This document provides an overview of industrial automation, including its history, components, programmable logic controllers (PLCs), and supervisory control and data acquisition (SCADA) systems. It discusses the evolution of automation from manual to electronic control. The main components of industrial automation systems are sensors, actuators, automation computers like PLCs and microcontrollers, and automation software. PLCs can be programmed to control industrial processes, and have components like a CPU, memory, input/output modules, and a power supply. SCADA systems are used for monitoring and controlling remote devices and providing overall process control. Industrial automation brings advantages like increased efficiency and productivity.

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INDUSTRIAL AUTOMATION

2. CONTENTS
1) Introduction to automation
2) Industrial Automation
3) History of automation
4) Components of Industrial Automation
5) What is PLC
6) Components of PLC
7) PLC Programming Fundamentals
8) Applications of PLC
9) Advantages and Disadvantages
10) SCADA-Definition and Components
11) Features of SCADA
12) Application of SCADA
13) Future scope of automation
14) Conclusion
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3. INTRODUCTION TO AUTOMATION
Automation= “Auto”(self) + “Matos”(moving)
•A step beyond mechanisation
• Use of computers to control the particular process with
minimal human involvement
•Increases the efficiency and productivity of the system
•Time taken for a process is less
BEFORE
AFTER
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4. INDUSTRIAL AUTOMATION
Use of control systems, such as computers or robots,
and information technologies for handling different
processes and machineries in an industry to replace a
human being
Industrial automation = process + automation
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History of automation
MANUAL
CONTROL
PNEUMATIC
CONTROL
RELAY LOGIC
CONTROL
ELECTRONIC CONTROL
USING GATES
PLC

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COMPONENTS OF INDUSTRIAL AUTOMATION
1. Sensors : Examples- temperature, pressure,
velocity
2. Actuators: Examples- Relays, magnets,
servomotors
3. Automation computers: microcontrollers,plc
,personal computers
4. Automation software system: Set of all
programs necessary for the execution of
automation tasks.
PLC
actuators
sensors

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WHAT IS PLC? • PLC - programmable logic controller
• Conceived by Dick Morley in 1968
• A special form of microprocessor-based
controller that uses a programmable memory
to store instructions and to implement
functions
• Can be programmed by non-specialists
• The automation of many different processes,
such as controlling machines or factory
assembly lines, is done through the use of
these small computers .
• Designed for (logic) control and regulation
tasks.
Continued....

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COMPONENTS OF PLC

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COMPONENTS OF PLC
1.The CPU :Contains Microprocessor which interprets the input signals and carries
out the control actions, according to the program stored in its memory
The CPU consists of following blocks :
 Arithmetic Logic Unit (ALU),
 Internal memory of CPU
 Internal timers ,counters .
2.Memory: Used to store programs, data and information in PLC
>ROM and RAM are the types of memory used.
3.Input modules: receives data from field devices, and sends it to processor.
Ex. Of i/p field devices: digital-Switches, Pushbuttons.
analog-LVDT,RTD
4.Output module: Receives command from the processor and give it to the output
field devices.
Ex. Of o/p field devices: digital: lamps, relay.
analog: motor spring, position of valve

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COMPONENTS OF PLC
5.Power supply: Provides the voltage needed to run the
primary PLC components.
6.Programming device: The programming terminal is used for
programming the PLC and monitoring/sequencing PLCs operation.

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PLC OPERATION
 CHECK INPUT STATUS
First the PLC takes a look at each I/O to determine if it is on or off.
 EXECUTE PROGRAM
Next the PLC executes the program
one instruction at a time.
 UPDATE OUTPUT STATUS
Finally the PLC updates the status of the outputs .It updates the
outputs based on which inputs were on during the first step.
For example

12. PLC PROGRAMMING FUNDAMENTALS AND EXAMPLES
Software used :RSLOGIX 500 (for micrologix Allen Bradley PLC)
RSLOGIX 5000( for control logics and compact logic PLCs)
Ladder Diagram is the most used programming language which has been specified by
IEC 1131-3 which is the international standard for programmable controller
programming languages.
>Developed to mimic relay logic
Basics :
RUNGES
RAIL RAIL
• vertical lines represent the power rails between which
circuits are connected.
•The power flow is taken to be from the left-hand vertical
across a rung
• Each rung defines one operation.
• A ladder diagram is read from left to right and from top to
bottom,
1. RAIL AND RUNG
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BASICS:
2.CONTACTS-
a. XIO:Examine if open-It acts like a Normally closed
push button
b. XIC:Examine if closed-It acts like a Normally open
push button
3. RELAY COILS-
The Output Energize (OTE) instruction looks and
operates like a relay coil.
>When set to 1 ,energizes the output.
13
(CONTACT)
(CONTACT)
COILS
Continued…

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INSTRUCTION ADDRESSING
To complete the entry of an instruction, addressing is needed..which will indicate
what input is connected to what input device, same for the output. Let’s first
understand the memory system:
Two fundamental types :- Program and Data files
Contains number of locations,
numbered from 0 to 999.
> For the input ‘I:’ and output ’O:’
files, these locations are converted
to physical locations on the PLC
using rack
and slot numbers.
Continued....

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INSTRUCTION ADDRESSING
Example-1
I:3/12 O:2/3
O:0
O:1
O:2
O:3
O:4
O:5
O:6
O:7
This is a
o:2/3

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BASICS:
TIMER COIL :
When its coil is energized, must wait for a fixed length of time before closing its contact or
must close its contact for some time only.
STATUS BITS: TT(timer timing),DN(done)
TYPES:
1.TON(TIMER ON DELAY)
2.TOFF(TIMER OFF DELAY)
3.RTO(RETENTIVE TIMER ON)
EXAMPLE:
I:2/3 PLC O:5/1
O:5/2
TT =1 when rung =1, remain set until
rung=0/DN bit=1
DN=0 until preset value=accumulated
value ,remain set until rung=0.

17. BASICS:
COUNTER COIL : Counting is critical in industrial application.
>Primary Counter Types:
>UP Counters - PLC sense how many finished products leaving the machine
>Down Counters - PLC sense how many parts are left
>Up/Down Counters - PLC monitors an automated storage system to track how
many are coming and how many are leaving to determine total number in stock
>Choice used depend on the task
I:2/1
I:2/3
O:5/1
O:5/2

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APPLICATION
 Manufacturing / Machining
 Food / Beverage
Textile Industry
 Travel Industry
 Aerospace
 Printing Industry
EXAMPLE-RO PLANT

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ADVANTAGES DISADVANTAGES
• PLC Devices Are
Proprietary
• Initial Costs Are High
•There's Too Much Work
Required In Connecting
Wires
• Unemployment Rate
Increases

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SCADA stands for supervisory control and data acquisition.
It generally refers to an industrial control system: a computer system monitoring and
controlling a process.
SCADA
The major function of SCADA is for acquiring data from remote devices such as valves,
pumps, transmitters etc. and providing overall control This provides process control
locally so that these devices turn on and off at the right time, supporting the control
strategy.
Softwares used:WONDERWARE INTOUCH
ALLEN BRADLEY- RSVIEW32

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Features of SCADA
DEVICE CONNECTIVITY
RECIPE SECURITY

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Features of SCADA
ALARMS
TRENDS SCRIPTS

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APPLICATION
1.MANUFACTURING
2.Food industry
3.Telecom and information technology
4.Wastewater treatment
ONCE AND
NOW.....

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FUTURE SCOPE OF INDUSTRIAL AUTOMATION
>It will generate explosive growth with :
>MEMS and NANOTECHNOLOGY
>Machine to machine networking (M2M)
>Wireless technology
CONCLUSION
Automation has many advantages over human operators.
Improves the economy of industries, society and humanity.
SCADA and PLC are the most important automation tools.
SCADA is used for controlling and monitoring activities.
PLC is used for automating things.

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1. Hugh Jack, Automated Manufacturing Systems PLCs (Second Draft), page number-16 to 28,
Hugh Jack, 1993-2001
2. Kevin Collins, PLC Programming for Industrial Automation, page number-5 to 18, Kevin
Collins
3.Bentley systems, The fundamentals of SCADA,page number-1 to 18 ,Bentley systems,2004
4. W.Bolton, Programmable Logic Controllers, page number-12 to 80, Elsevier Newnes, 1996
5.http://www.automation.com/library/articles-white-papers/articles-by-jim-pinto/the-future-of-
industrial-automation
6.http://paginas.fe.up.pt/~asousa/sind/acetat/IA_Stutg/ia_01___what_is_IA.pdf
7.http://www.machine-information-systems.com/PLC_History.html
8.http://science.jrank.org/pages/675/Automation-Types-automation.html
9.http://www.automation.com/library/articles-white-papers/articles-by-jim-pinto/the-future-of-
industrial-automation
10.http://www.allaboutcircuits.com/textbook/digital/chpt-6/programmable-logic-controllers-plc/
REFERENCES

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