AUTOMATION:

Automation is the use of control systems such as computers to control

industrial machinery and processes, replacing human operators. In the scope of
industrialization, it is a step beyond mechanization. Whereas mechanization
provided human operators with machinery to assist them with the physical
requirements of work, automation greatly reduces the need for human sensory
and mental requirements as well.
ADVANTAGES OF AUTOMATION:
The purpose of automation has shifted from increasing productivity and
reducing costs, to broader issues, such as increasing quality and fleibility in the
manufacturing process.
Automation is now often applied primarily to increase quality in the
manufacturing process, where automation can increase quality substantially.
!or eample, automobile and truck pistons used to be installed into
engines manually. This is rapidly being transitioned to automated machine
installation, because the error rate for manual installment was around "#".$%,
but has been reduced to &.&&&&"% with automation.
'azardous operations, such as oil refining, the manufacturing of industrial
chemicals, and all forms of metal working, were always early contenders for
automation.
Application of Automation
Power generation
TRANSMISSION AND DISTRIBUTION:
Oil and gas industries
Process industries
Building automation
HISTORY O AUTOMATION
MANUAL CONTROL
HARDWIRED CONTROL:
(rior to ()*s, many of these control tasks were solved with contactor or
relay controls. This is often referred to as hard#wired control. *ircuit diagrams
had to be designed, electrical components specified and installed, and wiring lists
created. +lectricians would then wire the components necessary to perform a
specific task. If an error was made the wires had to be reconnected correctly. A
change in function or system epansion required etensive component changes
and rewiring.
,-AW.A*/01
.ulky and comple wiring.
,ifficult to change the logic.
2nreliable.
RELAY :

RELAY LOGIC AND GATE:

ELECTRONICS CONTROL
Logic gates and Electronic Circuits are used
Ease o !rogra""ing
Ease o "aintenance
Dra#$ac%s:
Diicult to Trou$les&oot #&ile C&ange t&e Logic o t&e 'rocess
Diicult to e(!and
Not suita$le or industrial conditions
PROGRAMMABLE LOGICAL CONTORL
What is a Programmable Logic o!troller PL"
()* is a device, which is used to control a machine or process as per the
human control sequence. A ()* monitors inputs, makes decisions based on its
program, and controls outputs to automate a process or machine.
A#$a!tages
3 0maller physical size than hard#wire solutions
3 +asier and faster to make changes
3 ()*s have integrated diagnostics and override functions
3 ,iagnostics are centrally available
3 Applications can be immediately documented
3 Applications can be duplicated faster and less epensively

PROCESSOR MEMORY ORGANIZATION
T&e "e"or) o a 'LC is organi*ed $) t)!es+
T&e "e"or) s!ace can $e di,ided into t#o $road categories:
'rogra" and Data -e"or):
Ad,anced ladder logic unctins allo# controllers to !eror" calculatins.
"a%e decisions and do ot&er co"!le( tas%s+ Ti"ers and counters are e(a"!les o ladder
logic unctions+ T&e) are "ore co"!les t&an $asic in!uts contacts and out!ut coils and
rela) &ea,il) u!on data stored in t&e "e"or) o t&e 'LC+
'ROGRA- /ILES:

T&e user !rogra" #ill account or "ost o t&e "e"or) o a 'LC
s)ste"+
'rogra" iles contain t&e logic controlling "ac&ine o!eration+
T&is logic consistes o instructions t&at are !rogra""ed in a ladder
logic or"at+
DATA /ILES:
T&e data ile !rotion o "e"or) stores in!ut and out!ut status.
!rocessor status. t&e status o ,arious $its and nu"erical data+
INPUT TABLE FILE OPERATION:

'rocessor continuall) reads current in!ut status and u!dates in!ut
i"age ta$le ile+
OUTPUT TABLE FILE OPERATION:

'rocessor continuall) acti,ates or deacti,ates ou!ut status according
to out!ut i"age ta$le ile status
PROGRAM SCAN:
During eac& o!erating c)cle. t&e !rocessor reads all in!uts. ta%es t&ese
,alues. and energi*es or de0energi*es t&e out!uts according to t&e user
!rogra"+ T&is !rocess is %no#n as a scan+ 1ecause t&e in!uts can c&ange at
an) ti"e. t&e 'LC "ust carr) on t&is !rocess continuousl)+

2+ I3O scan records status data o in!ut de,ices+ Energi*es out!ut
de,ices t&at &a,e t&eir associated status $its set to ON 425
6+ 'rogra" scan instruction are e(ecuted se7uentiall)+
SCAN PROCESS:
T&e scan ti"e indicates &o# ast t&e controller can react to c&anges in
in!uts+ Scan ti"es ,ar) #it& co"!uter "odel and !rogra" content. and
lengt&+ I a controller &as to react to an in!ut signal t&at c&anges states t#ice
during t&e scan ti"e. it is !ossi$le t&at t&e 'LC #ill ne,er $e a$le to detect
t&is c&ange+

W&en t&e in!uts is closed. t&e in!ut "odule senses a ,oltage and an ON condition
425 is entered into t&e in!ut ta$le $it 89926:+
During t&e !rogra" scan t&e !rocessor sets instructins 89926: and 8;9<: to ON425+
T&e !rocessor turns lig&t out!ut 8;9<: ON during t&e ne(t I3O scan+
=EYENCE
ADDRESS:
IN'>TS:
9999 to 992;
9299 to 922;
9699 to 962;
9?99 to 9?2;
9@99 to 9@2;
O>T'>TS:
9;99 to 9;2;
9<99 to 9<2;
9A99 to 9A2;
9B99 to 9B2;
9C99 to 9C2;
INTERNAL -E-ORY 1IT:
2999 to 292;
>!to
2C99 to 2C2;
TI-ERS:
T-RDaddE s!ace FDti"eE 49+2sec5
T-HDaddE s!ace FDti"eE 49+92sec5
T-SDaddE s!ace FDti"eE 49+992sec5
CO>NTERS:
>! counter: CDaddE s!ace FDnu"$er o countEs!aceDinternal $itE
>!3D#n counter: CDaddEs!aceFDnu"$er o countE
'ROCED>RE /OR 'ROGRA--ING:



2 6 ? @ ; < A B C 29 22 26 2? 2@ 2; 2<
2+ Edit co""and3La$le
6+ Edit line co""and
?+ S&o#3Hide co""and
@+ Gu"! to s!eciied line3ste!
;+ /ind
<+ Re!lace o!erand
A+ >sage inor"ation
B+ Edit list
C+ co"!ail
29+ S&o# co"!ilation error
22+ Transer to 'LC
26+ Read ro" 'LC
2?+ 'lc "onitor
2@+ Si"ulator
2;+ Dis!la) "ode
2<+ Descri!tion o o!eration
2 6 ? @ ; < A B C 29
2+ N+O+ contact OR in!ut
6+ NC contact OR in!ut
?+ NO contact in!ut
@+ NC contact in!ut
;+ Out!ut coil
<+ NC out!ut coil
A+ In!ut ,ertical connection line
B+ Delete ,ertical connection line
C+ In!ut Hori*antal connection line
29+ Delete Hori*antal connection line
BASIC PROGRAMMES:
00H H00 NOR-ALY O'EN CONTACT
00H 3 H00 NOR-ALY CLOSED CONTACT
004 500 COIL
E: !
W&en t&e s#itc& 4SW5 is ON. t&e LOAD s&ould ON 4Rung 99925
W&en t&e s#itc& 4SW5 is O//. t&e LOAD s&ould ON 4Rung 9996
Not": T&e all !rogra""ing se7uence s&ould co"!lete #it& 8END: AND 8ENDH:+
LADDER LOGICS /OR DIGITAL GATES:
OR :
I2 I6 L
9 9 9
9 2 2
2 9 2
2 2 2
AN#:
I2 I6 L
9 9 9
9 2 9
2 9 9
2 2 2
NOR:
I2 I6 L
9 9 2
9 2 9
2 9 9
2 2 9
NAN#:
I2 I6 L
9 9 2
9 2 2
2 9 2
2 2 9
E$OR: E$NOR:
I2 I6 L
9 9 2
9 2 2
2 9 2
2 2 9
S%ITC& CONTACTS:
E !: SW2I 9999. SW6I 9992. LD2 I ;99. LD6 I ;92
SW2 SW6 LD2 LD6
2 9 2 9
2 2 9 2
E ':
SW2 SW6 SW? LD2 LD6 LD?
9 2 2 2 9 9
2 9 9 9 2 9
2 2 2 9 9 2
I2 I6 L
9 9 2
9 2 2
2 9 2
2 2 9