Topics

Automation and its benefits.

Automation Possibilities.
Automation History.
Parts of Automation system
Case studies.
How PLCs are economical
Communication Bus benefits

Automation And Its Benefits

What is automation?

To analyze and control all the process parameters in the plant

or in a machine with the help of automation devices.

Benefits of automation
Increasing productivity.
Increasing quality.
Reduced overall production cost.
Increases safety at work place.
Flexibility to expand system.
Power saving.

Automation Effect On Manufacturing

Process
Man power

Quality
Breakdown Accident

Overall
Prod.

A plant without automation

Quality
Man power

Breakdown Accident

A fully automated plant

Overall
Prod.

Automation Possibilities

There is a desire to enhance process efficiency.

There is a desire to exercise superior control on process parameters.
There is a desire to significantly reduce human intervention.
There is a belief that ' Prevention Is Better Than Cure .
Repetitive and monotonous jobs is involved and each stage of
production needs care full attention of operator to ensure good
quality of final products.
Hazardous conditions of operations are existing in plant.

Automation History

Programmable Logic Controller

Electronic Control Using Logic Gates

Hard Wired Logic Control

Pneumatic Control

Manual Control

Programmable Logic Controllers

PLC

replaced bulky electrical equipments such as contactors, relays that are used for making
control logic and huge Electronic control card used to achieve desired control.
Same PLC can be used in different application by just loading the logic of desired
application.

Advantages OF PLC
Space required for PLC installation is vary small.
Maintenance is easy.
Greater life and reliability.
Tremendous flexibility.
Easy to store.
Addition in logic is very easy.

A PLC (i.e. Programmable Logic Controller) is

a device that was invented to replace the
necessary sequential relay circuits for
machine control. The PLC works by looking at
its inputs and depending upon their state,
turning on/off its outputs. The user enters a
program, usually via software, that gives the
desired results.

Parts of Automation system

Field Instruments

Control Hardware
Control Software
Final control element

Installation
SCADA Software/HMI
Communication Cable

Control Hardware
Control Panel
Field Cabling

Junction Box
Field Cabling

Sensors Placed in the field

Final control
element

Structure of a Programmable Controller

PLC SCAN CYCLE

Reading and storing of sensor
status

Calculation: Processing of
equations (according to the
status of the sensors)
Transfer of the result of
calculations to the actuators.

Want to view scan cycle ex.

Programmable Logic
Controllers
Basic criteria for PLC Selection
Memory Capacity
I/O Range
Communication Possibility
Special factor some time PLC are selected on
the bases of there features like High speed
counters, PID,PLC with real Memory word for
accurate calculations.
Packaging and Cost per Point

Configuration of PLC : Modicon

Built in display for I/O
(in-rack, AS-i) and Diag

Programming Terminal PC Connection

8 Analog Inputs 1
Analog Output

I/O Modules
Up/Down Fast
Counter

Up Counter
Unitelway Port for connection
of up to 5 Slaves

TSX37-22
PCMCIA communications port

PCMCIA memory expansion port

Configuration of PLC : Siemens

CPU

I/O Modules
External Power
Supply

Configuration of PLC : Allen

Bradley

CPU

I/O Modules
Power Supply

PLC Programming Standards

The open, manufacturer-independent programming standard
for automation is IEC 61131-3. You can thus choose what configuration
interface you wish to use when writing your application :

Ladder Diagram
Instruction List
Function Block Diagram
Sequential Function Chart
Structured Text

Supervisory Control & Data

Acquisition Software
Features of typical SCADA software
Dynamic process graphic
Real-time and Historical trending
Alarms
Recipe Management
Security
Device connectivity
Script for logic development
Database connectivity

Some of the Leading SCADA Software

Wonderware : InTouch
Intellution : Fix DMACS
Merz : Aspic
Allen Bradley : Rsview
Siemens : WinCC
GE Fanuc : Cimplicity
KPIT : ASTRA
Modicon : Vijeo Look