Role of Automation in Industries by Rajesh

8/12/2019 Role of Automation in Industries by Rajesh

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Role of automation inindustries

Presented by

E.Rajesh kumar


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IndustrialAutomation

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


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What isAutomation ?

Automation is basically the delegation of human control

function to technical equipment for

Increasing Productivity

Increasing Quality

Reducing Cost

Increasing Safety in working conditions


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History of Automation

Pneumatic Control

Hard wired logic Control

Electronic Control using Logic GatesProgrammable Logic Controller

Manual Control


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Manual Control

All the actions related to process control are taken by theoperators

Drawbacks

Likely human errors and consequently its effect onquality of final product

The production, safety, energy consumption and usage ofraw material are all subject to the correctness and accuracyof human action.


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Pneumatic Control

Industrial automation, with its machine and process control,had its origin in the 1920s with the advent of "PneumaticControllers".

Actions were controlled by a simple manipulation ofpneumatic valves, which in turn were controlled by relays andswitches.

Bulky and Complex SystemInvolves lot of rework to implement control logicLonger project time

Drawbacks


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Electronic Control using Logic Gates

In 1960s with the advent of electronics, the logic gates startedreplacing the relays and auxiliary contactors in the controlcircuits.

The hardware timers & counters were replaced by electronictimers

Advantages

Reduced space requirements

Energy savingLess maintenance & greater reliability

Changes in control logic not possibleMore project time

Drawbacks


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Programmable Logic Controllers

In 1970s with the coming of microprocessors and associated peripheralchips, the whole process of control and automation underwent a radicalchange.

Instead of achieving the desired control or automation through physicalwiring of control devices, in PLC it is achieved through a program or saysoftware.

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 controllike replacing small number of relays to complex automation problems


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Advantages of PLCs

Reduced spaceEnergy saving

Ease of maintenanceEconomicalGreater life & reliabilityTremendous flexibility

Shorter project timeEasier storage, archiving and documentation


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Languages used in PLCs Ladder logic

Function block diagram (FBD)

Structural text language Instruction list

Sequential functional chart


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Plcs in our plant

Allenbradely plc

a) Controllogix processor 5561b) Compact logix

Schneider plc

Siemens plc


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Allenbradely plc

Controllogix processor 5561


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Compactlogix processor L32 E

Allenbradely plc


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Schneider plc

Quantum processor 65150


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PLC TypesNano (Small)

Micro (Medium)

Large

Basic criteria for PLC Types

Memory Capacity I/O Range

Packaging and Cost per Point



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Components Central Processing Unit (CPU) Input Output Modules

a) Analog input moduleb) Digital input modulec) Analog output moduled) Digital output module

Power Supply Bus system



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Central Processing Unit

It is a micro-controller based circuitry. The CPUconsists of following blocks :

Arithmetic Logic Unit (ALU), Program memoryProcess image memory (Internal memory of CPU)

Internal timers and counters

Flags

CPU performs the task necessary to fulfill the PLCfunctions. These tasks include Scanning, I/O bustraffic control, Program execution, Peripheral andExternal device communication, special functions or

data handling execution and self diagnostics.



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Central Processing Unit

The cpu reads input data from connected fielddevices through the use of its input interfaces,and then executes or performs the controlprogram that has been stored in its memorysystem.

Programs are typically created in ladder logic, alanguage that closely resembles a relay basedwiring schematic. and are entered into the cpusmemory prior to the operation.

Finally ,based on the program the plc writes orupdates output devices via the output interfaces.this process also known as scanning ,continues inthe same sequence with out interruption andchanges only when a change is made to the controlprogram


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Analog Input module These modules act as interface between real-time

status of process variable and the CPU.

Analog input module :The signal which varies withtime is called as Analog signalsTypical input to these modules is

4-20 mA, 0-10 V

Ex : Pressure, Flow, Level Tx,Analog signals, which are continuous, are converted by

the module and used by the controller to mandatefield-device results



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Digital input module :The signal which is high

or Low i.es either it is 1 or 0 is called a digital

signal

The signals coming from Mcc feeders or fieldinstruments comes to the terminals of the input

module

Typical input to these modules is 24 V DC, 115 VAC,

Ex. : Switches, Pushbuttons, Relays, pumpvalve on off status


Digital Input module


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Analog Output module These modules act as link between the CPU and the

output devices in the field. Analog output module :

The set points(seperator rpm,weighfeeder sp,etc) whicare given by the operator in scada station

Typical output from these modules is 4-20 mA, 0-10 VEx : Control Valve, Speed,

when an analog output module receives data from theowner-controller and when the output module echoesdata. An owner-controller sends data to an analog outputmodule only at the period specified in the RPI



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Programmable Logic ControllersDigital Output module As per our programming logic if our output is

healthy. this output signal is send to the requiredoutput module through the controller or Plcprocessor

Typical output from these modules is 24 V DC,115 V AC, 230 V AC

Ex. : Solenoid Valves, lamps, Actuators,dampers, Pump valve on off control


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Power Supply

The power supply gives the voltage required forelectronics module (I/O Logic signals, CPU, memoryunit and peripheral devices) of the PLC from the linesupply.

The power supply provides isolation necessary toprotect the solid state devices from most high

voltage line spikes. As I/O is expanded, some PLC may require additional

power supplies in order to maintain proper powerlevels.



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Bus System

It is path for the transmission of the signal . Busystem is responsible for the signal exchangebetween processor and I/O modules

The bus system comprise of several single line iewires / tracks



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PLC Cycle

Outputs

Machine

orProcess

Programmable

controller

Inputs

Sense the Input

Process the Logic

Give Output


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PLC Signal Flow

Programming Terminal

O:0/7

O:0/7

O:1/5

Output Devices

Output ModulesProcessor MemoryInput 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

DataInput

Image Table

Output

Image Table


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signals coming from fieldcomes to this terminal ies

from Mcc feeders, and fromfield Instruments

Input modulesOutput modules

These are the outputterminals, from this outputterminals signal goes to fieldactuators, motors ,solenoid

valves


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Definition of SCADA

Supervisory Control and Data Acquisition a computer system for gathering and analyzing

real time data.

Used to monitor and control a plant orequipment in industries such as cements,water and waste control, energy, oil and gas

refining and transportation.

Source: http://www.webopedia.com/TERM/S/SCADA.html


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A SCADA system gathers information, such as wherea leak on a pipeline has occurred, transfers theinformation back to a central site, alerting the homestation that the leak has occurred, carrying outnecessary analysis and control, such as determining ifthe leak is critical, and displaying the information ina logical and organized fashion.

Can be relatively simple

such as one that monitors environmental conditions of asmall office building

or complex

such as a system that monitors all the activity in a nuclearower lant or the activit of a munici al water s stem.

SCADA


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SCADA Supervisory Control And Data

Acquisition Supervisory control

Data acquisition In real-time

Network
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Scada screen shots


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Configurations required to

start a motor from scada Creating a new tag database

Creating a new motor page popup

Configuring page properties Configuring button properties

Configuring touch action to the motor


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Creating a new tag database

Creating a tag

The plc tag or address which is usedin the program, that tag had tobe addressed in tag database ofthe scada software ( EX:RsView32)

To create a new tag database

Go to Rs view 32 works

Go to edit menu Click on System folder

And now double click ontag database


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Click on new button to create anew tag database

Select the node name ( i.e. plcprocessor of the Correspondingsection)

Enter the address which we had

used in the plc programming

Give a new tag name so that thistag name is used for the corresponding plc address


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Creating a motor popup page

To create motor popup page justclick on display option which is ingraphics folder of the Edit menuin Rsview works

Now there appears a blank pageand make all the possible thingsin the page (ex: motor ,buttons)

From the library which is ingraphic folder

In this library we will be havinginbuilt mimics of motors , pipes,Etc


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Creating a motor popup page

Select the required fields fromthe library

Arrange the size of the page by

right clicking the mouse on thepage ,Adjust its properties onclicking on page properties

Save the file by any name or itsdrive number


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Generally we have start and stopare used as buttons in thesoftware so we have to configurethe button properties by Doubleclicking mouse on the button

Select the required Action forthe button wether it isset,reset,toggle,momentory offor momentary on

Now our requirement ismomentary on so click onmomentary on and browse therequired tag from tag databaseand click on ok


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Configuring touch action tothe motor

In Rsview works menu select the motor to which the touch actionto be provided

Right click the mouse by placing the pointer on the motor

Select on touch, there will appear a popup and give the required

command click next button And in the next page select the motor page and click on finish

button


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Documents

Role of Automation in Industries by Rajesh