What is Automation ?

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

Total Automation

Productivit y Manufacturing Competitivenes s Solution Plant Labor Cost

Qualit y

HISTORY OF AUTOMATION

Programmable Logic Controller Electronic Control using Logic Gates Hard wired logic Control Pneumatic Control

Manual Control

PROGRAMMABLE LOGIC CONTROLLER

PLC
Reliability in operation, Small physical size, Shorter project time, Speed in Operation, Ease of maintenance/Troubleshooting Applications : Machine controls, Packaging, Palletizing, Material handling, similar Sequential task as well as Process control

What is PLC ? Advantages of PLC

Ladder Diagram

The Ladder Diagram (LD) programming language originated from the graphical representation used to design an electrical control system

Finally CPUs were added to take over the function of the logic circuits o Control decisions accomplished through programming

OR

AND

Ladder diagram ( LD) was developed to make program creation and maintenance easier o Computer based graphical representation of wiring diagrams that was easy to understand o Reduced training and support cost

CPU

WHAT IS RUNG?

A rung of ladder diagram code can contain both input and output instructions
o

Input instructions perform a comparison or test and set the rung state based on the outcome

Normally left justified on the rung In some cases output instructions can set the rung state Normally right justified on the rung

Output instructions examine the rung state and execute some operation or function

Input Instruction

Output Instruction

PLC CYCLE

Sense the Input Process the Logic Give Output

Programmable controller

Inputs Machine or Process

Outputs

PROGRAMMING OF PLC
Start Stop the Motor

Configuration of PLC : Allen Bradley

The PLC is programmed interface between the field I/p element like limit switches, sensors, push button and the final control elements like actuator, solenoid/control valves, drives, hooters etc

CPU

I/O Modules
Power Supply

PLC Architecture Evolution

Today : Distributed I/O Modules

PLC

Distributed I/O scanner

Data Communication Bus

Distributed I/O modules

PLC SIGNAL FLOW

Input Module Processor Memory Data Output Input Image Table I:0/6 I:0/6 Image Table O:0/7

Output Modules O:0/7

I:1/4

O:1/5

Input Devices

Ladder Program I:0/6 I:1/4

O:0/7 O:1/5

Output Devices

I:1/4

O:1/5

Programming Terminal

PROGRAMMABLE LOGIC CONTROLLERS

PLC Types

Nano (Small) Micro (Medium) Large

Basic criteria for PLC Types

Memory Capacity I/O Range Packaging and Cost per Point

PLC SYSTEMS OF VARIOUS VENDORS

Siemens

S5 -110U, 115U, 135U S7 - 200, 300, 400

Allen Bradley

Micrologix 1000, 1200, 1500 SLC 5/01, 5/02, 5/03 PLC 5/10, 5/25 and 5/40

Modicon

Nano Micro Premium Quantum

Supervisory control & Data Acquisition (SCADA)

SUPERVISORY CONTROL AND DATA ACQUISITION

SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data. SCADA focuses on gathering and circulating the right amount of system information to the right person or computer within the right amount of time.

SCADA
Supervisory Control
Graphics and Batch processing

And

Data Acquisition
Archiving, Logging, Access Control, Alarms

Distributed database Data Server Data Server PLCs

Field Bus
Control Programs

SUPERVISORY CONTROL & DATA ACQUISITION SOFTWARE

Features of typical SCADA software

Dynamic process graphic Real-time and Historical trending Alarms Recipe Management Security Device connectivity Database connectivity

APPLICATION OF SCADA SYSTEM

Water Management Systems. Electric Power. Traffic Signals. Mass Transit Systems. Environmental Control Systems. Manufacturing Systems. Transmission, Generation, Distribution system. Mining plants, water and electrical utility installations to oil gas plants.

SCADA in Industries
Sr no. Vender SACDA Software

1.
2. 3. 4. 5. 6.

Wonder ware
Siemens Ltd. Allen Bradley Intellution Schneider KIPT

In Touch 5.0 to 10.0

Win CC/ Wincc Flexble Rs View Fix DMACS Factory View & CITEC ASTRA ( Indian SCADA)

7. 8

Merz GE Fanuc

Aspic Cimplicity