The document discusses automation and how to get started with automation. It can be divided into two main sections:
1) It classifies automation into industry automation (discrete, process, hybrid) and products (power, motion, field devices, control/monitoring). Discrete industry uses PLCs and closed/open loop control while process uses large I/O, instruments, and SCADA.
2) It provides steps to get started with automation from basics of electrical circuits to PLC programming to industrial communication. It covers electrical components, control circuits, motors, and programming basics. Automation combines electrical, mechanical, and software systems to control equipment and processes.
2. How to start with automation
Automation can be divided to two classes
1-industry : can be classified according to
A-discrete
B-process
C-hybrid (two step control)
2-products:can be classified according to
(power(low voltage)-motion-field devices-control monitoring)
3. Process vs discrete industry
Process industry: closed loop control
Food industry
oil and gas production lines
Sequence machines
Discrete industry: open& closed loop
Packaging
Machine tools
Injection machines
Car production lines
Do independent control to achieve a
specific task.
Raw
material
Do some
process
Final
product
4. Process vs Discrete industry
Discrete industry:
I/O low
Micro compact PLC
HMI
Motion protocols
Vector control VFD
Process industry:
I/O huge
Instruments
Scada
Wide industrial protocols
VFD
5. products
Power low voltage
Supply
Loads
Transformer
Circuit breakers
Control components
Switches
Panel accessories
Field devices
Sensors
Actuators
Transmitters
Transducers
6. products
control
PLC
Classic control
Control instruments
DCS
Motion
AC drive
Servo drive
Monitoring
HMI
SCADA
7. How to start with automation
Step 1(basics)
basic of electrical laws.
Basic of electrical circuits
Basic of electrical installation
Basic knowledge of control components
Ac induction motors
Dc motors
8. How to start with automation
Step 2(logic control)
Classic control
Use sensors ,counters and timers in sequential control
Step 3 (motor starter)
Star-delta connection
Soft starter
Ac motor inverse direction
9. How to start with automation
Step 4(motion)
Ac drive
Servo drive
CNC
Step 5 (Basic programming)
PLC
Numbering system
PLC memory management
HMI
10. How to start with automation
Step 6(industrial communication)
PLC with VFD
PLC with field devices
Step 7 (advanced level)
SCADA
Remote I/O
Industrial network
12. Electrical sources
Ac supply
Single phase: line & neutral
Three phase: 3 lines & neutral
Dc supply
+
-
L1
L2
L3
N
13. Basic electrical laws
V=I*R
P=V*I
Power loss=i2*R
Where
V:is the voltage supply
I:is the current
P:is the power
14. Loads
Motors
Induction motors
• Single phase
• Three phase
Servo motors
Stepper motors
Dc motors
Pneumatic cylinders
Hydraulic cylinders
15. Loads power calculation
Motor
Ac motor single phase I(load)=s*1000/v I(load)=4.5*S (V=220v)
AC motor three phase I(load)=(S*1000)/(0,866*380)=1.5*S
we are considering HP=KVA ………..P.F=1
DC motor I(load)=power/I
Pneumatic and hydraulics is deal as dc motors
16. Cables colors
Red color: for 110 or 220 volts
Blue color: for 12 or 24 volts
Black color: for ground or neutral
Orange color: its mean take current from another panel
For control cables :low thickness –low current
For power cables: huge thickness-high current
There are a relation between cable diameter and current
Cable diameter depends on current,environment
18. Control component selection
Circuit breaker
Short circuit current
Time
Voltage
Current =1.25*rated current
Over load
Current=1.2*rated current
voltage
19. Control component selection
contactor
Rated current
Voltage
Coil voltage
No .of . Connected open and close
relay
Current
Voltage
No .of . Connected open and close
20. Control component selection
Limit switch
Controller supply
sensors
Controller supply
Connection type
Switches
Open or close
current
preasure
29. Classic control circuits
Power circuit
Circuit breaker
Phase sequence
Over load
Fuse
contactor
30. Classic control circuits
control circuit
Phase sequence
Closes contact Over load
Contactor
Switches
Sensors
Limit switches
31. Exercises
Start motor , draw power circuit and control circuit that stop when release my
hand
Start -stop motor , draw power circuit and control circuit
Start – with two switches and stop from one switch
Start with one switch stop from another and emergency switch
draw power and control circuit.
32. Emad Elsheikh
32
KM1
A1
A2
S1
NO
S2
NC
KM1
13
14
L / +
N / -
Power Circuit Control Hardwire Circuit
L2
N
PE
L1
L3
M
3 ~
U V W
1
2
KM1
3
4
5
6
Q1
I> I> I>
1
2
3
4
5
6
Controlling 3 Phase Motor ( Relay
Control)