Additional Topic for

Process Control
Sessional
By International Institute for Advanced
Training on Control and
Automation(IIATCA)

Machine Vision and Motion

Control

Image Acquisition Applications:

Frame grabber: Blob analysis: Cell counting, Area

calculation, OCR
Line Scan Camera: Alignment testing

Motion Control: Applications

Factory Automation/ Industrial Robots

Automated Test Sequencing machines
Hazardous chemicals processing (explosive
powder packaging etc.)

PLC, DCS and Modern

Plant Control Systems

Programmable Logic
Controller (PLC)

Pre-PLC era: Electro-mechanical relay and

pneumatic couplings
PLCs are microcomputers developed to
handle industrial control applications
First CPU-based PLC in 1977 by Allan
Bradley corp. with an Intel 8080 processor
5.5 billion PLCs up to 1997, largest use in
Europe (45%), Japan (23%) & US (7%)
Many modern PLCs are Ethernet enabled

PLC Architecture
SC AN
S te p 2
E x e c u te th e
P ro g ra m m e d L o g ic

S te p 1
R e a d In p u ts

S te p 3
U p d a te th e
O u tp u t

P ro g ram
M e m o ry

In p u t
M o d u le s

In p u t D a ta
T a b le

Pow er
S u p p ly

CPU

O u tp u t
D a ta T a b le

C o m m u n ic a t io n
In t e r fa c e

O u tp u t
M o d u le s

Distributed Control System

(DCS)

Control logic is distributed across multiple

devices
PLC Networks alone and as part of a
heterogeneous network can be called a DCS
Most current PLC communication protocols
are proprietary, making DCS based on them
also proprietary
Expensive to purchase, maintain and expand
Industry trend is toward open standards

Industrial
Communication
Open standards lead to open systems

Background Information

Sampling Rate: Nyquist Theorem

Signal Conditioning

Multiplex
Amplify
Filter
Isolate
Excite
Complete bridge configurations

Bandwidth
Serial and Parallel: Benefits of serial comm.

Serial Communication:
Applications

Microcontroller & Flash memory I/O

Marine, Automotive and Aviation
Communication
Manufacturing & Factory Automation
Process Automation

High Channel count systems: Ammonia, PE plant

Distributed Control: Pipelines
Telemetry and Remote Control: Nuclear,
Biohazard and Hazardous chemical processing

Serial Hardware
Specification

EIA RS
RS-232, 232/C, 232/D

Laboratory Instruments
PC Serial Port

RS-422, RS-423
HPIB/GPIB
RS-485: Industrial networks
USB

Serial Software Application

Protocols

Manufacturing: FIP, DeviceNet

Automotive: CAN, CANOpen
Process Automation:

FieldBus:
FF (Foundation FieldBus), H1 Foundation
FieldBus
ProfiBus (Process FieldBus) and its variants
HART
Ethernet/IP and Fast Ethernet/IP: 10BaseT,
T4,TX, FX

Industrial Networking
Benefits:
Reduced Field Cabling

Industrial Networking
Benefits:
Multivariable, Bi-directional

Industrial Networking
Benefits:
Extended Horizon

The Sensor Network

The Device Network

Industrial Networking: OSI

Model

Comparing with the Internet and FieldBus

Comm. Stack

Web

FieldBus

Application

HTTP

H1

Transport

TCP

PPTP

Network

IP

Device ID

Physical

RS-232

RS-485

The OSI model is universal networking standard

The Control Network

The Enterprise Network

Real-time Control

IIATCA

Real-time Control

Real-time control
Control loop cycle time
Determinism and jitter
Hardware real-time and
software real-time
Real-time operating
systems
Embedded and
Headless applications

Role of the Real-time

Controller

End of Class
IIATCA