Awareness about Industrial Automation for Electrical, Electrical and Electronics & Electronics and Communication Engineer .

1. INDUSTRIAL
AUTOMATION
Shashi Shankar
Technical trainer
@ ITDP Bhopal
Presented By:

2. What is Automation ?
The word ‘Automation’ is derived from Greek words
“Auto”(self) and “Matos” (moving).
 Automation therefore is the mechanism for systems that
“move by itself”.
Shashi Shankar
Technical trainer

3. Why Automation ?
Increasing Productivity Increasing Quality
Save Time & Cost Increasing Safety
in
working conditions.
Shashi Shankar
Technical trainer

4. Types of Automation ?
Building Automation
Example: Lifts, smoke detector
Office Automation
Scientific Automation
Light Automation
Industrial Automation
Example: Printers, CCTV cameras
Example: Rocket & Satellite launching
Example: Street Solar lightening
Example: Automated Bottle filling stations,
Steel factories, Cement factories etc.
Shashi Shankar
Technical trainer

5. History of Industrial Automation ?
Pneumatic Control
Hard wired logic Control
Electronic Control using Logic Gates
Programmable Logic Controller
Manual Control
Shashi Shankar
Technical trainer

6. History of Industrial Automation ?
Manual control
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.
Shashi Shankar
Technical trainer

7. History of Industrial Automation ?
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
Shashi Shankar
Technical trainer

8. History of Industrial Automation ?
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
Shashi Shankar
Technical trainer

9. History of Industrial Automation ?
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.
Drawbacks
•Reduced space requirements
•Energy saving
•Less maintenance & greater reliability
Advantages
Changes in control logic not possible.
More project time.
Shashi Shankar
Technical trainer

10. History of Industrial Automation ?
Programmable logic
controller
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.
Shashi Shankar
Technical trainer

11. History of Industrial Automation ?
Programmable logic
controller
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
Shashi Shankar
Technical trainer

12. History of Industrial Automation ?
Programmable logic
controller
 Reduced space
 Energy saving
 Ease of maintenance
 Economical
 Greater life & reliability
 Tremendous flexibility
 Shorter project time
 Easier storage, archiving and documentation
Advantages
Shashi Shankar
Technical trainer

13. Role of automation in INDUSTRY
 Manufacturing processes, basically, produce finished product
from raw/unfinished material using energy, manpower and
equipment and infrastructure.
Since an industry is essentially a “systematic economic
activity”, the fundamental objective of any industry is to make
profit.
Roughly speaking,
Profit = (Price/unit – Cost/unit) x Production Volume
So profit can be maximized by producing good quality products,
which may sell at higher price, in larger volumes with less
production cost and time.
Shashi Shankar
Technical trainer

14. Role of automation in INDUSTRY
The component of per unit Manufacturing cost
Shashi Shankar
Technical trainer

15. Tools of Industrial Automation
Switchgear & Protection
Control Panel
HMI
SCADA
Shashi Shankar
Technical trainer

16. Tools of Industrial Automation
PLC
SCADA
HMI
SWITCHGEAR
VFD
PANEL DESIGNING
INSTRUMENTATION
AUTOCAD
Shashi Shankar
Technical trainer

17. PLC (Programmable logic controller)
Shashi Shankar
Technical trainer

18. PLC (Programmable logic controller)
Language of Programming
Ladder Logic Programming
Shashi Shankar
Technical trainer

19. SCADA (supervisory control and data acquisition system )
Shashi Shankar
Technical trainer

20. HMI (Human machine interface)
SCADA is a system(PC) control and supervise
system.
HMI is screen touch control and supervise
system.
Shashi Shankar
Technical trainer

21. Switchgear
The proper Arrangement or connection of input & output
device with PLC is called Switchgear.
Input Device
Sensor
Switches
Toggle switch
Pushbutton
Output Device
Relay
contactor
Protective Device
OLTR
MCB
ELCB
Shashi Shankar
Technical trainer

22. Switchgear
Shashi Shankar
Technical trainer

23. Switchgear
Shashi Shankar
Technical trainer

24. Panel Design?
Control panel is a cabinet which contains electrical components to
control the motors and equipments.
Shashi Shankar
Technical trainer

25. Panel Design?
Shashi Shankar
Technical trainer

26. VFD(Variable Frequency Drive)?
Variable frequency drives (VFD) enable speed
control for three-phase AC motors such as
those in conveyors, fans, pumps, HVAC and
material handling.
Shashi Shankar
Technical trainer

27. Electrical Instrumentation ?
 Electrical Instrumentation deals with the design of devices to
measure physical quantities such as pressure, flow and
temperature.
 It used in design and configuration of automated
systems in Industrial Automation.
Various Instrumentation sensors are –
Level Measurement sensor
Temperature Measurement sensor
Flow Measurement sensor
Pressure Measurement sensor
Shashi Shankar
Technical trainer

28. Auto-CAD
AutoCAD Electrical is a powerful AutoCAD add-on for electrical
designers and engineers.
Offering automated drafting tools for designing wiring, circuiting,
PLC modules, panels, and data and schedules.
Shashi Shankar
Technical trainer

29. Auto-CAD
Shashi Shankar
Technical trainer

30. Role of Engineers In
Industrial Automation
 Designing of the Automation system.
 Erection and Commissioning.
 Maintenance and Troubleshooting of existing system.
Shashi Shankar
Technical trainer

31. 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.
Shashi Shankar
Technical trainer

32. Job prospects for Engineers In Industrial
Automation
 Manufacturing Industries like Reliance, CEAT, Godrej,
Colgate ….
 Automation Solution Products manufacturer/developer
like Rockwell, Siemens Groups, Schneider, Yokogawa, ABB
 System Integrators for Schneider, Rockwell, Siemens, etc
 Consultants for Automation
Shashi Shankar
Technical trainer

33. 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.
Shashi Shankar
Technical trainer

34. “PREPARATION MATCHING OPPERTUNITY”
Prepare today,
Opportunity will definitely follow You ..
Shashi Shankar
Technical trainer
Email- shashishankar11211@gmail.com