Industrial Automation

WELCOME TO Solwins Technologies, Bhilai

Automation is the use of control systems (such as numerical control, programmable logic control, and other industrial control systems), in concert with other applications of information technology (such as computeraided technologies [CAD, CAM, CAX]), to control industrial machinery and processes, reducing the need for human intervention.[1]

The main advantage of automation are:

Replacing human operators in tedious tasks. Replacing humans in tasks that should be done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, under the water, etc) Making tasks that are beyond the human capabilities such as handling too heavy loads, too large objects, too hot or too cold substances or the requirement to make things too fast or too slow. Economy improvement. Sometimes and some kinds of automation implies improves in economy of enterprises, society or most of humankind. For example, when an enterprise that has invested in automation technology recovers its investment; when a state or country increases its income due to automation like Germany or Japan in the XX Century or when the humankind can use the internet which in turn use satellites and other automated engines

What is a PLC?

Picture Source: RSView32 Automotive Demo

Programmable Logic Controllers (PLC)

(PLC)

PLC Presentation Contents

Introduction What is a PLC PLC Types Choosing PLC Hardware PLC Applications Programming PLC s Advantages of PLCs Questions

Traditional PLC Concept

PLC performs relay equivalent functions PLC performs ON/OFF control Ladder diagram programming Designed for industrial environment

Source: A-Bs Micro Solutions Presentation

Input Wiring: PLC input is the load in the circuit, sensing if voltage is present
Terminal Block Isolation Barrier

Input Devices

1 2 3 4 5 6 7 8 9 10 COM

L1 L1

P L C

L2

Output Wiring: PLC output is the switch, controlling current flow to load
Isolation Barrier Terminal Block

Output Devices L1 L2

OUT 1
CR

OUT 1 OUT 2 OUT 2

P L C

OUT 3 OUT 3 OUT 4 OUT 4 OUT 5 OUT 5 OUT 6 OUT 6

L1 L2

Output Devices
Valves Motor Starters Solenoids Control Relays Alarms Lights Fans Horns Relays
120 VAC/VDC 240 VAC 24 VAC/VDC

Triac
120/230 VAC

Transistor MOSFET
24 VDC

Inside a PLC
Communications

I n p u t

C i r c u i t s

Central Processor

O u t p u t

C i r c u i t s

CR

High Voltage
Isolation Barrier

MEMORY
program
Low Voltage AC Power Supply 85-264 VAC, 50/60Hz

Isolation Barrier

High Voltage

data

or

External DC Power Supply

Most Basic of PLC Systems

In the most basic of PLC systems, a self contained (shoe box) PLC has 2 terminal blocks, one for Inputs and one for Outputs Today, most PLC s in this category are know as Micros. Typically they provide front panel LED status indication of I/O and Processor states
Inputs Outputs

Programmable Controller
C R

Modular Chassis Based PLC s

The vast majority of PLC s installed today are modular chassis based systems consisting of: 1. Processor Module (CPU) 2. Input & Output Modules 3. Chassis 4. Power Supply

PLC Application Considerations

Inputs/Outputs
Type,
AC, DC, sourcing, sinking, etc.

Functions required
Instruction set
Messaging PID PTO, PWM

Number of
10, 16, 20, 32, 156

Memory
Type
Flash or Battery backed

Arithmetic Communications
DeviceNet, Ethernet Remote I/O, DH+

Size
1k, 6k, 12k, 16k, 64k

Report generation

SOURCING vs. SINKING

SOURCING Pushbutton (PNP) SINKING Pushbutton (NPN)
+VDC

+ +
DC Power Supply DC Power Supply

DC COM

SOURCING vs. SINKING DC Inputs

SOURCING (PNP)
Field Device

SINKING (NPN)
+VDC IN1

+
DC Power Supply

+
DC Power Supply

DC Input Module
DC COM

Field Device

DC Input Module
IN1

Logical AND Construction

IF input 4 AND input 5 have power THEN energize output 0

I/4 I/5 O/0

On

||
T

||
T
Logical Continuity

()
T

Logical OR Construction

IF input 4 OR input 5 have power THEN energize output 0

I/4

T
Logical Continuity

O/0On

||
F I/5

()

|| ||

I/4

F
Logical Continuity

O/0

On

()

T I/5

||

Basic PLC Advantages

Ease of programming Ease of maintenance Designed for industrial environment Quick installation Adaptable to change

Source: A-Bs Micro Solutions Presentation

Advantages over Relays

All the capabilities of the earlier systems Dramatic performance increase over the relay logic systems Greater reliability Little maintenance due to no moving parts No special programming skills required by maintenance personnel Physical size of the PLC system is much smaller than the conventional relay based logic And most importantly much lower cost
Source: C.Maynard@curtin.edu.au

VVVF Drives Variable frequency drives DCS - Distributed Control System HMI - Human Machine Interface SCADA - Supervisory Control and Data Acquisition PLC - Programmable Logic Controller PAC - Programmable Automation Controller Instrumentation - Instrumentation

Installed and Running Systems in RI

Conveyors Curtain rods Deodorants Donuts Duplex Receptacles Fibers Filters Forged Parts Glass Goggles Grinding and Polishing Heat Treating Metal Products Jails Lenses Nails Natural Gas Paper
Pharmaceuticals Plastics Plating Plating Machines Power Generation Power Supplies Product Assembly Machines Rubber products Seafood Processing Soda Staples Warehouse Automation Waste Water Systems Drinking Water Systems Water Heaters Web Handling (paper/plastic) Wire / Cable