Industrial Automation

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

Increasing Productivity Increasing Quality Reducing Cost Increasing Safety in working conditions CONTROL SYSTEM

MACHINE

INFORMATION TECHNOLOGY

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 todays globally competitive market

Dont Surprise

IT IS ALSO AUTOMATION
Processor (Brain) Feedback(Eyes) controlling unit(Hand) Output action unit (Leg)

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 Automation Any systematic operation required intelligence and as well as monitoring action.

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 devices symbols Drives (AC) HMI Networking

ELECTRONIC CONTROLLER
TIMER It is used for time delay generation for the operation of different Machinery

COUNTER It is used for counting the no. of event

PID Controller

Thermocouple
PID Controller
Analog Input Signal (FEEDBACK)

Regulated Controlled Signal ( Output)

Frequency controlled Power supplied to Blower Motor

Blower

Temperature controlling by the use of PID controller in Industry

VFD

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)

Programmable Logic Controller

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 operations in a plant.

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 Diagram Instruction 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 A OR Gate B Output Electrical Circuit

A B

Output Ladder Logic

AND Gate

Output Electrical Circuit

Output Ladder Logic

Output NOT gate A Electrical Circuit

Output Ladder Logic

Motion Control System

We can operate these Drive through Keypad , external Switch and also through PLC Induction Motor

VFD

Stepper Drive

Stepper Motor

Servo Drive

Servo motor

Industrial Robotic is also the part of Automation Industry

Industrial 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
Data Acquisition mean collecting data Information from Different controller, Sensor , Drives , Motor which are connected at distance through wire , Ethernet , wireless

Supervisory means Monitoring entire system through GUI representation of working Status ,of the entire system

Control means Controlling the entire System such as ON/OFF operation , Speed controlling, temperature Controlling

PLC is just like a Black Box, internal operation of its user can`t see until the entire process complete or halt the SystemThus 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.

HMI
Human 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 Sensor it has switching b/w ( 0,24V)

Analog Sensor It is basically are of two type Current type analog Sensor (4mA20mA) Voltage type analog Sensor (010V)

Advantage of Implementation of automation in Industry

Increase In Production Reliability in operation Flexibility in control techniques Flexibility in programming and reprogramming in the plant Large quantity of I/O s are connected Online/ 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

In Industry and Research Lab

Industrial Automation is the End Consumer of the Engineering field.

Mechanical
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 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