INTRODUCTION TO

AUTOMATION

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 AUTOMATION
Automation is the use of
control systems such as
computers to control the
industrial machinery and
processes, replacing human
operators.

Automation is an allocation
of human control sequence
to a technical equipment and
to control the process.
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HISTORY OF AUTOMATION

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 MANUAL CONTROL
All the actions related to process control are taken
by the operators.

Drawbacks:
More manpower is required
Less accuracy
Less efficiency
Less safety
Time consumption is high

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 HARDWIRED CONTROL
The relays together with hardware timers and
counters were used in achieving the desired level of
automation.

Drawbacks:
Bulky panels
Complex wiring
Longer project time
Difficult maintenance and troubleshooting

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 ELECTRONIC CONTROL
The logic gates started replacing the relays in the
control circuits. The hardware timers & counters
were replaced by electronic timers.

Drawbacks:
Changes in control logic not possible
More project time
Not suited for industrial conditions

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PROGRAMMABLE LOGIC CONTROLLERS

PLC is a device, which is used to control a machine

or process as per the human control sequence.

A PLC monitors inputs, makes decisions based on

its program, and controls outputs to automate a
process or machine.
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PROGRAMMABLE LOGIC
CONTROLLER

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 INTRODUCTION
Widely used industrial process
control technology PLC
PLC:
Digital computer designed for use in machine control.
Designed to operate in the industrial environment.
Equipped with special input/output interfaces and a
control programming language.

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PLC replaced relay logic, but its ever-increasing
range of functions includes:
Timing Counting Calculating
Comparing Processing of analog signals

The structure of a PLC is based on the same principles as

those employed in computer architecture.
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 ADVANTAGES

PLC
control
panel

Re
lay
control
panel

Elimination of much of the hardwiring

associated with conventional relay control circuits. 11
Increased
Reliability :
Since all the logic is
contained in the
PLCs memory,
there is no chance
of making a logic
wiring error.

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More
Flexibility :
It is easier to create
and change a
program in a PLC
than to wire and
rewire a circuit.

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Lower
Cost :
Generally, if an
application has
more than about a
half- dozen control
relays, it will
probably be less
expensive to install
a PLC.
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Communications
Capability :
A PLC can communicate
with other controllers or
computer equipment to
perform such functions as
supervisory control, data
gathering, monitoring
devices and process
parameters, and download
and upload of programs. 15
 Sensor
Faster
Response
Time :
Machines that process
thousands of items per
second and objects that
spend only a fraction of a
second in front of a sensor
require the PLCs quick-
response capability.
Sensor 16
Easier to Troubleshoot :
To find and fix problems, users can display the
control program on a monitor and watch it in
real time as it executes.
PLC
Monitor
Process

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 ARCHITECTURE
OF
PROGRAMMABLE LOGIC
CONTROLLER

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The term architecture can refer to PLC
hardware, to PLC software, or to a
combination of both.

Open architecture This design allows the

system to be connected easily to devices and
programs made by other manufacturers.

Closed architecture (proprietary) This

design is more difficult to connect to other
systems.

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The major parts of a PLC system:
Central Processing Unit (CPU)
Input/Output (I/O) section
Power supply
Programming device

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Central Processing Unit:
The processor (CPU)
consists of:
Microprocessor for
implementing the logic
and controlling the
communications among
the modules.
Memory for storing
the results of the logical
operations performed by
the microprocessor.
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Input/Output (I/O) section:
It forms the interface by which field devices are
connected to the controller.
Input devices
such as
pushbuttons,
limit switches,
and sensors
are
hardwired to
the input
module
terminals.
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Output devices
such as motor
starters, solenoid
valves, and
indicator lights
are hardwired to
the output module
terminals.

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Power supply:
It provides DC power to all modules that plug
into the rack.
For large PLC systems, this power supply
does not normally supply power to the field
devices.

Power Supply 24
Programming device:
It is used to enter the desired program into the
memory of the processor.

Personal Computer as
Hand-held
programming device programming device: The program
is entered using the ladder logic
programming language. 25
A personal computer (PC) is the most commonly
used programming device.

The computer
monitor is able
to display more
logic on the
screen thus
simplifying
interpretation of
the program.

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A program is a series of instructions that
directs
the PLC to execute actions.

Ladder logic is the standard programming language.

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 TYPES OF PLC
(Based on I/O)
Fixed I/O: Modular I/O:
It is typical of small PLCs that come It is divided by compartments into
in one package with no separate, which separate modules can be
removable units. The processor and plugged. This feature greatly
I/O are packaged together. increases your options and the
units flexibility.

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Sourcing & Sinking concept
Sourcing and Sinking are terms to describe a
current flow relationship between field input and
output devices in a control system and their
power supply.
Sourcing I/O circuits supply current to sinking field
devices.

Sinking I/O circuits receive current from sourcing

field devices.

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Sourcing Field Device with Sinking
Input Module Circuit :

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Sourcing Field Device with Sinking
Output Module Circuit :

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Sinking Field Device with Sourcing
Input Module Circuit :

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Sinking Field Device with Sourcing
Output Module Circuit :

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 PLCs
versus
Computers

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The architecture of a PLC is basically
the same as that of a personal
computer :
Unlike PCs, the
PLC is designed
to operate in the
industrial
environment with
wide ranges of
ambient
temperature and
humidity.

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A properly designed PLC installation
is not as afected by the electrical
noise inherent in most industrial
locations:

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Unlike the personal computer, the
PLC is
programmed in ladder logic or other
easilylearned languages:

The PLC comes with its program language built into

its memory and has no permanently attached
keyboard, CD drive, or monitor.
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Computers are complex
computing machines capable
of executing several programs
or tasks simultaneously
and in any order.

PLCs execute a single

program in an orderly and
sequential fashion from
first to last instruction.

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 PLC control systems is easily
installed and maintained:

Troubleshooting is
simplified by the use of
fault indicators and
message displayed
on the programmer
screen.

Input/output modules
for
connecting the field
devices
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are easily connected
Software associated with a PLC but
written and run on a personal
computer falls into the following
two broad categories:
PLC software that allows the user to program and
document:
It gives the user the tools to write a PLC program
using ladder logic or another programming
language
and document or explain the program in as much
detail as is necessary.

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PLC software that allows the user to monitor and
control the process is also called a human machine
interface (HMI).
It enables the user to:
view a process - or a graphical representation
of a process on a monitor.
determine how the system is running, trend
values, and receive alarm conditions.

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 PLC SIZE
AND
APPLICATION

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The criteria used in categorizing PLCs
include functionality, number of inputs and
outputs, cost, and physical size

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The I/O count is the most important
size factor.
Nano type (smallest size)(less than 15
I/O points)
Micro types (15 to 128 I/O points)
Medium types (128 to 512 I/O points)
Large types (over 512 I/O points)

Matching the PLC

with the application
is a key factor
in the selection
process.
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TYPES OF PLC APPLICATIONS:
Single ended, Multitask, and Control management
A single ended application involves one PLC
controlling one process.

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A multitask PLC application involves one PLC
controlling several processes.

Adequate I/O
capacity is a
significant factor
in this type of
installation.

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A control management PLC application involves
one PLC controlling several others.

This kind of application requires a large PLC

processor designed to communicate with other PLCs
and computers.
The control management PLC supervises several
PLCs by downloading programs that tell the other PLCs
what has to be done.
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