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• PART 2:
Automation and PLC.
Synopsis
Synopsis Learning
Learning Outcomes
Outcomes
This
This course
coursecover
cover topics
topics related
related to
to measurements
measurements
(PLTF)
(PLTF) and automation in the processindustry.
and automation in the process industry.These
These that
thatstudents
studentsare
areexpected
expectedtotoachieved
achievedafter
after
include
includeaastudy
studyon
onindustrial
industrialsensors
sensorsandandactuators,
actuators, successfully completing the course
successfully completing the course
industrial
industrialcontrollers
controllerssuch
suchas ascomputer-based
computer-basedcontrol,
control,
PLC, DCS and FF.
PLC, DCS and FF.
Process
Process ,, Industrial
Industrial Instr.&
Instr.& Meas.
Instr.& Meas. Automation
Automation DCS
DCSand
and Foundation
Foundation Fieldbus
Fieldbus
The learning outcomes related to The learning outcomes related to The learning outcomes related to
Industrial instruments and Automation and the implementation of DCS and Foundation Fieldbus use
Measurements Programmable logic controller in process industries.
• Have knowledge and
understanding of the various
• Have knowledge and • Have knowledge and
process industry instruments,
understanding of the PLC understanding of a DCS and its
concept of measurements,
architecture and its importance in use in process industries, and
calibration and configuration
automation. the features and architecture of a
requirements and their applications.
Foundation Fieldbus system, and
• Be able to develop a PLC program
• Be able to design and develop a its improvement over the
to perform sequential, and batch
control loop consisting the process conventional DCS.
control.
instruments, based on a prescribed
requirement.
PL
ns
Manufacturing system
or
s
Programming!!!
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 3
CONTENTS
• Overview of Automation
• Programmable Logic Controller
• Development of Ladder diagram
and,
• Several examples
What is ‘Automation’?
The term Automation also been used to describe
non-manufacturing system in which programmed or
automatic devices can operate independently or
nearly independently of human control. In the fields
of communications, aviation, or astronautics, for
example, such devices as automatic switching
equipment, automatic pilots, and automatic guidance
control systems are used to perform various
operations much faster or better that could be
accomplished by humans.
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 7
Why need ‘Automation’?
• To increase product standards with consistent
quality.
- increased production and lowered costs,
thereby making goods available to more people
with better quality.
• To gain higher throughput.
- more can be produced at lower costs, thus
allows wages to increase which leads to the
increase of workers’ motivation.
• To reduce labor dependencies.
• Assembly line
• Test and finishing packaging (repetitive
process)
• Hazardous environment
• High speed and precision process, and
• Computerized-plant management.
Advantages Disadvantages
Selector switch
Alarm
Pushbuttons
Control relays
Photoelectric switches Relays
Fans
Limit switches Timers
Lights
Circuit breakers Counters
Horns
Proximity switches Logic Units
Valves
Level switches Mechanical Cams
Motor starters
Motor starter contacts etc.
Solenoids
Relay contacts
etc.
etc.
RRE
EPPL
LAAC
CEED
DBBY
Y
Programmable
Programmable
Logic
Logic Controller
Controller
Output 1
- -
Input devices
Power P> θ
terminals Input
240 VAC
terminals
INPUT 1 INPUT 2 INPUT 3
PE
N N PLC
L
L
θ Ρ>
Selector switch
RATING:
24 Volts AC/DC
Pushbutton switches
48 Volts AC/DC
Photoelectric switches
120 Volts AC/DC
Limit switches
230 Volts AC/DC
Proximity switches
TTL level
Level switches
(Transistor-to-
Thumbwheel switches transistor +/- 5V)
Slide switches Isolated Input
Input
Inputlevel
level Processing
Processing Output
Outputlevel
level
(Reactions) (Details)
Reads in The given The outputs are
inputs and commands set according to
transfers the (program) will results of the
value to a be executed step processor
memory area by step
Input circuits
The The power supply
Power supply
processor serves the
takes its Memory Micropro controller with a
instructions cessor variety of stable
from the (CPU)
direct voltages
memory
Output circuits
1. SYSTEM MEMORY
• Executive- A permanently stored collection of
supervisory programs to direct system activities
e.g., program execution, communication with
other devices, and fault diagnosis.
• Scratch pad- A temporary store used by the
CPU to store small amount of data generated
during program execution.
Analog outputs:
Analog meters, analog valves and
actuators, DC and AC motor drives.
Network module.
PLC + -
A 01 01 02 HR20 +V
02 11 MTR
B HR20
03 12
External HR20 11
switches
-V
Stored program
Or
L1 L2 + - + -
AC input
+V
devices
1 1
1
2 2 2
3
3 3
-V
DC
COMMON input GND
devices
(a)
(b) (c)
AC 120 or 230VAC, e.g.,
AC input modules convert DC TTL
signals to logic ‘1’ or ‘0’ Low level DC
High DC (compatible with TTL)
state
L1 L2 + - + -
+V
+V
L1
1
1 1
2 2 2
3
3 3
-V
-V
GND
(a) (b) (c) TTL
AC output module interface DC output module interface TTL output module
logic signal from processor with logic signal from processor interface logic signal
a AC output field device : with a DC output field device : from processor with a
voltage > +5 V. TTL compatible
voltage 120 or 230 VAC.
voltages
+
DC power +V Sinking
supply Output input
terminal
- Switching
element
PNP
DC common
‘1’ state: +DC voltage
Conventional Sourcing
+ current
DC power
Output input
supply DC common terminal
- Switching
element NPN
+VDC
Conventional
current
Output Field DC Power
device Supply
DC
Common
To DC
Switching element Sinking output common
terminal
NPN transistor
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 49
Current sourcing: the load (field device) is connected bet.
the output and the negative common lead of the P/S.
To +V DC
+ V DC
Conventional
current
Output Field
device
DC To DC
Common common
Switching element
PNP transistor
SCAN Input
Idle cycle
Resolve
EEB5223/EAB4223 Industrial Automation & Control Systems
logic Topic 2- 52
Factors influencing scan time
Scan time (time required to make a single scan) vary
between 1 ms to 30 ms.
The use of remote I/O subsystems increases scan
time: having to transmit the I/O update to remote
subsystem.
Monitoring of the control program adds overhead
time to the scan: the micro has to send the status of
the coils and contacts to the display (CRT) or other
monitoring devices.
Rung
R1 A
LATCH
1. Relay
2. Timer and Counter
3. Program Control
4. Arithmetic
5. Data Manipulation
6. Data Transfer, and
7. Others, such as sequencers.
A Relay consists of
coil two parts, the coil and
input the contact.
Relay coil
R1
Output contact R1
Contacts: Coil:
a. Normally open a. Coil
b. Normally closed b. Negative coil
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 58
LOGIC STATES
TIMER
5
R2
R1 (MOTOR)
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 60
Rung 1: R1=(LS1+R1).(~PB1.~LS2)
Rung 2: R1 (delayed 5 seconds)
LS1 PB1
R1
LS2
R1
TIMER R2
R1
PR=5
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 61
EXAMPLE: CONTROLLING A CONVEYOR BELT
PARTS
BIN
INFRA RED
st REFLECTIVE
LATCH
HRMC SET=st
HRMC=(st+HRMC).s0
RESET=s0
mct HRMC
mc-
HRMC
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 64
Program 2:
When START switch (st) is energized, the conveyor
will move. It will stop 1.5 sec after the infra red through
sensor is blocked by part on the belt.
mc
st
s0
TIM01
tim01
HRT1 Set=s0
Reset=tim01
HRT1=(s0+HRT1).tim01
HRMC Set=st HRMC=(st+HRMC).tim01
Reset=tim01
mct mct=HRMC
mc- EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 65
FLOW CHART
A pictorial representation of the sequence of operations to
be carried out.
Different shaped boxes are used to represent different
actions.
PROCESS ACTIVATE
BOX RELAY R1
DECISION
LS1 active
BOX
?
TERMINATION
BOX START
CONNECTOR
A
no
L1 active
? yes L2 L3
no L2 active
?
P1 active
no
? yes L3 active
?
ACTUATE
RELAY R1
NOT NOR
1 >1
T=A’ T=(A+B)’
AND NAND
& & T=(A.B)’
T=A.B
OR Inhibition
>1 & T=A.B’
T=A+B
R-S Flip-flop
EX-OR
=1 S Y
T=A.B’+B.A’ R Y’
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 68
Example: The use of a logic diagram
A process:
“If limit switch L1 AND key P1 are activated, OR,
NOT limit switch L2 AND limit switch L3 are
activated, then relay R1 is activated.”
Expressed by a single Boolean equation: L1.P1 + L2.L3 = R1
L1
P1 & R1
1
L2
1 &
L3
S2 S3 S4 S5
Y1 Y2
START
S1
S2 S3 S2 S3
Y1 Y1
S1
00000 10000
+ S2 Y1
00001 10001
- S3 00002 10002
S4
00003 10003
S5 Y2
00004 10004
00005 10005
. .
. + .
. .
-
COM COM
+ -
+12VDC
Input
Clock
Reset
Accumulator
reset
Register Output
Contact
output
Count
0 1 2 3 4 5
On-delay energise
Time delay
On-delay de-energise
Time delay
Input
input Register 5
Reset
Accumulator
reset
Output
Contact
output
Count
0 1234 5 0 1
Count Counter
input CNT 01 number
003 SV
Reset
input
A B
C D
ROUTE B
Red
Amber
Green
ROUTE C
Red
Amber
Green
ROUTE D
Red
Amber
Green
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 80
Solution: Consider routes A and B ONLY.
24s 4s 2s 24s 4s 2s
TIM0
tim0
TIM1
tim1
TIM2
tim2
TIM3
tim3
TIM4
tim4
TIM5
tim5
ROUTE A
Red [(tim5+tim0+tim1).tim2]+[tim4.tim5]
Amber tim3+tim4
Green
tim2+tim3
ROUTE B
Red (tim1+tim2+tim3+tim4).tim5
Amber
Green tim0+tim1
tim5+tim0
TIM0
TIM0 TIM1 AMBER-B
TIM1
TIM5 TIM0 GREEN-B
TIM4 TIM5
END
Car coming in
CAR PARK
FULL
S1 (00000) (00200)
S2 (00001)
DIFU
DIFD
Ladder symbols:
CMP
source
destination
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 2- 86
Examples of ADD
ADD (Addition)
ADD totals the data in two different channels, or one
channel and a constant and then outputs the sum to a third
channel.
Three data must be specified: an augend, an addend and a
result channel.
Ladder symbols:
ADD
Augend
Addend
Results
Ladder symbols:
SUB
Minuend
Substracthend
Results
0 Motor stopped
Forward pushbutton?
Sensor S1 is blocked?
54 57 59 •Steps 57, 58
q t
•Step 59
55 58
If 53 is active and ‘p’ is true, 54, 57, and 59 are
activated together.
r When 55, 58, and 59 are active and ‘r’ is true, 56
56
is activated.