AUTOMATION
AUTOMATION
What is AUTOMATION ?
As the name suggest 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.
In the scope of industrialization, automation is a step
beyond mechanization.
It is used to reduce human interference and an efforts.
AUTOMATION
Tools of Automation
Programmable Logic Controller (PLC)
Supervisory Control And Data Acquisition (SCADA)
Human Machine Interface (HMI) or Touch Screen (TS)
Variable Frequency Drive (VFD)
AUTOMATION
ADVANTAGES : ~
Replacing human operators in tasks that involve
hard physical or monotonous work.
Replacing humans in tasks done in dangerous
environments.
Performing tasks that are beyond human
capabilities of size, weight, speed, endurance, etc.
Economy improvement: Automation may improve
in economy of enterprises, society or most of
humanity.
AUTOMATION
DISADVANTAGES : ~
Unemployment rate increases due to machines
replacing humans and putting those humans out of
their jobs.
Technical Limitation
Security Threats
High initial cost.
PLC
What is PLC ?
PLC - programmable logic controller
A Programmable Logic Controller, or PLC for short,
is simply a special computer device used for
industrial control systems. They are used in many
industries such as oil refineries, manufacturing lines,
conveyor systems and so on.
PLC implements logic control functions by means of
a program.
PLC
How does a PLC differ from a computer ?
A computer is optimized for calculation and
display tasks.
A computer is programmed by specialists
A PLC is designed for (logic) control and
regulation tasks.
A PLC is programmed by non-specialists
A PLC is
environment.
well
adapted
to
industrial
PLC
Components of PLC : ~
PLC
Components of PLC : ~
1. Inputs Circuits
2. Outputs Circuits
3. CPU (Central Processing Unit )
4. Memory for program and data storage
5. Programming device
6. Communication Device
7. Power Supply
PLC
1. PLC inputs : ~
ANALOG inputs
DIGITAL inputs
Pressure Transducer
Push buttons
Flow meter
Sensors
Thermocouples
Selector switches
PLC
PLC outputs : ~
ANALOG outputs
DIGITAL outputs
LEDs
Pressure regulator
Small motors
Position controller
Relays
PLC
Memory for program and data storage : ~
Memories used: RAM Random access memory
Volatile
Made up of metal oxide semiconductor
lose it's information if power is removed.
PLC
Power Supply : ~
A power supply of 120v ac is typically used to drive
the PLC (some units operate on 240v ac).
The power supply converts the 120v ac into dc
voltages of +5v.
These low voltages are used to operate equipment
that many have much higher voltage and power
ratings than the PLC itself.
PLC
Programming In PLC :~
Languages used in PLC for the purpose of programming are
1. Ladder language
2. Functional Block Diagram (FBD)
3. Instructional List (IL)
4. Drive Functional Block (DFB)
5. Structural test language
PLC
Ladder language used in PLC programming
There are two PLC in which ladder programming
is used : ZELIO PLC : - It uses Zelio soft 2 software for
the programming.
DELTA PLC : - It uses WPL soft software for
their programming.
PLC
ZELIO PLC
PLC
Parameters used in Zelio and delta PLC in
ladder programming
Parameters
ZELIO plc
Inputs
In
Outputs
Qn
DELTA plc
Xn
Yn
NC of input
NO of input
Timer
Tt1, t1
PLC
Zelio soft 2 ladder programming
The various parameters used in zelio soft 2 while
operating ladder program and their relationship
amongst them are as follows: INPUT CONTACT
OUTPUT CONTACT
INTERLOCKING
MEMORY COIL
LATCHING
TIMER
COUNTER
PLC
INPUT AND OUTPUT CONTACT
Inputs in Zelio soft 2 is represented by I1, I2, I3,I5,I6.
Inputs are further classified as: NORMALLY CLOSED
NORMALLY OPEN
PLC
Examples for Normally open contact
PLC
Example of Normally closed contact
PLC
INTERLOCKING
Interlocking means to interlock something by placing
NC of coil or input in front. The concept of interlocking
reduces the complexity in PLC programming
PLC
Example of Interlocking
PLC
MEMORY COIL
PLC
Example of Memory coil
PLC
When memory coil gets energized
PLC
LATCHING
Latching is the process in which once output or a coil
is energized it remains energized forever. Latching is
done by the contact of output or coil which we want
to switch ON permanently.
PLC
When contact I1 is turned ON
PLC
TIMER
Timer is basically used add some delay in the
programming circuit by adding a particular time to
each circuit.
Types of timers : ON delay timer
OFF delay timer
PLC
Example of Timer
PLC
COUNTER
PLC
DELTA PLC
It is high-speed, stable and highly reliable PLC's are
applied in various automation machines.
it is totally similar to zelio plc programming but the
specifications of DELTA plc are different from zelio plc
as shown above.
In DELTA plc memory space has been allotted
according to the types of plc.
PLC
Timers in Delta PLC
Timers in DELTA plc are used to add some delay in the
circuit, timers can be of two types as follows: ON delay timer.
OFF delay timer.
Commands for applying timer are as
follows: TMR<space>t0<space>k100
PLC
Example of delta PLC
PLC
WIRING OF PLC
The operating voltage of plc is 220v (Ac) / 24v
(dc)/10v (dc). The operating voltage of plc is 220v
(Ac) / 24v (dc)/10v (dc).
Components used in wiring of plc are: SMPS- Switch Mode Power Supply
OUTPUT- Y0 ,C0
SOURCE/SINK (S/S)- S0,S1.........
PLC
COMPONENTS
SWITCH MODE POWER SUPPLY: SMPS is used to provide power supply to plc; SMPS
can be of different power supply mode. Ex - 220v (Ac) / 24v (dc)/10v
(dc).
Y0
C1
Y1
PLC
Example of wiring of PLC
PLC
Applications of PLC
Gate Control : -
PLC
Applications of PLC
Conveyor System: -
VFD
VARIABLE FREQUENCY DRIVE (VFD)
VFD or Variable Frequency Drives are used
to run the motors of single phase or three
phase supply.
VFD is used to accelerate and deaccelerate
the speed of motor with in a particular time.
Drives commands: Start/Stop
Speed reference
Acceleration/ deacceleration
VFD
Parameters of VFD
P = 200 = 0 (digital keypad)
= 3 (potentiometer on drive)
P = 201 = 0 (digital keypad)
= 1 (external terminal) / keypad stop/enable
= 2 (external terminal)/keypad stop/disable
START/STOP command
= 0 (on board)
= 1 (ext M0=forward, M1= reverse)
= 3(M0=forward, M1= reverse, M2=stop)
P = 109 = acceleration time
P = 110 = deacceleration time
VFD
Advantages of VFD
Dynamic braking : -Dynamic braking stops the
system more quickly than coasting
Highly efficient
Low power consumption
Small space consumption
Low cost
Easy to use
Highly specific
SCADA
SCADA System
SCADA
Why SCADA?
Saves Time and Money
Saves energy
Reliable
HMI
HUMAN MACHINE INTERFACE (HMI)