PLC / SCADA / HMI

Controllers:

Name : Muhammad Zunair

Comsats University
Date: 28-October-2018
PLC (Programmable Logic Controller):
 It is used for the automation of various
electro-mechanical processes in
industries.
 These controllers can automate a
specific process, machine function, or
even an entire production line.
 These controllers are specially
designed to survive in harsh situations
and shielded from heat, cold, dust, and
moisture etc.
 PLC consists of a microprocessor
which is programmed using the
computer language.
How does a PLC work?
 The PLC receives information from connected sensors or input
devices, processes the data, and triggers outputs based on pre-
programmed parameters.
 Depending on the inputs and outputs, a PLC can monitor and record
run-time data.
 Such as machine productivity or operating temperature,
automatically start and stop processes, generate alarms if a machine
malfunctions, and more.
 Programmable Logic Controllers are a flexible and robust control
solution, adaptable to almost any application.
PLC Hardware:
 The hardware components of a PLC system are CPU, Memory, Input/Output, Power supply
unit, and programming device. Below is a diagram of the system overview of PLC.
Difference between PLC and HMI:

 PLC (Programmable Logic HMI (Human Machine

Controller) Interface)
 Most modern control systems Computer based HMI (Human
employ a PLC (Programmable Machine Interface) products
Logic Controller) as a means to provide the means by which process
control motors, pumps, valves and personnel interact with
various other equipment used in a the PLC control system
process.
HMI ( Human Machine Interface):
 A Human-Machine Interface (HMI) is a user interface or
dashboard that connects a person to a machine, system, or device.
 While the term can technically be applied to any screen that
allows a user to interact with a device.
 HMI is most commonly used in the context of an industrial
process.
 It is sometimes referred to as Man-Machine Interface (MMI),
 Operator Interface Terminal (OIT),
 Local Operator Interface (LOI), or Operator Terminal (OT).
 HMI and Graphical User Interface (GUI) are similar but not
synonymous.
How HMI works:
 HMIs communicate with Programmable Logic Controllers (PLCs) and
input/output sensors to get and display information for users to view.
 HMI screens can be used for a single function, like monitoring and
tracking.
 For performing more sophisticated operations, like switching machines off
or increasing production speed, depending on how they are implemented.
 HMIs are used to optimize an industrial process by digitizing and
centralizing data for a viewer.
 By leveraging HMI, operators can see important information displayed in
graphs, charts, or digital dashboards, view and manage alarms.
 It reduces many costly problems caused by lack of information or human
error.
Difference Between HMI and SCADA?
 Supervisory Control and Data Acquisition (SCADA) and HMI are closely
related, and often referred to in the same context since they are both part of
a larger industrial control system.
 They each offer different functionality and opportunities.
 While HMIs are focused on visually conveying information to help the
user supervise an industrial process.
 SCADA systems have a greater capacity for data collection and control-
system operation.
 Unlike SCADA systems, HMIs do not collect and record information or
connect to databases. Rather, HMI provides an effective communication
tool that functions as part of, or alongside, a SCADA system.
SCADA(Supervisory control and data acquisition) System:

 Supervisory control and data acquisition (SCADA) is a system of

software and hardware elements that allows industrial organizations
to:
 Control industrial processes locally or at remote locations
 Monitor, gather, and process real-time data
 Directly interact with devices such as sensors, valves, pumps, motors,
and more through human-machine interface (HMI) software
 Record events into a log file
Example:

 For example, the SCADA system quickly notifies an

operator that a batch of product is showing a high
incidence of errors. The operator pauses the operation and
views the SCADA system data via an HMI to determine
the cause of the issue. The operator reviews the data and
discovers that Machine 4 was malfunctioning. The SCADA
system’s ability to notify the operator of an issue helps him
to resolve it and prevent further loss of product.
Thank you