seminar on plc automation required for biginers.ppt
- 1. Industrial Automation 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 today’s globally competitive market
- 2. What is Automation ? 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
- 3. History of Automation History of Automation Pneumatic Control Hard wired logic Control Electronic Control using Logic Gates Programmable Logic Controller Manual Control
- 4. 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.
- 5. Pneumatic Control 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
- 6. Hard wired logic control Hard wired logic control The contactor and 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
- 7. Electronic Control using Logic Gates Electronic Control using Logic Gates In 1960s with the advent of electronics, the logic gates started replacing the relays and auxiliary contactors in the control circuits. The hardware timers & counters were replaced by electronic timers Advantages Drawbacks •Reduced space requirements •Energy saving •Less maintenance & greater reliability •Changes in control logic not possible •More project time
- 8. Programmable Logic Controllers 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
- 9. Advantages of PLCs Advantages of PLCs Reduced space Energy saving Ease of maintenance Economical Greater life & reliability Tremendous flexibility Shorter project time Easier storage, archiving and documentation
- 10. Industrial Automation Components … Industrial Automation Components … Field Instruments Control Hardware Control Software
- 11. Sensors Placed in the field Automation : Typical installation . . . Automation : Typical installation . . . . Junction Box Field Cabling Control Panel Control Hardware SCADA Software Communication Cable Field Cabling
- 12. Smart Transmitters Placed in the field Automation : Advanced Technology . . . Automation : Advanced Technology . . . . Field Bus Scanners Field Cabling Control Panel Control Hardware SCADA Software Communication Cable Field Bus Network
- 13. Sensors ( Field Instruments ) 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
- 14. Widely used Sensors ( Field Instruments ) 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
- 15. Leading Manufacturers in Sensors Leading Manufacturers in Sensors ( Field Instruments ) ( Field Instruments ) Fisher Rosemount Yokogawa Anderson & Housers Radix ToshBro
- 16. Control hardware Control hardware Standalone PID Controllers Programmable logic controllers (PLC) Distributed Control System
- 17. Standalone PID Controllers 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
- 18. Typical Installations using PID Controllers Typical Installations using PID Controllers RS-232 Controllers placed in field RS-485 Bus
- 19. Leading Manufacturers in PID Controllers Leading Manufacturers in PID Controllers Yokogawa ABB Moore Eurotherm ASCON Chino Bells Fuji
- 20. Programmable Logic Controllers 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
- 21. What Constitutes A PLC ? 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
- 22. 8 Analog Inputs 1 Analog Output Up/Down Fast Counter Up Counter Programming Terminal PC Connection Unitelway Port for connection of up to 5 Slaves PCMCIA memory expansion port PCMCIA communications port TSX37-22 Built in display for I/O (in-rack, AS-i) and Diag I/O Modules Configuration of PLC : Modicon Configuration of PLC : Modicon
- 23. Configuration of PLC : Siemens Configuration of PLC : Siemens CPU External Power Supply I/O Modules
- 24. Configuration of PLC : Allen Bradley Configuration of PLC : Allen Bradley CPU Power Supply I/O Modules
- 25. Distributed I/O Modules Distributed I/O Modules Distributed I/O modules PL C Distributed I/O scanner Data Communication Bus
- 26. Remote I/O Network SPLITTERS FIBER OPTIC LINK TAPS Remote I/O Hot Redundant System Configuration Hot Redundant System Configuration
- 27. Networking of PLCs Networking of PLCs Supervisory HMI Modicon : Modbus +, Uniteleway, Ethernet Allen Bradley : DH+, DH485, Ethernet, Control Net, Devicenet Siemens : Sinec L1/L2/H1, Profibus
- 28. Programming Languages in PLCs Programming Languages in PLCs Ladder Logic ( LAD/LD ) Structured Text ( ST) Instruction List ( IL ) Sequential Function Chart ( SFC ) Function Block Diagram ( FBD )
- 29. 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 Supervisory Control & Data Supervisory Control & Data Acquisition Software Acquisition Software
- 30. Some of the Leading SCADA Software Some of the Leading SCADA Software Wonderware : InTouch Intellution : Fix DMACS Merz : Aspic Allen Bradley : Rsview Siemens : WinCC GE Fanuc : Cimplicity KPIT : ASTRA
- 31. Role of Engineers In Role of Engineers In Industrial Automation Industrial Automation Designing of the Automation system Erection and Commissioning Maintenance and Troubleshooting of existing system
- 32. Job Prospect for Fresher Job Prospect for Fresher Today management of almost all manufacturing units are going for industrial automation to survive in globally competitive market. Most of these industrial units are looking forward for trained engineers in the field of industrial automation. Since they are thinking about more accuracy, productivity in less time & with minimum manpower , It’s a golden opportunity to prepare yourself to take on this task.
- 33. Job prospects for Engineers In Job prospects for Engineers In Industrial Automation Industrial Automation Manufacturing Industries like Reliance, Ceat, Godrej, Colgate …. Automation Solution Products manufacturer/developer like Rockwell, Siemens, Grouppe Schneider, Yokogawa, ABB System Integrators for Grouppe Schneider Rockwell, Siemens, etc Consultants for Automation
- 34. Current Situation Current Situation Automation is a high growth sector globally hence it is essential to all professionals and students to have practical knowledge about the hardware and software used in Industrial Automation.
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