AUTOMATION

What is AUTOMATION ?
Automation is the use of control systems and
information technologies to reduce the need for
human work in the production of goods and services.
In the scope of industrialization, automation is a step
beyond mechanization.
It is used to reduce human interference and an efforts.
As the name suggest Automation means to
perform automatic operations by means of different
kinds of machines.
Tools of Automation
AUTOMATION

Programmable Logic Controller (PLC)

Supervisory Control And Data Acquisition (SCADA)

Human Machine Interface (HMI) or Touch Screen (TS)

Variable Frequency Drive (VFD)
AUTOMATION

ADVANTAGES : ~
Replacing human operators in tasks that involve
hard physical or monotonous work.

Replacing humans in tasks done in dangerous
environments.

Performing tasks that are beyond human
capabilities of size, weight, speed, endurance, etc.

Economy improvement: Automation may improve
in economy of enterprises, society or most of
humanity.
AUTOMATION

DISADVANTAGES : ~
Unemployment rate increases due to machines
replacing humans and putting those humans out of
their jobs.

Technical Limitation

Security Threats

High initial cost.
PLC
What is PLC ?
A Programmable Logic Controller, or PLC for short,
is simply a special computer device used for
industrial control systems. They are used in many
industries such as oil refineries, manufacturing lines,
conveyor systems and so on.

PLC implements logic control functions by means of
a program.

PLC - programmable logic controller
How does a PLC differ from a computer ?
PLC
A computer is optimized for calculation and
display tasks.

A computer is programmed by specialists

A PLC is designed for (logic) control and
regulation tasks.

A PLC is programmed by non-specialists

A PLC is well adapted to industrial
environment.
Components of PLC : ~
PLC
1. Inputs Circuits
2. Outputs Circuits
3. CPU (Central Processing Unit )
4. Memory for program and data storage
5. Programming device
6. Communication Device
7. Power Supply
PLC
Components of PLC : ~
PLC
1. PLC inputs : ~
ANALOG inputs DIGITAL inputs

Pressure Transducer Push buttons

Flow meter Sensors

Thermocouples Selector switches



PLC
PLC outputs : ~
ANALOG outputs DIGITAL outputs
Mass flow controller

Pressure regulator

Position controller
LEDs

Small motors

Relays


Memory for program and data storage : ~
PLC
Memories used: -

RAM Random access memory

Volatile
Made up of metal oxide semiconductor
lose it's information if power is removed.
ROM Read only memory
Non-volatile
don't need an external power source to
keep information
PLC
Power Supply : ~
A power supply of 120v ac is typically used to drive
the PLC (some units operate on 240v ac).
The power supply converts the 120v ac into dc
voltages of +5v.
These low voltages are used to operate equipment
that many have much higher voltage and power
ratings than the PLC itself.
PLC
Programming In PLC :~
Languages used in PLC for the purpose of programming are
1. Ladder language
2. Functional Block Diagram (FBD)
3. Instructional List (IL)
4. Drive Functional Block (DFB)
5. Structural test language
PLC
Ladder language used in PLC programming
There are two PLC in which ladder programming
is used : -
ZELIO PLC : - It uses Zelio soft 2 software for
the programming.

DELTA PLC : - It uses WPL soft software for
their programming.
PLC
ZELIO PLC
The softwares used for different types of Zelio PLCs are
as follows:-

Zelio 1- non expandable- zelio soft 1
Zelio 2- non expandable- zelio soft 2
Zelio 3- expandable- zelio soft 2
PLC
Parameters used in Zelio and delta PLC in
ladder programming
Parameters ZELIO plc DELTA plc

Inputs I
n
X
n

Outputs Q
n
Y
n

NC of input

NO of input


Timer T
t1
, t1 command has to be provided
(e.g.- TMR T0 k150)

PLC
Zelio soft 2 ladder programming
The various parameters used in zelio soft 2 while
operating ladder program and their relationship
amongst them are as follows:-
INPUT CONTACT
OUTPUT CONTACT
INTERLOCKING
MEMORY COIL
LATCHING
TIMER
COUNTER
PLC
INPUT AND OUTPUT CONTACT
Inputs in Zelio soft 2 is represented by I1, I2, I3,I5,I6.

Inputs are further classified as: -


NORMALLY CLOSED

NORMALLY OPEN
PLC
Examples for Normally open contact
PLC
Example of Normally closed contact
PLC
INTERLOCKING
Interlocking means to interlock something by placing
NC of coil or input in front. The concept of interlocking
reduces the complexity in PLC programming
Interlocking in ladder programming means whenever
we want to off some output by input or any type coil,
then we have to place NC of that input or a coil in front
of output which we want to off.
PLC
Example of Interlocking
PLC
MEMORY COIL
Memory coil in ladder programming is used for
reversing the contacts whenever coil is get
energized.
In ladder programming memory coil is represented
by M
1
and its contact is represented by m
1
.
When memory coil M1 gets the signal it gets
energized and then it reverses the terminal of its
contact m1 which reverses the operation.
PLC
Example of Memory coil
PLC
When memory coil gets energized
PLC
LATCHING
Latching is the process in which once output or a coil
is energized it remains energized forever. Latching is
done by the contact of output or coil which we want
to switch ON permanently.
PLC
When contact I1 is turned ON
PLC
TIMER
Timer is basically used add some delay in the
programming circuit by adding a particular time to
each circuit.
Types of timers : -

ON delay timer

OFF delay timer
PLC
Example of Timer
PLC
COUNTER
Counter is same as timer. Counter works on the
method of counting the number of pulse.
Types of counter : -

UP counter- UP counter counts in increment order.
Ex . 1, 2, 4.n.

DOWN counter- DOWN counter counts in
decrement order. Ex. 5,4,3,2,1
PLC
DELTA PLC
It is high-speed, stable and highly reliable PLC's are
applied in various automation machines.
it is totally similar to zelio plc programming but the
specifications of DELTA plc are different from zelio plc
as shown above.
In DELTA plc memory space has been allotted
according to the types of plc.
PLC
Timers in Delta PLC
Timers in DELTA plc are used to add some delay in the
circuit, timers can be of two types as follows: -
ON delay timer.
OFF delay timer.
Commands for applying timer are as
follows: -

TMR<space>t0<space>k100
PLC
Example of delta PLC
PLC
WIRING OF PLC
The operating voltage of plc is 220v (Ac) / 24v
(dc)/10v (dc). The operating voltage of plc is 220v
(Ac) / 24v (dc)/10v (dc).
Components used in wiring of plc are: -
SMPS- Switch Mode Power Supply
OUTPUT- Y0 ,C0
SOURCE/SINK (S/S)- S0,S1.........
PLC
COMPONENTS
SWITCH MODE POWER SUPPLY: -
SMPS is used to provide power supply to plc; SMPS
can be of different power supply mode. Ex - 220v (Ac) / 24v (dc)/10v
(dc).
C0

Y0
C1

Y1
OUTPUT: -
Output Y0 actually connected to C0 the pair of Y0 C0 is responsible
for working of plc.


PLC
Example of wiring of PLC
PLC
Applications of PLC
Gate Control : -
PLC can sense a vehicle at the entrance or exit, and open
and close the gate automatically.
The current vehicle count is easily determined by
programming a simple counter.
Gate control system can also be used for domestic purpose.
PLC
Applications of PLC
Conveyor System: -
PLC can be used to start/stop latching logic for motor
control
Counters can be used for monitoring product amounts
Conveyor system using plc can be used in car washing
system
VFD
VARIABLE FREQUENCY DRIVE (VFD)
VFD or Variable Frequency Drives are used
to run the motors of single phase or three
phase supply.
VFD is used to accelerate and deaccelerate
the speed of motor with in a particular time.
Drives commands: -
Start/Stop
Speed reference
Acceleration/ deacceleration
VFD
Parameters of VFD
P = 200 = 0 (digital keypad)
= 3 (potentiometer on drive)
P = 201 = 0 (digital keypad)
= 1 (external terminal) / keypad stop/enable
= 2 (external terminal)/keypad stop/disable
START/STOP command
= 0 (on board)
= 1 (ext M0=forward, M1= reverse)
= 3(M0=forward, M1= reverse, M2=stop)
P = 109 = acceleration time
P = 110 = deacceleration time

VFD
Advantages of VFD
Dynamic braking : -Dynamic braking stops the
system more quickly than coasting
Highly efficient
Low power consumption
Small space consumption
Low cost
Easy to use
Highly specific
SCADA
SCADA System
SCADA is Supervisory Control and Data Acquisition
real time industrial process control systems used to
centrally monitor and control remote or local industrial
equipment such as motors, valves, pumps, relays, etc
A SCADA system gathers information (such as where a
leak on a pipeline has occurred), transfers the information
back to a central site, then alerts the home station that a
leak has occurred, carrying out necessary analysis and
control, such as determining if the leak is critical, and
displaying the information in a logical and organized
fashion.
SCADA
Why SCADA?
Saves Time and Money
Less traveling for workers (e.g. helicopter
ride)
Reduces man-power needs
Increases production efficiency of a
company
Cost effective for power systems
Saves energy
Reliable
Supervisory control over a particular system
HMI
HUMAN MACHINE INTERFACE (HMI)
A human machine interface (HMI) is an interface
which permits interaction between a human being
and a machine.
. Human machine interfaces vary widely, from
control panels for nuclear power plants to the
screen and input buttons on a cell phone.
Two components are needed in a human machine
interface. The first is an input. A human user needs
some way to tell the machine what to do, to make
requests of the machine, or to adjust the machine.
Examples of input devices include keyboards,
toggles, switches, touch screens,