Productivity

Quality Labor

Cost

Plant

Total Automation

Manufacturing Competitiveness Solution

What is Automation ?

Automation is basically the delegation of human control function to technical equipment for

HISTORY OF AUTOMATION

Pneumatic Control

Hard wired logic Control

Electronic Control using Logic Gates

Programmable Logic Controller

Manual Control

PROGRAMMABLE LOGIC

CONTROLLER

• What is PLC ?• Advantages of PLC

Reliability in operation, Small physical size, Shorter project time, Speed in Operation, Ease of maintenance/Troubleshooting

• Applications :Machine controls, Packaging, Palletizing, Material handling, similar Sequential task as well as Process control

PLC

• The Ladder Diagram (LD) programming language originated from the graphical representation used to design an electrical control system

• Finally CPUs were added to take over the function of the logic circuitso Control decisions accomplished

through programming

• Ladder diagram ( LD) was developed to make program creation and maintenance easiero Computer based graphical

representation of wiring diagrams that was easy to understand

o Reduced training and support cost

ANDOR

CPU

Ladder Diagram

WHAT IS RUNG?

• A rung of ladder diagram code can contain both input and output instructionso Input instructions perform a comparison or test and set the rung state based

on the outcome Normally left justified on the rung

o Output instructions examine the rung state and execute some operation or function

In some cases output instructions can set the rung state

Normally right justified on the rung

Input Instruction Output Instruction

PLC CYCLE

• Sense the Input • Process the Logic• Give Output

Outputs

Machineor

Process

Programmablecontroller

Inputs

PROGRAMMING OF PLC

Start Stop the Motor

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

CPU

Power Supply I/O Modules

Configuration of PLC : Allen Bradley

Today : Distributed I/O Modules

Distributed I/O modules

PLC

Distributed I/O scanner

Data Communication Bus

PLC Architecture Evolution

PLC SIGNAL FLOW

Programming Terminal

O:0/7O:0/7

O:1/5

Output Devices

Output Modules

Processor Memory

Input Module

Input Devices

Ladder Program

O:0/7

O:1/5

I:0/6

I:1/4

O:1/5

I:0/6

I:1/4

I:0/6

I:1/4

DataInputImage Table

OutputImage Table

PROGRAMMABLE LOGIC CONTROLLERS

PLC Types

• Nano (Small)• Micro (Medium)• Large

Basic criteria for PLC Types

• Memory Capacity • I/O Range• Packaging and Cost per Point

PLC SYSTEMS OF VARIOUS VENDORS

Siemens

• S5 -110U, 115U, 135U• S7 - 200, 300, 400

Allen Bradley

• Micrologix 1000, 1200, 1500• SLC 5/01, 5/02, 5/03• PLC 5/10, 5/25 and 5/40

Modicon

• Nano • Micro • Premium • Quantum

Supervisory control & Data Acquisition (SCADA)

SUPERVISORY CONTROL AND

DATA ACQUISITION

• SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data.

• SCADA focuses on gathering and circulating the right amount of system information to the right person or computer within the right amount of time.

Data Server

SCADA

SupervisoryControl

And DataAcquisition

Graphics and Batch processingArchiving, Logging, Access Control, Alarms

Distributed database

PLC’s

Field Bus

Data Server

Control Programs

SUPERVISORY CONTROL & DATA ACQUISITION SOFTWARE

Features of typical SCADA software

• Dynamic process graphic• Real-time and Historical trending• Alarms• Recipe Management• Security• Device connectivity• Database connectivity

APPLICATION OF SCADA SYSTEM

• Water Management Systems.• Electric Power.• Traffic Signals.• Mass Transit Systems.• Environmental Control Systems.• Manufacturing Systems.• Transmission, Generation, Distribution system.• Mining plants, • water and electrical utility installations to oil gas plants.

SCADA in Industries

Sr no. Vender SACDA Software

1. Wonder ware In Touch 5.0 to 10.0

2. Siemens Ltd. Win CC/ Wincc Flexble

3. Allen Bradley Rs View

4. Intellution Fix DMACS

5. Schneider Factory View & CITEC

6. KIPT ASTRA ( Indian SCADA)

7. Merz Aspic

8 GE Fanuc Cimplicity