Industrial Automation
Automation is encompassing virtually every
walk of life.
Automation solutions are required right from
agricultural to space technology.
Plant Automation is the necessity for the
manufacturing industry to survive in todays
globally competitive market
What is Automation ?
Automation is basically the delegation of human control
function to technical equipment for
Increasing Productivity
Increasing Quality
Reducing Cost
Increasing Safety in working conditions
Why Automation required in Industry
Productivity
Total Automation
Plant
Quality
Manufacturing
Competitiveness
Solution
Labour Cost
History of Automation
Programmable Logic Controller
Electronic Control using Logic Gates
Hard wired logic Control
Pneumatic Control
Manual Control
Manual Control
All
the actions related to process control are taken
by the
operators
Drawbacks
Likely human errors and consequently its effect on
quality of final product
The production, safety, energy consumption and
usage of raw material are all subject to the
correctness and accuracy of human action.
Pneumatic Control
Industrial
automation, with its machine and process
control, had its origin in the 1920s with the advent of
"Pneumatic Controllers".
Actions were controlled by a simple manipulation of
pneumatic valves, which in turn were controlled by
relays and switches.
Drawbacks
Bulky and Complex System
Involves lot of rework to implement control logic
Longer project time
Hard wired logic control
The
contactor and Relays together with hardware timers
counters were used in achieving the desired level of autom
Drawbacks
Bulky panels
Complex wiring
Longer project time
Difficult maintenance and
troubleshooting
Electronic Control using Logic Gates
In 1960s with the advent of electronics, the logic gates
replacing the relays and auxiliary contactors in the contro
circuits.
The
hardware timers & counters were replaced by electr
timers
Advantages
Reduced space requirements
Energy saving
Less maintenance & greater reliability
Drawbacks
Changes in control logic not possible
More project time
Programmable Logic Controllers
In
1970s with the coming of microprocessors and associated
peripheral chips, the whole process of control and automation
underwent a radical change.
Instead
of achieving the desired control or automation through
physical wiring of control devices, in PLC it is achieved through a
program or say software.
The
programmable controllers have in recent years experienced
an unprecedented growth as universal element in Industrial
Automation.
It
can be effectively used in applications ranging from simple
control like replacing small number of relays to complex
automation problems
Advantages of PLCs
Reduced space
Energy saving
Ease of maintenance
Economical
Greater life & reliability
Tremendous flexibility
Shorter project time
Easier storage, archiving and documentation
Industrial Automation Components
Field
Instruments
Control Hardware
Control Software
Automation : Typical installation . . . .
SCADA Software
Communication Cable
Control Hardware
Control Panel
Field Cabling
Junction Box
Field Cabling
Sensors Placed in the field
Automation : Advanced Technology . . . .
SCADA Software
Communication Cable
Control Hardware
Control Panel
Field Bus Network
Field Bus Scanners
Field Cabling
Smart Transmitters Placed in the field
Sensors ( Field Instruments )
Sensors with transmitters are the field devices
placed in the field who actually sense the parameter
and send the analog signal to the control hardware.
The analog signals used are Ohm (RTD), mV
(Thermocouple), 4-20 mA, +/-10 V, etc
Widely used Sensors ( Field
Instruments )
RTD : Output in Ohms (Temperature)
Thermocouples : Output in mV (Temperature)
Pressure Transmitters : 4-20mA, 0-10 V ..
Flow Transmitter : 4-20mA, 0-10 V ..
Level Transmitter : 4-20mA, 0-10 V ..
Conductivity meter : 4-20mA, 0-10 V ..
Density meter : 4-20mA, 0-10 V ..
pH transmitter : 4-20mA, 0-10 V ..And Many more
Leading Manufacturers in Sensors
( Field Instruments )
Fisher Rosemount
Yokogawa
Anderson & Housers
Radix
ToshBro
Control hardware
Standalone PID Controllers
Programmable logic controllers (PLC)
Distributed Control System
Standalone PID Controllers
These are the independent small hardware units which
caters requirement of closed loop controls in the process.
These hardware can be installed in field or in control
room. These hardware can be connected on the network.
Currently the controllers are available with 100s of
segment and programming patterns
Typical Installations using PID
Controllers
Controllers placed in field
RS-232
RS-485 Bus
Leading Manufacturers in PID
Controllers
Yokogawa
ABB
Moore
Eurotherm
ASCON
Chino
Bells
Fuji
Programmable Logic Controllers
Now a days PLCs are the most widely used control
hardware in control applications. The applications ranges
from standalone system for CNC machines to Hot
swappable Redundant System for Critical Process Control
What Constitutes A PLC ?
The PLC is programmed interface between the field I/p
element like limit switches, sensors, push button and the final
control elements like actuator, solenoid/control valves, drives,
hooters etc
PLC consist of
Input Module
CPU with Processor and Program memory
Output module
Bus System
Power Supply
Configuration of PLC : Modicon
Built in display for I/O
(in-rack, AS-i)
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
communications port
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
Distributed I/O Modules
PL
C
Distributed I/O scanner
Data Communication Bus
Distributed I/O modules
Hot Redundant System Configuration
TAPS
SPLITTERS
Remote
I/O Network
FIBER OPTIC LINK
Remote I/O
Networking of PLCs
Supervisory HMI
Modicon : Modbus +, Uniteleway, Ethernet
Allen Bradley : DH+, DH485, Ethernet, Control Net, Devicenet
Siemens : Sinec L1/L2/H1, Profibus
Programming Languages in PLCs
Ladder Logic ( LAD/LD )
Structured Text ( ST)
Instruction List ( IL )
Sequential Function Chart ( SFC )
Function Block Diagram ( FBD )
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
Role of Engineers In
Industrial Automation
Designing of the Automation system
Erection and Commissioning
Application Engineering
Maintenance and Troubleshooting of existing system
