICAL energy

SENSOR: convert one form of energy into any other form of energy

Page 45: Automation basics by raj nayak

Commonly used sensors for industrial

applications Information from the

sensor / Transducer can be in two forms

• Analog

• Digital

• LVDT• Pressure Transducer• Strain Gauge sensor• Magnetic sensors• Piezoelectric sensors• Photoelectric sensors• Limit switches• Relays (Relay contacts• Auxiliary contacts of

switch/ contactor /breaker

Page 46: Automation basics by raj nayak

SENSORS used in the Industry

• Thermocouples• Proximity sensors• Limit switches• RPM sensor• CT /PT Current and voltage Transformer•  Rogowski coil• 4-20 mA Transducers (current

voltage,frequency,KW,KVA,KVAR,PF,Phase angle)

Page 47: Automation basics by raj nayak

•Sensors

•Controllers•Actuators

• HMI

• Display & alarm

Basic Elements of Automation

Page 48: Automation basics by raj nayak

What is a controller ?

•  A controller is a device which monitors and affects the operational conditions of a given system.

• A controller is a transfer element which compares the feedback value received from a transducer (sensor) to a predetermined value (i.e. set-point) and processes it in such a way that a control signal is transmitted in the form of an appropriate variable to the actuating element .

• Anything which is controllable must be measurable and comparable

• Comparator compares a given value with a set value

• The simplest controller is a comparator.

Page 49: Automation basics by raj nayak

What is a controller ?

• A device which accepts the inputs , measure them and depending on the predetermined conditions actuate one or more devices is called the controller.

• Input signal which represents certain physical quantity can be digital or analog in the nature

• An information from the sensor is to be converted into electrical form by signal conditioners and amplifiers before it is processed by the controller

• If the information is analog then a suitable ADC is used to enable controller read information

Page 50: Automation basics by raj nayak

Programmable Automation Controller

• A programmable automation controller (PAC) is a compact controller that combines the features and capabilities of a PC-based control system with that of a typical programmable logic controller (PLC). PACs are most often used in industrial settings for process control, data acquisition, remote equipment monitoring, machine vision, and motion control. Additionally, because they function and communicate over popular network interface protocols like TCP/IP, OLE for process control (OPC) and SMTP, PACs are able to transfer data from the machines they control to other machines and components in a networked control system or to application software and databases.

• [edit]PAC Origins

Page 51: Automation basics by raj nayak

Types of controllers

Controllers can be categorized based on 1 Parameter Or physical quantity they are controlling Examples Temperature controller,RPM controller, Pressure controller etc 2 The manner in which they are controlling the Physical quantity Proportional controller P Proportional Integral controller PI Proportional Integral derivative Controller PID ON –OFF (Bang Bang) Controller 3 Analog or Digital controller 4 The device used for controlling { PLC , PC ( computer), Digital circuits using comparators }

Page 52: Automation basics by raj nayak

• Controllers used for building automation can be grouped in 3 categories.

1. Programmable Logic Controllers (PLCs)2. , System/Network controllers, and 3. Terminal Unit controllers.

• PLCs provide the most responsiveness and processing power, but at a unit cost typically 2 to 3 times that of a System/Network controller intended for BAS applications.

Terminal Unit controllers are usually the least expensive and least powerful.

Page 53: Automation basics by raj nayak

Types of Controller

• ON OFF controller

a bang–bang controller (on–off controller), also known as a hysteretic controller,  that switches abruptly between two states. 

(also called a Bang- bang Controller)

• Bang–bang controls frequently arise in minimum-time problems.

• For example, if it is desired to stop a car in the shortest possible time at a certain position sufficiently far ahead of the car….. the solution is to apply maximum acceleration until the unique switching point, and then apply maximum braking to come to rest exactly at the desired position.

• This solution, which can be "uncomfortable" for the passengers, is a bang–bang solution: maximum engine throttle followed by maximum braking.

• A familiar everyday example is bringing water to a boil l in the shortest time, which is achieved by applying full heat, then turning it off when the water reaches a boil.

Page 54: Automation basics by raj nayak

Controller

• Controllers are essentially small, purpose-built computers with input and output capabilities.

• These controllers come in a range of sizes and capabilities to control devices commonly found in buildings, and to control sub-networks of controllers.

• Inputs allow a controller to read temperatures, humidity, pressure, current flow, air flow, and other essential factors.

• The outputs allow the controller to send command and control signals to slave devices, and to other parts of the system.

• Inputs and outputs can be either digital or analog

Page 55: Automation basics by raj nayak

MicroProcessor and Microcontroller

• Microprocessors are these days replaced by Microcontrollers

Page 56: Automation basics by raj nayak

Selection Criteria for Controller:

• Speed• Memory• I/O handling capability• Communication capability• Built in Features

in Built ADC

in built DAC

Page 57: Automation basics by raj nayak

Intel seriese of processors & Operating systems:• 4004• 8008• 8080• 8085• 8086• 80186• 80286 PC XT• 80386 PC• 80486-Dx2• 80486-Dx4• Pentium • P3• P4• 32 bit processors

• Linux / VariantsMacOSMS-DOSIBM OS/2 WarpUnix / VariantsWindows CEWindows 3.xWindows 95Windows 98Windows 98 SEWindows MEWindows NTWindows 2000

Windows XPWindows VistaWindows 7

Page 58: Automation basics by raj nayak

Programming:• A controller chip without a S/W

loaded in it has little power to control.

• A controller understands only zeros and ones (in fact it doesn't even understand zeros and ones …it can only distinguish two levels …low and High

• The lowest level language is Machine language which has only two characters . The morse code is perhaps the best example of machine language

Assembly level language depends on the type of the controller …each contrller will have a fixed number of instruction set.

• Highest level languages are those in which human beings communicate..

• There are many higher level languages depending on the type of application for which they are used.

Examples are FORTRAN COBOL BASIC FOXPro

Compilers and Assemblers

Page 59: Automation basics by raj nayak

• C

• C++

• Java

Page 60: Automation basics by raj nayak

Programming the controllers:

• Controller without programming has no value

Programming Languages Higher level Languages

C,C++.Java,Visual Basic

Assembly languages Controller specific Machine language Will have series of zeros

and ones (morse code is the best

example)

Page 61: Automation basics by raj nayak

Types of Instructions

• I/O Handling

• Assigning

• Mathematical

• Logical

• Repetitive

• Branching

Page 62: Automation basics by raj nayak

• A building Automation system (BAS)

Page 63: Automation basics by raj nayak

Industrial Automation Process Control System:

• In practice, an industrial automation process control system can be characterized as one or more of the following:

I. Batch processingII. Continuous processingIII. Discrete

Batch processes are used to produce a relatively low to intermediate quantities of product.

BATCH processingApplications that require specific quantities of raw materials combinedin specific ways for particular durations to produce an

intermediate or end result. Examples 1 production of adhesives and

glues, (which require the mixing of raw materials in a heated vessel for a period of time to form a quantity of end product.

2 Production of food, beverages and medicine.

3 PCB assemblies

Page 64: Automation basics by raj nayak

Continuous and Discrete Systems:

II. Continuous – Continuous processes used in

industrial automation applications produce very large quantities of product.

Examples The control of the water

temperature in a heating jacket, is an example of continuous process control. Some examples of continuous processes are the production of fuels, chemicals and plastics.

3 Discrete –

Found in manufacturing, motion and packaging applications.

Examples : Robotic assembly,

commonly found in automotive production, can be characterized as discrete process control.

Most discrete manufacturing involves the production of discrete pieces of product, such as metal stamping.

Page 65: Automation basics by raj nayak

Supervisory control & Data Acquisition (SCADA)

SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data.

SCADA focuses on gathering and circulating the right amount of system information to the right person or computer within the right amount of time.

Page 66: Automation basics by raj nayak

DCS and SCADA• DCS is a very broad term used in a variety of industries, to monitor and

control distributed equipment.

• SCADA is an acronym for Supervisory Control And Data Acquisition. SCADA systems perform data collection and control at the supervisory level. Some systems labeled as SCADA perform data acquisition only.

• A SCADA system should not be critical to the controlled process. The SCADA connects to a PLC or real time device, so there is a separate or integrated real-time automated control system that responds quickly enough to compensate for process changes within the time constants of the process.

• The SCADA controls and monitors the process, but the process must also run independently from the SCADA system in case of failure.

Page 67: Automation basics by raj nayak

Features of SCADA

Features of typical SCADA software

• Dynamic process graphic• Real-time and Historical

trending• Alarms• Recipe Management• Security• Device connectivity• Database connectivity

Page 68: Automation basics by raj nayak

Role of communication in Automation:

• Communication has played a vital role in the process of Automation

• The controller receives the inputs from various sensors and also receives the inputs from the communication bus.

• Master control is usually at centralized location and in it must receive data from all the locations to enable it to to process the inputs and reach to the decision

• Different protocols are used to transfer the data to the controller

Page 69: Automation basics by raj nayak

Different Protocols

• IEEE Instrumentation BUS

• CAN Bus

• Modbus

• Prophi Bus

• 61850 Protocol

• TCP/IP

Page 70: Automation basics by raj nayak

Different Protocols

• IEEE Instrumentation BUS

• CAN Bus

• Modbus

• Prophi Bus

• 61850 Protocol

• TCP/IP

Page 71: Automation basics by raj nayak

•Sensors•Controllers

•Actuators• HMI

• Display & alarm

Basic Elements of Automation

Page 72: Automation basics by raj nayak

What is an actuator ?Definition for actuator:a mechanism that puts

something into automatic action .• An actuator is a

mechanical device for moving or controlling a mechanism or system.

• An actuator is operated by a source of energy, usually in the form of an electric current, hydraulic fluid pressure or Pneumatic pressure , and converts that energy into some kind of motion.

Different actuators used to control the given system

• Relay• Solenoid• Valve• Motor• MHT• Contactor

In addition to above types of actuators a system can be controlled by a digital signal (flag )generated locally or received from remote end device through communication channel using a certain protocol for the communication

Page 73: Automation basics by raj nayak

Actuators

Actuators can be categorized based on

1. Energy source used– electrically operated– Pneumatically operated– Hydraulically operated– Gas operated

2. Type of Motion Linear motion Rotary motion Oscillatory motion

• Perhaps the most common type of actuator is powered by air — the pneumatic cylinder, also known as the air cylinder

.  Air cylinders  are air-tight cylinders, typically made from metal, that use the stored energy of  compressed air to move a piston when the air is released or uncompressed. They are most commonly used in manufacturing and assembly processes.

Grippers, which are used in robotics, use actuators that are driven by compressed air to work much like human finger

Page 74: Automation basics by raj nayak

RELAY:

• Relay is an electromechanical device and has a predesigned operating voltage.

• Essentially it has a coil,a plunger,a spring and atleast one pair of sands operations coil gets energized and electromagnetic action as aresult of current flow in the coil attracts the plunger resulting in the change of contact position.

• Contacts are designed to carry large current compared to the operating current of the coil.Contact material can withsatnd several thousands operations

• The relays are available in different types (sealed,Unsealed) latching /non latching and ac/dc operating voltages, The contacts available in the relays are N/O .N/c or C/O types.

Page 75: Automation basics by raj nayak

Relay and Contactor:

• Contactor again works on the same principle however contactor has two types of contacts ….Main contacts and auxiliary contacts. Auxiliary contacts are used to give the status to the controller while main contacts carry the controlled current.

• Contactors are available in different sizes depending on the current carrying capability of the main contacts

Page 76: Automation basics by raj nayak

Solenoid:

• A solenoid also operates on the principle of electromagnetism like relay however in addition to changing the status of the contacts solenoid plunger movement also initiates mechanical movement leading to change in the positions of other mechanical components to control the pnematic Hydraulic or electrical circuits.

Page 77: Automation basics by raj nayak

• Stepper Motors• Used for measured

rotationCan be held at a

particular position of the shaft

Ideal for many autonomous robots requiring higher precision

Page 78: Automation basics by raj nayak

• Servo Motors :Used in closed loop control

systems in which work is the control variable.

An integral feedback device (resolver) or devices (encoder and tachometer) are either incorporated within the servo motor or are remotely mounted, often on the load itself

Page 79: Automation basics by raj nayak

Double acting actuator• A double acting actuator is a mechanical device designed to supply powered bi-

directional actuation for secondary mechanisms. This is in contrast to single action or spring return actuators and solenoids, which feature a powered stroke in one direction only and rely on a secondary source of energy to reset or return the actuator. The double acting actuator is typically driven by electric motors or compressed oil and gas. Electrically-driven double action actuators supply their bi-directional force by means of a motor reversing control circuit. Compressed gas and oil actuators feature opposed inlet valves that direct the motive agent to one side or the other of the actuator mechanism.

• Actuators are devices used to operate a machine or mechanism remotely by supplying a predetermined range of powered output movement. This movement is generally broken down into two strokes in opposed directions. These may be activation and recovery strokes or bi-directional operating strokes. Activation and recovery systems are well-illustrated by a metal stamping machine where the die is pushed down for the activation stroke and recovered, or returned, to a neutral position in readiness for the next cycle. A bi-direction output may be seen in a valve actuator, which turns in one direction to open the valve and in the opposite direction to close it.

• Ads by Google

Page 80: Automation basics by raj nayak

Summary• Automation has a wide spread presence in almost every industry and

homes• Automation systems consist of sensors controllers and an actuators. • There are variety of sensors depending on the physical quantity to be

controlled. In power system the most common sensors are CTs and PTs• The simplest type of controller is a comparator and the advanced controllers

are programmable and are capable of handling number of inputs and outputs. Microcontrollers and computers are widely used these days in the automation.

• Controllers must be programmed for the given sets of Inputs and outputs to get the desirable results. All the intelligence is embedded in the controller after programming in higher level languages and using suitable compilers.

• There are different types of actuators controlling linear and rotational motion and the most common actuators are Solenoids ,Relays and Motors

• Communication plays a very important role in the Automation system and depending on the application a particular Protocol is used. Internet technology has revolutionized the automation. In Substation Automation 61850 protocol is used for acquiring data .

• Automation has many advantages including making our lives comfortable and enable human beings to do the things which otherwise would have been impossible to do manually with same efficiency and accuracy.

• Automation changes the nature of jobs and demands new skills and it is a myth that it leads to unemployment…It has shifted the focus from Manufacturing industries to the Service related industries

Page 81: Automation basics by raj nayak

Questions from the Audiance

Page 82: Automation basics by raj nayak

THANKS

Page 83: Automation basics by raj nayak

For More detail Visit

• http://www.srturboenergy.com/