Industrial Automation
Automation is encompassing virtually every
walk of life.
Automation solutions are required right fro...
What is Automation ?
Automation is basically the delegation of human control
function to technical equipment for
•Increasi...
History of Automation

Programmable Logic Controller
Electronic Control using Logic Gates
Hard wired logic Control
Pneumat...
Manual Control
All

the actions related to process control are taken by the
operators

Drawbacks
Likely human errors and ...
Pneumatic Control
Industrial

automation, with its machine and process control,
had its origin in the 1920s with the adve...
Hard wired logic control
The

contactor and Relays together with hardware timers and
counters were used in achieving the ...
Electronic Control using Logic Gates
In 1960s with the advent of electronics, the logic gates started
replacing the relays...
Programmable Logic Controllers
In

1970s with the coming of microprocessors and associated peripheral
chips, the whole pr...
Advantages of PLCs

Reduced space
 Energy saving
 Ease of maintenance
 Economical
 Greater life & reliability
 Tremen...
Industrial Automation Components
…

Field Instruments
Control Hardware
Control Software
Automation : Typical installation . . . .
SCADA Software
Communication Cable

Control Hardware
Control Panel
Field Cabling...
Automation : Advanced Technology . . . .
SCADA Software
Communication Cable

Control Hardware
Control Panel
Field Bus Netw...
Sensors ( Field Instruments )
Sensors with transmitters are the field devices placed in
the field who actually sense the p...
Widely used Sensors ( Field Instruments )
RTD : Output in Ohms (Temperature)
Thermocouples : Output in mV (Temperature)
Pr...
Leading Manufacturers in Sensors
( Field Instruments )

Fisher Rosemount
Yokogawa
Anderson & Housers
Radix
ToshBro
Control hardware

Standalone PID Controllers
Programmable logic controllers (PLC)
Distributed Control System
Standalone PID Controllers
These are the independent small hardware units which
caters requirement of closed loop controls...
Typical Installations using PID Controllers

Controllers placed in field

RS-232
RS-485 Bus
Leading Manufacturers in PID Controllers
Yokogawa
ABB
Moore
Eurotherm
ASCON
Chino
Bells
Fuji
Programmable Logic Controllers

Now a days PLCs are the most widely used control
hardware in control applications. The app...
What Constitutes A PLC ?
The PLC is programmed interface between the field I/p element like limit
switches, sensors, push ...
Configuration of PLC : Modicon
Built in display for I/O
(in-rack, AS-i) and Diag

Programming Terminal PC Connection

8 An...
Configuration of PLC : Siemens

CPU
I/O Modules
External Power
Supply
Configuration of PLC : Allen Bradley

CPU
I/O Modules
Power Supply
Distributed I/O Modules
PL
C

Distributed I/O scanner

Data Communication Bus

Distributed I/O modules
Hot Redundant System Configuration

TAPS
SPLITTERS
Remote
I/O Network
FIBER OPTIC LINK

Remote I/O
Networking of PLCs
Supervisory HMI

Modicon : Modbus +, Uniteleway, Ethernet
Allen Bradley : DH+, DH485, Ethernet, Control...
Programming Languages in PLCs

Ladder Logic ( LAD/LD )
Structured Text ( ST)
Instruction List ( IL )
Sequential Function C...
Supervisory Control & Data
Acquisition Software
Features of typical SCADA software
Dynamic process graphic
Real-time and H...
Some of the Leading SCADA Software
Wonderware : InTouch
Intellution : Fix DMACS
Merz : Aspic
Allen Bradley : Rsview
Siemen...
Role of Engineers In
Industrial Automation
Designing of the Automation system
Erection and Commissioning
Maintenance and T...
Job Prospect for Fresher
Today management of almost all manufacturing
units are going for industrial automation to
survive...
Job prospects for Engineers In
Industrial Automation
Manufacturing Industries like Reliance, Ceat, Godrej,
Colgate ….
Auto...
Current Situation
Automation is a high growth sector globally
hence it is essential to all professionals and
students to h...
How prolific will Help You
Fortunately you have Prolific with you. Our practical and
professional training courses in dive...
Do you want to be Lucky….
Many intellectuals define “Luck” as
“PREPARATION MATCHING OPPERTUNITY”
Can you afford to miss pr...
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Industrial Automation

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Industrial Automation

  1. 1. 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. 2. 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. 3. History of Automation Programmable Logic Controller Electronic Control using Logic Gates Hard wired logic Control Pneumatic Control Manual Control
  4. 4. 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. 5. 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. 6. 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. 7. 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 •Reduced space requirements •Energy saving •Less maintenance & greater reliability Drawbacks •Changes in control logic not possible •More project time
  8. 8. 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. 9. 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. 10. Industrial Automation Components … Field Instruments Control Hardware Control Software
  11. 11. Automation : Typical installation . . . . SCADA Software Communication Cable Control Hardware Control Panel Field Cabling Junction Box Field Cabling Sensors Placed in the field
  12. 12. Automation : Advanced Technology . . . . SCADA Software Communication Cable Control Hardware Control Panel Field Bus Network Field Bus Scanners Field Cabling Smart Transmitters Placed in the field
  13. 13. 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. 14. 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. 15. Leading Manufacturers in Sensors ( Field Instruments ) Fisher Rosemount Yokogawa Anderson & Housers Radix ToshBro
  16. 16. Control hardware Standalone PID Controllers Programmable logic controllers (PLC) Distributed Control System
  17. 17. 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. 18. Typical Installations using PID Controllers Controllers placed in field RS-232 RS-485 Bus
  19. 19. Leading Manufacturers in PID Controllers Yokogawa ABB Moore Eurotherm ASCON Chino Bells Fuji
  20. 20. 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. 21. 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. 22. Configuration of PLC : Modicon Built in display for I/O (in-rack, AS-i) and Diag Programming Terminal PC Connection 8 Analog Inputs 1 Analog Output I/O Modules Up/Down Fast Counter Up Counter Unitelway Port for connection of up to 5 Slaves TSX37-22 PCMCIA communications port PCMCIA memory expansion port
  23. 23. Configuration of PLC : Siemens CPU I/O Modules External Power Supply
  24. 24. Configuration of PLC : Allen Bradley CPU I/O Modules Power Supply
  25. 25. Distributed I/O Modules PL C Distributed I/O scanner Data Communication Bus Distributed I/O modules
  26. 26. Hot Redundant System Configuration TAPS SPLITTERS Remote I/O Network FIBER OPTIC LINK Remote I/O
  27. 27. Networking of PLCs Supervisory HMI Modicon : Modbus +, Uniteleway, Ethernet Allen Bradley : DH+, DH485, Ethernet, Control Net, Devicenet Siemens : Sinec L1/L2/H1, Profibus
  28. 28. Programming Languages in PLCs Ladder Logic ( LAD/LD ) Structured Text ( ST) Instruction List ( IL ) Sequential Function Chart ( SFC ) Function Block Diagram ( FBD )
  29. 29. Supervisory Control & Data Acquisition Software 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
  30. 30. Some of the Leading SCADA Software Wonderware : InTouch Intellution : Fix DMACS Merz : Aspic Allen Bradley : Rsview Siemens : WinCC GE Fanuc : Cimplicity KPIT : ASTRA
  31. 31. Role of Engineers In Industrial Automation Designing of the Automation system Erection and Commissioning Maintenance and Troubleshooting of existing system
  32. 32. 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. 33. Job prospects for Engineers In 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. 34. 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.
  35. 35. How prolific will Help You Fortunately you have Prolific with you. Our practical and professional training courses in diversified hardware and software used in Industrial Automation are designed to fill the vacuum between your practical knowledge and industry demands. Hundreds of Individuals have benefited by our courses. They have increased their technical knowledge, thus leading to better job opportunity.
  36. 36. Do you want to be Lucky…. Many intellectuals define “Luck” as “PREPARATION MATCHING OPPERTUNITY” Can you afford to miss preparation ? Prepare today, Opportunity will definitely follow
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