This presentation discusses industry automation using programmable logic controllers (PLCs). It provides an overview of PLCs, their advantages over traditional control systems, and examples of their use in a textile mill. The presentation covers PLC architecture, programming, and a practical example of a mixer process control problem implemented with a PLC. The presenter aims to share what they learned during an internship about automating industrial processes using PLCs.

1. Presentation
On
“Industry Automation with
Programmable Logic Controller”
Md. Arifur Rahman
ID# 08105054
Program: BSEEE
IUBAT- International University of Business Agriculture and Technology
23rd, December 2011
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2. Objective
Main objective of this presentation is to show my practical
work, what ever I learnt in practical field.
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3. Sequence
1. About Industry Automation
2. PLC- Programmable Logic Controller
3. Advantage of PLC control system
4. PLC used in Niagara Textile ltd
5. Typical work done by PLC in Niagara Textile LTD
6. PLC Architecture
7. PLC system
8. Input/output section
9. Programming device
10.Device connectivity
11.Practical Example
12.Recommendation
13.Conclusion
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4. About Industry Automation
Industry Automation is the uses of industry control system to reduce
the need for human work in the production of goods and service.
Automation greatly decreases the need for human sensory and mental
requirements as well.
Automation plays an increasingly important role in the world economy
and in daily experience.
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5. PLC- Programmable Logic Controller
A Programmable Logic Controller is a specialized computer used
to control machines and process.
PLC Uses a memory to store instructions and specific functions
that include ON/OFF
control, timing, counting, sequencing, arithmetic and data
handling.
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6. Contd.
Figure 1: TSX-Micro 3722 PLC Used in Niagara Textile ltd
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7. Advantage Of PLC control System
Flexible
Faster Response time
Less and simple wiring
Solid-state – no Moving part
Modular Design - easy to repair and expand
Handle much more complex system
Easy to troubleshoot
Less expensive
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8. PLC Used in Niagara Textile
Two type PLC I saw in Niagara textile:
1. TSX-Micro 3722-101
2. Logimate P160
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9. Typical work done by PLC in Niagara Tex:
1. Controlling of finish Fabrics Diameter
2. Speed control of induction motor
3. Water level control for dyeing machine
4. Different type of temperature control
5. Automatic dyeing processing with control
6. Control finishing machine
7. Control shift counter
8. Identification of safety work.
9. Emergency Alarm system
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10. PLC Architecture
Figure: Typical PLC Architecture
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11. PLC System
Figure: PLC System Construction
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12. The Processor
Is the brain of the PLC
Consists of a microprocessor for implementing the logic, and
controlling the communications among the modules
Designed so the desired circuit can be entered in relay ladder
logic form
The processor accepts input data from various sensing
devices, executes the stored user program, and sends
appropriate output commands to control devices.
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13. Input/Output Section
I/O Section Consists Of :
Input Modules
Output Modules
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14. Input Module
Forms the interface by which
input devices are connected to the
controller.
Input device is physically wired
into the system.
Like temperature sensor, water
level sensor, pressure sensor.
Figure: Input Module
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15. Output Module
Forms the interface by which output field
device are connected to the controller.
PLC employ an optical isolator which uses
light to electrically isolate the internal
components from the output terminal.
Figure: output module detail.
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16. Power Supply
Supplies DC power to other modules
that plug into the rack
In a large PLC systems, this power
supply does not normally supply power
to the field device
In small and micro PLC systems, the
power supply is also used to power field
devices.
Figure : Power Supply Unit
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17. Programming Device
Figure: PLC connected with Programming device
A personal computer(PC) is the most commonly used programming
device
The software allows users to create, edit, modify, and troubleshoot the
program.
The personal computer communicates with the PLC processor via a
serial or parallel data communication link.
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18. Software
For PLC Programming:
1. PL7 4.4
2. Win pro ladder
For HMI Design:
1. Vijeo-Designer 1.1
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19. Basic Device Connectivity
PLC Connected with Laptop
using serial Port
And inverter connected to PLC
Motor connected to Inverter.
So, here make a program in
computer, transfer the program to
PLC and control motor from PLC
Computer is also used for
monitoring device activity.
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20. Contd.
Figure: PC-PLC Connectivity
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21. Cable Used for connection PC-PLC
Figure: RS-232 Cable Figure: PS2-USB Cable
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22. Sensors Connection
Here we can see Water level sensor and Hydrostatic sensor connected to
PLC and transmit different types of signal to PLC
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23. Wire connectivity with PLC
Figure: Wire connectivity with PLC
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24. Human Machine Interface
This device is used for:
Manually control PLC
Monitor device activity in different level
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25. Practical Example
Mixer Process Control Problem
Mixer Motor to automatically stir the
liquid in the vat when the temperature
and pressure reach at preset value
Alternate manual pushbutton control
to start/stop motor manually.
The temperature and pressure sensors
switches close their respective contacts
when condition fulfill.
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26. Process Control Relay Ladder Diagram
Motor starter coil is energized when both the sensors are
closed or pushbutton is pressed.
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27. PLC Input Module Connection
The same input field devices
are used
Those devices are wired to
the input module according to
the manufacturers labeling
scheme
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28. PLC Output Module Connection
Same output field device is used and wired to
the output module
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29. PLC Ladder Logic Program
The format used is similar to that of the hard=wired relay circuit
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30. Entering And Running the PLC Program
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31. PLC Operation Cycle
During each operating cycle, the controller examines the status of input
devices, executes the user program, and changes output accordingly.
The completion of one cycle of this
sequence is called scan. The scan
time, the time required for one full
cycle, provides a measure of the
speed of response of the PLC
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32. Personal Computer Based Control System
Advantages:
Lower Initial Cost
Less hardware and software required
Straight-forward data exchange with other system
Speedy information processing
Easy customization
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33. Recommendation
Need skilled person in this automation field
Need extra course in study level
Make some part of Automation system wirelessly
Well this is a big sector and we have to take it seriously
Need more opportunity for practical works
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34. Conclusion
In my total internship period I learn lots of things related to industry
automation. I tried to focus those things into my presentation.
Mostly I focused about automation and programmable logic controller.
This presentation I try to show how I learn and how to work in
practical field.
Most time I saw connectivity and controlling. This connectivity and
controlling is related to programmable logic controller. PLC is so much
important device in this sector. Plc doing many types of automation
works in industrial field.
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