Date post: | 13-Nov-2014 |
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Industrial Automation
MACHINE
CONTROL SYSTEM
INFORMATION TECHNOLOGY
Automation is basically the delegation of human control
function to technical equipment for
•Increasing Productivity• Increasing Quality
• Reducing Cost• Increasing Safety in working conditions
What is Industrial Automation ..?
Automation is encompassing virtually every walk of life.
Automation solutions are required right from agricultural to space technology.
Plant Automation is the necessity for the manufacturing industry to survive in today’s
globally competitive market
IT IS ALSO AUTOMATION
Feedback(Eyes)
Processor (Brain)
controlling unit(Hand)
When Human Operator can operate the machine ,taking Feedback of a Machinery performance and he can change or adjust according to requirement,that why it also called as Automation.
Thus ,we can define AutomationAny systematic operation required intelligence and as well asmonitoring action.
Don’t Surprise
Output action unit (Leg)
Scope of Automation in industries
• Power & Steel plant
• Chemical
• Paint
• Gas & oil
• Automobile Industries
• Mobile manufacturing industries
• Textile industry
• Medicine
Industrial Automation
• PLC
• SCADA
• PID Controller
• Industrial Instrumentation
• Motor(AC)
• Relay & Contactor ,electrical device’s symbols
• Drives (AC)
• HMI
• Networking
ELECTRONIC CONTROLLER
TIMER
It is used for time delay generationfor the operation of different Machinery
COUNTER
It is used for counting the no. of event
PID Controller
Thermocouple
PID Controller
VFD
Temperature
controlling
by the use of PID
controller in
Industry
Blower
Analog Input Signal (FEEDBACK)
Regulated Controlled Signal ( Output)
Frequency controlledPower supplied toBlower Motor
Limitation of Electronic Controller in a Industry
In industry where large number of a Timer , Counter, PID, Relay, Switches and etc ,which all makes the entire system costly and complicated .
Thus, there is need of One Controller which can monitor the entire system
And also generate delay and count a event
Easy to be program , modify whenever needed
All this feature are add up in a one controller PLC (Programmable Logic Controller)
History of Automation
• Manual control system
• Pneumatic control system
• Hard wired logic control system
• Electronic control using logic gate
• PLC (Programmable logical controllers)
A PLC is a micro processor based 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.
PLCs are used successfully to execute complicated control operationsin a plant.
Programmable Logic Controller
History of PLC
The PLC was invented in response to the needs of the American automotive
manufacturing industry.
Programmable logic controllers were initially adopted by the automotive industry where
software revision replaced the re-wiring of hard-wired control panels when production
models changed.
In 1968 GM Hydramatic (the automatic transmission division of General Motors) issued a
request for proposal for an electronic replacement for hard-wired relay systems. The winning
proposal came from Bedford Associates
of Bedford, Massachusetts.
The first PLC, designated the 084 because it was Bedford Associates' eighty-fourth project,
was the result. Bedford Associates started a new company
dedicated to developing, manufacturing, selling, and servicing this new product:
Modicon, which stood for Modular Digital Controller. One of the people who worked on that
project was Dick Morley, who is considered to be the "father" of the PLC. .
Global Player in a Automation Industry
1. Siemens
2. Allen Bradelly
3. Mitsubhisi
4. GE
5. ABB
6. Delta
7. Yokogawa
8. Omran
9. National Instrument
10. Schinider Electric
11. honeywell
Programming In a PLC
User have a multiple Choice for programming a PLC
Ladder logic Functional Block DiagramInstruction List
Ladder Logic Programming
It is a easier way of Programming the PLC.
So that Engineer must be concerned only on procedure and functional of the
machinery design
For this knowledge of basic Electronic Circuit is sufficient.
For Example
Basic Gate Logic
OR Gate
A
B
Output
A
B
Output
Electrical Circuit
Ladder Logic
AND Gate A Output
A B Output
B
Electrical Circuit
Ladder Logic
NOT gate
A
Output
A Output
Electrical Circuit
Ladder Logic
Motion Control System
VFDInduction Motor
Stepper DriveStepper Motor
Servo Drive Servo motor
We can operate these Drive throughKeypad , external Switch and also through PLC
Industrial Robotic is also the part of Automation IndustryIndustrial robotic is the finest example of motion control system, One robot required one controller for the specific operation but when multiple robot working together thus we required no. of PLC connected together by Master PLC, so that entire process can be synchronized
SCADA
Supervisory Control and Data Acquisition
Supervisory means Monitoringentire system throughGUI representationof working Status ,of the entire system
Control means Controlling the entire System such as ON/OFF operation ,Speed controlling, temperature Controlling
Data Acquisitionmean collectingdata Information from Different controller, Sensor , Drives , Motor which are connected at distance through wire , Ethernet , wireless
PLC is just like a Black Box, internal operation of its
user can`t see until the entire process complete or halt the
System…Thus we required GUI(Graphical User Interface)
Representation of the entire process……..
Main feature of SCADA
•GUI is designed by simple Drag and Paste concept.
•Tagging and Coding is done by considering programming bit .
•On SCADA ,we can monitor Real Time operation and Historical Trend .
•Alarm triggering which also used in this system , it trigger when certain
task complete or sudden brake of a system.
•Recipe management ,it provide the operator multiple choice for mixing the
variety of chemical and solution.
We can also monitor the Real time operation and the process on Graph .
In Industry SCADA were designed on Computer
System , and display may be on computer
screen, LCD Display or Projector
Here we can see, all the sensor , chemical tank, filling process , temperature ,ON /OFF status of Motor .All this thing, it has being monitor on the PC screen and big LCD Screen or projector.
HMIHuman 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 Networking
Eternet, Device net,Modbus , Profibus cable are used for connecting entire Controller , Sensor , PLC and SCADA
Industrial Sensor
It is basically are of two type
Digital Sensorit has switching b/w ( 0,24V)
Analog SensorIt is basically are of two typeCurrent type analog Sensor
(4mA—20mA)Voltage type analog Sensor
(0—10V)
Advantage of Implementation of automation in Industry
Increase In ProductionReliability in operation Flexibility in control techniques Flexibility in programming and reprogramming in the plant Large quantity of I/O s are connectedOnline/ offline modifications Cost effective for controlling complex systems In-house simulation & testing of project Speed in operation Ability to communicate with computer systems in the plant. Ease of maintenance / troubleshooting
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 .
SCOPE OF AUTOMATION
In the Research Lab such as CERN,NASA,ISRO,DRDO and etc Where very small unit of machine to the very heavy Machinery Unit designed are interlink together , A to Z controlling in came under industrial Automation.
In Heavy industry such as Steel ,Automobile , and Food industry where the man are not able to work in a such hostile condition ,thus sensor, controller & PLC are diploid there and monitoring & controlling is done from SCADA based control room
Industrial Automation is the End Consumer of the
Engineering field.
In Industry and Research Lab
All the Mechanical machinery from small to large such as Hydraulic system, pneumatic system, Induction motor are consumes in the Automation industry
Relay ,Contactor and large Amount of Switch Gear(MCB,MCCB,OLR ,Push Button) are also consumes in this industry
Industrial sensor (Proximity ,IR Sensor , Level sensor) & instrument (Pressure Switch , limit Switch, Flow Meter)are also consumes in this
Embedded product such counter , timer, PID controller and electronic Regulator and PLC are also consumes in the automation
Mechanical
For connecting different device , controller , PLC and SCADA so that they can communicate with each other thus Industrial networking requirement is essential
Electrical
Instrumentation
Electronic
Information Technology
Role of Engineers In Industrial Automation
• Designing of the Automation system
• Erection and Commissioning
• Application Engineering
• Maintenance and Troubleshooting of existing system