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 What is Industrial Automation?
The term automation, inspired by the earlier word automatic .

It is the use of various control systems for operating equipment with

minimal or reduced human intervention.

Automation has been achieved by

various system:-
Mechanical
Hydraulic
Pneumatic
Electrical
Electronic and computers.
Complicated systems, such as modern
factories, airplanes and ships typically
use all these combined techniques.
 Industrial Automation

The use of Computerized or robotic devices to complete manufacturing tasks.

 History of industrial Automation

NIKOLA TESLA is the father of Automation system.

It was not widely used before 1947.
Before the used of automation system FEEDBACK CONTROLLERS was used,
which was introduced in 1930s and applied on general motors.
A DCS and PLC was developed in the 1970's and Several innovative start-ups developed
HMI software and sensor for PLCs and industrial I/O.
The real race to automate manufacturing can be said to have begun in the 1980s, when US
car manufacturers came up with the vision of lights-out manufacturing.
Industrial engineers have envisioned fully automated factories since at least the middle of
the 20th century.
MAIN PARTES OF AUTOMATION

SCADA

Auto PLC
CAD AUTOMATION

HMI
 Supervise Control And Data Acquisition
(SCADA)

Meaning of Supervise Control Meaning of Data Acquisition

To supervise the controls. Collection or grouping of data.

It is similar to the work of a
Supervise.
Which monitors and controls all
the activities.
The data are gathered from like
sensors & instrument.
These data are collected in
SCADA software.
 Block diagram and their arrangement

Block diagram Simple Arrangement

 SCADA SOFTWARES

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

and many more ..

 Features of SCADA system

Animation property.
Dynamics property.
Trends.
Alarms.
Security.
Scripts.
Communication with Excel.
Communication with PLCs.
Mimics (miscellaneous)
 Tag name
It is a tool to communicate different objects and operators in SCADA.

Object types
Analog (-32768 to +32768 )
Digital (0 , 1 )
String (to pass text )
 Tag in SCADA

Types of Tag Saved in

Analog Tag Memory Real
Digital Tag Memory descript
String Tag Memory message
For communicating with excel I/O Real, I/O Descript .
 Animation properties

In this property we will design an industrial plant layout for industrial process .

Tools for Animation

Drawing Tools Industrial Tools

Line Ball
Poly line Valve
Circle Pump
Rectangle Motor
Round rectangle etc. Tank etc.
Application of Animation
 Dynamics properties

Their are three types of Dynamics properties

Location property
Percent fill property and
Object size property.
 Location property

In this property We change the location of any object either horizontally or

vertically both at a time.

Horizontally motion Vertically motion

 Application Location properties

Horizontal Application Vertical Application

 Object Size Property

To vary the size of any object either height or width or both at a time.
.

Width wise Height wise

 Percent filling property

This property is used to show the filling and infilling of tanks, pipes etc.
 Trends

Trend are used for graphical representation of any process.

Types of Trends

Real Time Trend

Historical Trends
 Real Time Trend

It show only present

change in value.
It updates automatically
with time.
It uses four numbers of
pans / inputs at a time.
 Historical Trend

It shows both present and

past change in value.
It updates manually.
It uses eight numbers of
pans/inputs at a time.
 Scripts

This languages support in SCADA systems significantly enhanced their

capabilities to efficiently perform diverse industry automation operations
with flexibility and simplicity.

Simple problem Scripts

If Slider <= 100 and button == 0 then
slider = slider +1 ;
Endif ;
If slider >= 100 then
Button == 1;
Endif ;
If Slider >= 100 and button == 1then
slider = slider 1;
Endif ;
If slider <= 0 then
Button = 0 ;
Endif ;
 Miscellaneous property

I. Visibility
II. Blink
III. Orientation and
IV. Disable
 PLC
(Programmable Logic Controller)

Definition Collection of some plc.

It is an industrial computer that monitors

inputs, makes decisions based on its
program and controls outputs to automate
a process or machine.
The automation of many different
processes, such as controlling machines
or factory assembly lines, is done through
the use of small computers called a
programmable logic controllers (PLCs).
 History of PLC

PLC was introduced in late 1960s.

First commercial & successful Programmable Logic Controllers was
designed and developed by Modicon as a relay replacer for General
Motors.
Earlier, it was a machine with thousands of electronic parts.
Later ,in late 1970s,the microprocessor became reality & greatly
enhanced the role of PLC permitting it to evolve form simply relay to the
sophisticated system as it is today.
 Simple working of PLC

Machine can be controlled by PLC without human efforts.

 Size of PLC

SMALL
It covers units with up to128 I/Os and memories up to 2 Kbytes.
These PLCs are capable of providing simple to advance levels or
machine controls.
MEDIUM
Have up to 2048 I/Os and memories up to 32 Kbytes.
LARGE
They have up to 8192 I/Os and memories up to 750 Kbytes.
It Can control individual production processes or entire plant.
 Major Components of a Common PLC

POWER
SUPPLY

I M O M
N O U O
P D T D
U U PROCESSOR P U
T L U L
From E T E To
SENSORS OUTPUT
Pushbuttons,
contacts,
limit switches,
etc.
PROGRAMMING
DEVICE
 Programming Languages of PLC

Most common languages encountered in PLC programming are:

1) Ladder Logic
2) Functional Block Diagram
3) Sequential Function Chart
4) Boolean mnemonics
 Block diagram of a PLC
LEDs
Outputs

Inputs
 Programming of PLC

Ladder Logic Program for Start/Stop of Motor

Starting of Motor
Continuous Running of motor when Start Button is released
To Stop The Motor
 PLC operation sequence

Self test.
Input scan
Logic solve/scan
Output scan
Over all steps depends up on the
clock frequency.
 Communication between SCADA and PLC

The is a process in which both ( PLC &SCADA ) work together at a time .

Software's
For Allen - Bradley : Abkf2 and
For all PLC : KEP serverex

The software in which facilities are

present for communication is
Allen-Bradley Logixpit.
 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
 Sensor

A sensor is a device that detects and

responds to some type of input from
the physical environment.
Types
Analog
a) RTD
b) LVDT
c) Thermocouple etc.
Digital (proximity)
a) Capacitive For all objects
b) Inductive - For all metals
c) IR Sensor For all's.
 Automatic Computer Aided Design
(AutoCAD)

For controls designers, purpose-

built to create and modify
electrical control systems.
It includes all the functionality of
AutoCAD plus comprehensive
symbol libraries.
 Common Commands

CO - Copy an object
Z - Zoom in display
E - Erase selection
EX - Extend a selection
J - Joins 2 objects to form single
object
TR - Trim a selection
O - Offset an object by distance
EXTRUDE - Converts 3D to 2D
FLATTEN - Converts 3D to 2D
 Project worked

PLC Based automatic water bottle filling system

 Software Work

We have solved the problem and

configure the Allen Bradly micro
logic 1000 series plc. with pc, with
the help of Rs-2-32 cable and the
software RS LOGIX micro.
We have developed normal basic
program with timer and counter
based control.
 Hardware Implementation

Design of conveyor belt

A simple conveyor belt will be stretched between two rollers, one
roller which pushes it and other roller which pulls belts as the belt moves
Dimension of conveyor belt

Material used Length in inch Width in inch Thickness in mm

PVC 24 3 2

Roller
Quantity : Two rollers
Dimension of Roller
Material used Diameter in inch Length in inch
PVC 1.53 4
Assembly of conveyor belt and Roller
 Electrical components
Component name Quantity specifications
Voltage regulator 3 12v
( L7812)
IR proximity 1 pnp , No types
sensor range 400 mm
Pump/ solenoid 1 12v DC
Relay 4 24 v
Gear motor 1 10 rpm
12v DC
SMPS 1 24 DC
2.5 A
Electrical circuit
 Working

Start MOTOR SENSOR

PLC

BOTTLE PUMP/
SOLENOID
FILLING
 Conclusion

The automated bottle filling system

is beneficial in reducing:-
work,
time and
cost of filling.
Hence it must be used in application
specific.
Thank You!!!