short description

1. Industrial Automation
MOHAMED ABD EL-GHAFFAR

2. Introduction

3. Automation :
 Increase and optimize productivity
 Decrease human errors ( more safety )
 save time and effort
 low costs in the long run
Raw
Material
Do Some
Process
Final
production
 Various control systems for operating equipment
prepared by : Mohamed Abd El-Ghaffar

4.  control loop
sensing
elements
Actuators
loads
Controller
 physical quantity
( heat , pressure,
sound , distance)
prepared by : Mohamed Abd El-Ghaffar
 Electrical signal
which have the
information of
quantity that
measured
 I Give it a set point
and some condition
for the process that
I want
 Set point
 Electrical signal
which have
Commands
from controller
to loads
 physical quantity but this
time quantity which
I need like ( motion of
some thing )

5. • There are a boiler that I want its temperature fixed at
100 ‘C and you have
Solution :
 A Heater
 Temperature sensor
 Any type of controller
boiler Temperature
sensor
controller
Heater
prepared by : Mohamed Abd El-Ghaffar
80 ‘C
80 ‘C
80 < 100 E.S mean 80 ‘C
100 ‘C
Heater on
add heat
110 ‘C
110 ‘C
E.S mean 110 ‘C110 > 100
Heater off
Stop adding
note : that’s called feedback
“system modify itself
without human handling”

6. Signals :
• Information's about the behaviors or attributes of a
phenomenon which happened around our system or inside it
prepared by : Mohamed Abd El-Ghaffar
 Digital Signal : Signal which has only two value “ 0 ” or “ 1 ”
 Digital Signal
 Analog Signal
 Analog Signal : Signal which has different values when time
change “Range of values ( from -5v to 5v ) ”
“there are two types”

7. Sensing elements :
• Device which is used to tell controller information's about
system and its behavior and about environment around it
 Types of sensors
Analog sensors
digital sensors
 only told my if there are a physical quantity or not
like switches
 told my if there are a physical quantity or not and also told me its value
all analog sensors worked on specific range ( -5 , 5 ) , ( -10 , 10 ) ,
( 0 , 10 ) so you must know range and type of sensor ( temperature ,
pressure , distance .......)
 There are
no force so
there are no
signal note the difference
“there are two types of
sensors depend on types
of signal digital or analog”
prepared by : Mohamed Abd El-Ghaffar

9. Controller :
 MANUAL CONTROL
 CLASSIC CONTROL
 MODERN CONTROL
 Completely depend on human “ human error “
Manual control :
Known as
automatic control
Classic control :
 Based on wiring
prepared by : Mohamed Abd El-Ghaffar
Note : when you open lamp In you home you actually use classic
control concept because there are a wire to carry signal
“ limited control used In small projects depend on
some control devices like relay , contactor , H.W
timers , H.W counters “

10. Modern control :
prepared by : Mohamed Abd El-Ghaffar
 micro controller
like ( PIC , AVR , ARM , 8051… )
 PLC “Programmable logic controller ”
companies ( Siemens , Allen Bradley ,
Schneider , TOSHIBA … )
 SCADA “ Supervisor Control And Data Acquisition”
( Visualization and limited control )
 DCS “ Distributed Control Systems “
 Based on Microprocessor
“unlimited control used In industrial projects”
“hard ware , soft ware”

11. prepared by : Mohamed Abd El-Ghaffar

12.  STEP 1 “BASICS”
How to start in Automation ?
 Basics of Electrical Laws
 Electrical Circuit Fundamental
 Basics of Electrical installation
 H W Electrical components
 Load types
 STEP 2 “LOGIC CONTROL ”
 Logic Gates Operation
 Classic control Concept
 Motors types and Differences
 Motor starting with circuits
 Use HW Electrical components to Drive Loads
 STEP 3 “BASIC PROGRAMMING”
 Software concept
 Discrete control operations
 Timer and counter in sequence control
 Numerical and comparison operations
 Analog in PLC and how to calibration
 PLC Memory Management

13.  STEP 4 “MOTION”
How to start in Automation ?
 Drives concept
 Speed control and V/F control concept
 Ac Drives
 Special motor drives
 PLC with variable freq control
 STEP 4 “REMOTE CONTROL”
 HMI
 PLC with Field Devices
 Remote I/O and networks
 SCADA

14. STEP 1
“Basics”

15.  Voltage supply:
• ( DC ) voltage “battery or rectifier ”
• ( AC ) voltage
R
S
T
N
380v line
 1 Phase
 Search about inverters , converter , cycloconverter
+
-
220v phase
 3 Phase
prepared by : Mohamed Abd El-Ghaffar

16. • At first we must know our load characteristics :
• Active power “In watt”
• Working voltage “line value”
• Rated current “In amp”
• Load power factor “ take it 0.866 if not found”
• Efficiency
 The full-load current is given by :
• 3-phase loads : I = Pn / (√3 x V x η x cos ϕ)
• 1-phase loads : I = Pn / (V x η x cos ϕ)
 Load Estimation
 DC Loads like
• DC Motors
• Hydraulic and Pneumatic Loads  I = P / V && P = I^2 * R
prepared by : Mohamed Abd El-Ghaffar
“standard tables”

17.  EX:
• You have a 3 phase induction motor it‘s power 30 (HP) .85
Power Factor and 380 Vline what is your max Amps with S.F
• P (w) = P (HP) * 746 = 30 *746 = 22380 watt
• P (w) = √3 × I (A) × VL (V) ×PF
• 22380 = √3 × I (A) × 380 × .85
• I (A) = 40 A I (A)
• S.F = 40 × 1.25 = 50 (A)
 1.5 amp For “1” HP
 2 amp for “1” kw
 “1” HP = 746 watt
prepared by : Mohamed Abd El-Ghaffar
TRY
 Vphase = 220 volt
 Efficiency = 90%
 PF = 1
 Power = 4 KW

21.  WHAT IS THE DIFFERENCE BETWEEN POWER CIRCUIT AND CONTROL ONE?
 Is the circuit which has “ high signal”
(220v, 380v, 440v …) and it has my loads which need
this power to work
 power circuit
 control circuit
 Is the circuit which has “low signal”
(5 v, 12v, 24v …) and it has my Control device like
boards ,timer, counters…
 Each one has its own components we will discuss them later
prepared by : Mohamed Abd El-Ghaffar

22.  LOADS
• Motors
1- 3 phase induction Motor 80 % of industrial loads
 Stator : provides a rotating magnetic field that drives the rotating
armature which called rotor this field rotate with a speed
called synchronous speed
• synchronous speed “NS” = (120*F) / P rpm
SEE VIDEO

24.  Rotor : the moving part, which turns the shaft to deliver the mechanical power
• rotor speed = (1-s) Ns rpm
 Wound rotor
 Squirrel-cage rotor

25. 2- Single phase induction Motor
3- Heater

26. 4- valves

27.  Steps we must flow:
 function of our system “ why I do it”
 Simulation
 Design power circuit
 Design control circuit
 Elements selection
 Finishing my project
This sequence is very important because it makes it easy to finish
any project in a few steps
prepared by : Mohamed Abd El-Ghaffar

28.  Basics of logic operation
1- AND Gate
 output action will become TRUE only if
all events are TRUE

29. 2- OR Gate
 output become TRUE if only one “OR”
more events are TRUE

30.  INVERT or COMPLEMENTATION function.
 known as Inverters because they invert the signal.
 Represented by a normally closed switch.
2- OR Gate