INDUSTRIAL AUTOMATION

Automation

• The technique of making an apparatus, a process, or a

system operate automatically.
or
• The creation and application of technology to monitor
and control the production and delivery of products and
services
 Automation
Automation is basically a delegation of human control function to control technical
equipment.
Automation is the use of control systems and information technologies reducing the
need for human intervention.
Automation Encompasses Many Vital Elements,
Systems, & Job Functions

• Automation provides benefits to virtually all of industry. Here

are some examples:
• Manufacturing , including food and pharmaceutical, chemical
and petroleum, pulp and paper
• Transportation , including automotive, aerospace, and rail
• Utilities , including water and wastewater, oil and gas, electric
power, and telecommunications
• Defense
• Facility operations , including security, environmental control,
energy management, safety, and other building automation
• And many others
Industrial Automation

• Which automate systems is work without human

intervention in Industries & saves time, energy & get
Increase the production we called this system is - Industrial
Automation.

• And Also in Other Words,

• Sometimes, Something that would be impossible by human

& we depend on which technology system that called is
industrial automation.
 Why Automation?

• Reliability and precision

• Health and environment

• Convertibility and turnaround time

• Automation tools
 Role of Automation in Industries
• Manufacturing processes, basically, produce finished product from
raw/unfinished material using energy, manpower and equipment and
infrastructure.
• Since an industry is essentially a “systematic economic activity”, the
fundamental objective of any industry is to make profit.

• Roughly,
Profit = (Price/unit – Cost/unit) x Production Volume

• So profit can be maximised by producing good quality products,

which may sell at higher price, in larger volumes with less
production cost and time. Fig 1.2 shows the major parameters that
affect the cost/unt of a mass-manufactured industrial product.
Automation History
1.MANUAL CONTROL 2.PNEUMATIC CONTROL 3.HARD WIRE LOGIC CONTROL

5.PLC

4.ELECTRONIC CONTROL USING GATES

 Automation Tools

Different types of Automation Tools

PLC - Programmable Logic Controller
SCADA - Supervisory Control and Data Acquisition
DCS - Distributed Control System
ANN - Artificial neural network
HMI - Human Machine Interface
Instrumentation
Motion control
Robotics
CONCEPT OF AUTOMATION
 Three Automation Types

Programmable
Automation
Variety Flexible
Automation
Fixed
Automation

Quantity
 Fixed Automation

• Sequence of processing (or assembly) operations is fixed by the

equipment configuration

Typical features:
• Suited to high production quantities
• High initial investment for custom-engineered equipment
• High production rates
• Relatively inflexible in accommodating product variety
 Reasons for Automating

1. To increase labor productivity

2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating
 Automation Principle
1. Understand the existing process
– Input/output analysis
– Value chain analysis
– Charting techniques and mathematical modeling

2. Simplify the process

– Reduce unnecessary steps and moves

3. Automate the process

– Ten strategies for automation and production systems
– Automation migration strategy
 Automation Strategies
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing
Programmable Logic Controllers (PLC’s)

• A programmable logic controller (PLC) is a special purpose

computer aimed at implementing control solutions.

• Historically PLC’s have been used mainly for on-off or logic

type applications.

• However, modern PLC’s have become increasingly

sophisticated and can now cover quite complex control tasks.
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 PLC – Contd.
• These notes emphasize the switching capability of a PLC. However,
the reader is urged to think of the dynamics of the underlying system.

• For example, we recently heard of a seemingly straightforward

application of a PLC to a reservoir level control problem.

• The algorithm had many features but in essence conformed to the

rule that if the level was too low then the pumping rate should be
increased.

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 PLC – Contd.
• This can be seen as an approximate form of integral control.

• However, pure integral control when applied to a tank (which is also

an integrator) will lead to self sustained oscillations.

• The reader is encouraged to verify this by drawing a root locus plot

for the closed loop poles.

• The moral of this story is that when implementing a controller in a

PLC one needs to consider the combined dynamics of the control law
and system.

• In this way a PLC is no different from any other form of control

implementation platform.
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 Typical Areas of Application

• For past 30 years PLC’s have been in the first level of control
because of their ability to run uninterrupted for extended
periods of time (usually measured in months or even years).

• The PLC layer in industrial applications is shown in figure

below

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Control hierarchy of PLC’s

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 Ladder Logic
• The remained of this chapter will look at Ladder Logic, which
is the most common programming structure used in PLC’s.

• Several examples of common Ladder Logic programs will be

demonstrated to show the simple structure of this coding
style.

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 Relay Ladder Logic

• Ladder logic is possibly the simplest programming language.

• The principle behind the language is illustrated by a simple

electrical relay. (Electrical relay logic preceded PLC’s as
initially all logic was implemented in hard wired panels using
actual relays, timer, Counters etc.)

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Simple Relay Circuit

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 Boolean Logic

• The above diagram can be expressed in Boolean logic “Motor

Coil = Switch”, ie if the Switch is on the Motor coil is
energized and Motor is activated.

• All ladder logic takes the form of that shown in Figure above.

• Thus it connects the positive and neutral rail representing

positive and negative power supply to the relay.
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 Ladder Logic Instructions

• The three most common instructions in ladder logic are:

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 SCADA SYSTEM
SCADA stands
SCADA for
stands for supervisory
supervisory control
control and dataand data
acquisition.
acquisition.
It generally refers to an industrial control
system: a computer system monitoring and
controlling a process.
The process can be industrial, infrastructure or
facility-based.

Supervisory Control and Data Acquisition System refers

to a system that enables an electric utility to monitor,
coordinate, control and operate distribution components
and devices in a real-time mode from remote locations
with acquisition of data for analysis and planning, from
one central location
 SCADA SYSTEM

• SCADA stands for supervisory control and data acquisition.

It generally refers to an industrial control system: a computer system
monitoring and controlling a process. The process can be industrial,
infrastructure or facility based.

• Supervisory Control and Data Acquisition System refers to a system

that enables an electric utility to monitor, coordinate, control and
operate distribution components and devices in a real- time mode
from remote locations with acquisition of data for analysis and
planning from one central location.
BOILER
 Features of SCADA
RECIPE SECURITY

DATABASE CONNECTIVITY DEVICE CONNECTIVITY

 SCADA Softwares

WONDERWARE - INTOUCH
ALLEN BRADLEY- RSVIEW32
SEIMENS - WINCC
GE FANUC - CIMPLICITY
KPIT - ASTRA