AUTOMATION

Higher productivity Superior quality of end product

Efficient usage of raw materials and energy

Improved safety in working condition

HISTORY OF CONTROL & AUTOMATION

Manual control Hard-wired logic control
Electronics control with logic gates

Programmable logic controller (PLC)

MANUAL CONTROL

Human errors subsequently affects quality of end product

HARD-WIRED CONTROL
Too much work in connecting wires Difficulty with changes or replacement
Difficulty in finding errors, requiring skillful

workforce

When problem occurs, holdup time is indefinite

ELECTRONIC CONTROL WITH LOGIC GATES

Implementation of changes in the control logic as well as reducing the project lead-time was not possible

PROGRAMMABLE LOGIC CONTROLLER (PLC)

Fast implementation of changes Easy troubleshooting Larger quantities of contacts are available High expansion capabilities Sequential/Logic modification without wiring changes Progress of sequencing easily monitored Reduced space and energy Greater life, reliability and flexibility

LOGICAL CONTROL WITH RELAYS

115V C A wall plug

relay logic

input A (normally closed)

input B (normally open)

output C (normally open)

C ladder logic

Relay Logic In a PLC

power supply +24V com.

push buttons

PLC
inputs

ladder logic

outputs

115V ac AC power neut.

light

PROCESS CONTROL INSTRUMENTATION

INSTRUMENTATION
Measurement and control of process variables

PROCESS VARIABLES
eg: voltage, current, pressure, flow,

PROCESS
Method or Mechanism involved in manufacturing a product

DIFFERENT TYPES OF PROCESS

PROCESS

Simple

Complex

Sequential Continuous

Batch

PROCESS
PROCESS INVOLVES
Measurement - Transducers Compare Compute Control

- Lesser or Greater - ( Set point Process Variable )

=Error

- Actuator

GENERAL ARCHITECTURE OF COMPLEX PROCESS

Input from Field control element

Set point

Measurement system

P.V

Compare Compute
error

Control system
-Analog

Controller

-Digital -Microprocessor -Micro controller -PLC -DCS

SYSTEM UNIT OF PLC

Central Processing Unit(CPU) having processor
and program memory

Input/Output Modules Bus System Power supply

SYSTEM UNIT OF PLC

Programming Device
User input Devices

PLC

Program Memory

User output Devices

Acknowledge ments (Limit switches, Sensors) Control elements (Push buttons, switches)

Input modules (Input cards )

Central control unit

(single or multibit processor )

Output modules (Output cards )

Final control elements

( relays, electrical switches, solenoid valves)

Indicators
(Lamps)

Power Supply

INPUT TYPES AND INPUT VOLTAGE LEVELS

Input Types : Switches Proximity switches Limit switches Potentiometer LVDTs Thermocouple Pressure transducers Input Voltages : 12-24 V dc 100-120 V ac 10-60 V dc 12-24 V ac/dc 5 V dc 200-240 V ac 48 V dc 24 V ac

OUTPUT TYPES AND OUTPUT VOLTAGE LEVELS

Output Types : Output Voltages :

Solenoid Valves Lights Motor Starters Servo Motors Heaters Sirens/Horns

120 Vac 24 Vdc 12-48 Vac 12-48 Vdc 5Vdc (TTL) 230 Vac

Bus system
Address Bus Data Bus Control Bus

DIFFERENT TYPES OF MEMORY

RAM ROM PROM EPROM EEPROM
Read

- Random Access Memory - Read Only Memory - Programmable Read Only Memory - Erasable Programmable Read Only Memory - Electrically Erasable Programmable Read
Only Memory

EAPROM

- Electrically Alternatively Programmable

Only Memory

Flash Memory

FACTORS WHICH AFFECTS THE PERFORMANCE OF PLC

Temperature Noise Dust Humidity Operating system(OS)

FACTORS TO BE CONSIDERED FOR PLC CLASSIFICATION

I/O Expansion Memory Expansion Processor speed Scan time

PLC PROGRAMMING
Relay Ladder Logic Statement Listing (STL) Functional Block Diagram(FBD) Instructional Listing Sequential Flow Chart

PLC WORKING (7 STEPS) (SCAN CYCLE)

Initialization Reading inputs Program execution Update outputs(User control) Error checking Monitoring Communication

STEPS TO BE FOLLOWED WHILE WORKING IN LADDER

Create a project Select Processor type I/O and Channel configuration Create/Edit ladder logic Compile/Verify Download Run Online/Monitoring

PLC COMMUNICATIONS
Network
Physical hardware or Communication channels

Protocol
Defined means of establishing criteria for receiving and transmitting data through communication channels

NETWORKS AND PROTOCOLS

NETWORKS
RS232C RS422 RS485 Ethernet DH+ Devicenet Profibus

PROTOCOL
MODBUS TCP/IP DH+ Devicenet Profibus

DIFFERENT COMMUNICATION PROTOCOL

Protocol Baud rate No. of nodes -2 - 32 - 64 - 64 - 2(100m) & 48(250m) - 64 - 126 (500m)

RS232C DH485 DH+ Ethernet Controlnet Devicenet Profibus

19.2kbps 19.2kbps 57.6kbps 10.0Mbps 5.0Mbps 500kbps 12.0Mbps

DEVICENET
A single bus cable that delivers data and power Up to 64 nodes Data packet size of 0-8 bytes Lengths of 500m/250m/100m for speeds of respectively Devices can be added/removed while power is ON Addressing includes peer-peer, multicast, master/slave, polling or change of state. Can be connected directly to sensor and actuators Noise resistant and robust
125kbps/250kbps/500kbps

PROFIBUS(PROCESS FIELD BUS)

Token passing can be between up to three masters Maximum of 126 nodes 2 data line and shield Lengths from 9600m/9.6kbps to 500m/12Mbps With fiber optic cable lengths can be over 80Km Straight bus topology Uses RS-485, Ethernet, fiber optics, etc. 2048 bits of I/O per network of frame

ALLEN BRADLEY(AB)

DIFFERENT MODELS OF ALLEN BRADLEY (AB) PLC

Pico Controller Micrologix series SLC family Flexlogix Controllogix Compactlogix Softlogix

PROGRAMMING SOFTWARE USED FOR ALLEN BRADLEY (AB) PLC

RSLOGIX 500 RSLOGIX 5000 RSLOGIX 5

DIFFERENT MODELS & DIFFERENT SOFTWARE FOR ALLEN BRADLEY (AB) PLC Pico Controller
(HHP

Hand Held Programmer)

RSLOGIX 500

Micrologix series SLC family Flexlogix Controllogix Compactlogix Softlogix

RSLOGIX 5000

RSLOGIX 5

MICROLOGIX AND SLC FAMILY

MICROLOGIX
Lower version Fixed I/O type E.g.: 1000, 1200 and 1500

SLC Family
Higher version Modular I/0 type E.g.: SLC 500, 5/01, 5/02, 5/03, 5/04, 5/05

FLEXLOGIX AND CONTROL LOGIX

Supports RSLOGIX 5000 only Supports Ladder,FBD and Statement listing On-line editing On-line I/O removal/insert Supports advance instructions - e.g. PID,ASCII

FACTORS WHICH CLASSIFY ALLEN BRADLEY (AB) PLC

Memory - (16k, 32k, 64k and 256k) Communication protocol Number of inputs/outputs Instructions

DIFFERENT FORMS OF PLC

Rack Mini Shoebox Micro Software

DIFFERENT FORMS OF PLC