role of automation in industries by rajesh
TRANSCRIPT
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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
Programmable Logic Controllers
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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
Programmable Logic Controllers
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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.
Programmable Logic Controllers
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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
Programmable Logic Controllers
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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
Programmable Logic Controllers
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
Programmable Logic Controllers
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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.
Programmable Logic Controllers
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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
Programmable Logic Controllers
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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
http://images.google.com/imgres?imgurl=http://www.sigmaplus.fr/images/Synergy2000/plc.jpg&imgrefurl=http://www.sigmaplus.fr/page4.php%3Finfo%3D007~13~09~&h=112&w=231&sz=19&tbnid=TVnmSaRXmJwJ:&tbnh=49&tbnw=103&hl=en&start=283&prev=/images%3Fq%3Dplc%2B%252Bomron%26start%3D280%26svnum%3D10%26hl%3Den%26lr%3D%26sa%3DNhttp://images.google.com/imgres?imgurl=http://www.apelzv.sk/Obrazky/Zen1.gif&imgrefurl=http://www.apelzv.sk/pdrs.htm&h=324&w=467&sz=81&tbnid=yDHZd3lMUbwJ:&tbnh=86&tbnw=125&hl=en&start=175&prev=/images%3Fq%3Dplc%2B%252Bomron%26start%3D160%26svnum%3D10%26hl%3Den%26lr%3D%26sa%3DN -
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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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