Prateek Sharma submitted a document to ElectroCus Solution about industrial automation and Industry 4.0. The document introduces industrial automation and its benefits, including increased productivity, safer work environments, reduced costs, higher quality, and more. It discusses industrial controllers like PLCs, their components, architecture, programming, and brands. The document also covers topics like variable frequency drivers, HMI systems, fieldbuses like PROFIBUS and PROFINET, DCS systems, IIoT, networking protocols, real-time vs batch data processing, key IIoT technologies, the digital twin concept, and the future of Industry 4.0.

1. ELECTROCUS SOLUTION
INDUSTRIAL AUTOMATION
INDUSTRY 4.0
SUBMITTED BY
NAME: Prateek Sharma
SUBMITTED TO
ELECTROCUS SOLUTION

2. INTRODUCTION OF INDUSTRIAL AUTOMATION
Industrial automation is the use of technologies such as computer software
and robotics to control machinery and processes which replace human
beings in performing specific functions.
Benefits of Industrial Automation
1. Industrial Automation Significantly Increases Productivity
2. Automation Creates a Safer Work Environment
3. Production Costs Are Reduced with Automation.
4. Quality Throughout Each Process is Much Higher
5. Automation is Essential for Complex Processes
6. Automation Produces Precise, Consistent Information About the Process and Result
7. Automation Allows Human Workers to Perform Other Important Tasks
By Prateek Sharma

3. INDUSTRIAL REVOLUTION

4. By Prateek Sharma

5. INDUSTRIAL CONTROLLERS
A programmable logic controller (PLC) or programmable controller is an industrial computer that
has been ruggedized and adapted for the control of manufacturing processes, such
as assembly lines, machines, robotic devices, or any activity that requires high reliability, ease
of programming, and process fault diagnosis.
COMPONENTS IN PLC UNITS.
1. Processor
2. Rack/Mounting
3. Input Assembly
4. Output Assembly
5. Power Supply
6. Programming Device/Unit
By Prateek Shar

6. PLC ARCHITECTURE
By Prateek Sharma

7. TYPES OF PLC
There are mainly three types of Programmable Logic Controllers
PLC
COMPACT MODULAR RACK
By Prateek Sharma

8. TYPES OF PROGRAMMING
PLC
PROGRAMMING
LANGUAGE
LADDER
DIAGRAM
FUNCTIONAL
BLOCK
DIAGRAM
INSTRUCTION
LIST
STRUCTURED
TEXT
SEQUENCIAL
FUNCTION
CHART
By Prateek Sharma

9. INDUSTRIAL DEVICES
PROGRAMMABLE LOGIC CONTROLLERS
BRANDS
•Siemens
•Allen Bradley
•ABB
•Omron
•Delta
•Honeywell
•Mitsubishi
•Schneider Electric
By Prateek Sharma

10. VARIABLE FREQUENCY DRIVER
A variable frequency drive (VFD) is a type of motor controller that drives an electric motor by varying
the frequency and voltage of its power supply. The VFD also has the capacity to control ramp-up and
ramp-down of the motor during start or stop, respectively.
There are many reasons why we may want to adjust this
motor speed.
For example, to
•Save energy and improve system efficiency
•Convert power in hybridization applications
•Match the speed of the drive to the process requirements
•Match the torque or power of a drive to the process
requirements
Improve the working environment
Lower noise levels, for example from fans and pumps
•Reduce mechanical stress on machines to extend their
lifetime
Shave peak consumption to avoid peak-demand prices and
DELTA
SIEMENS
By Prateek Sharma

11. HUMAN-MACHINE INTERFACE
The hardware or software through which an operator interacts with a controller. An HMI can range
from a physical control panel with buttons and indicator lights to an industrial PC with a color
graphics display running dedicated HMI software.
There are various applications of HMI technology in industries.
You can use it to:
•Track production time within the industry.
•Display data such as temperature, humidity, and speeds.
•Monitoring the amounts of inputs and outputs.
BRAND
1. Siemens
2. ABB Ltd
3. Mitsubishi Electric Corporation
4. Honeywell International Inc.
5. DELTA
By Prateek Sharma

12. By Prateek Sharma

13. PROFIBUS PROFINET
PROFIBUS is based on RS-485, which is
a common serial communication method.
In a PROFIBUS network, you have
PROFIBUS masters and PROFIBUS
slaves. The master can be, for example, a
PLC, PAC, or DCS. And the slaves can be
a wide array of devices: drives, motors,
IOs, sensors, field devices, robots,
actuators, and more.
PROFINET is based on standard
Ethernet, the same Ethernet that you
might have encountered in your home or
office. Standard Ethernet cables are
suitable for PROFINET networks.
However, most users employ PROFINET
cables, which are just Ethernet cables but
ruggedized, built to withstand the rough
environment of a factory. Just like with
PROFIBUS, in a PROFINET network,
you have PLCs, PACs, and DCSs and
also sensors, actuators, robots, RFID
readers, and other IOs
RJ-45
connector
RS 485
By Prateek Sharma

14. DISTRIBUTED CONTROL SYSTEM (DCS)
A distributed control system (DCS) is a specially designed automated control
system that consists of geographically distributed control elements over the
plant or control area.
BRANDS
1. ABB- Freelance 800F and 800 xA
2. Yokogawa- Centum CS 3000 and
1000
3. Honeywell-TDC 3000
4. Emerson- Delta V Digital
Automation
5. Siemens- Simatic PCS 7
6. Allen- Bradley- NetLinx
By Prateek Sharma

15. INDUSTRIAL INTERNET OF THINGS (IIOT)
Industrial Internet of Things (IIoT), is a vital element of Industry 4.0. IIoT harnesses the power of
smart machines and real-time analysis to make better use of the data that industrial machines have
been churning out for years. The principal driver of IIoT is smart machines, for two reasons. The
first is that smart machines capture and analyze data in real-time, which humans cannot. The
second is that smart machines communicate their findings in a manner that is simple and fast,
enabling faster and more accurate business decisions.
By Prateek Sharma

16. OSI MODEL
OSI stands for Open Systems Interconnection. It has been developed by ISO – ‘International Organization
for Standardization‘, in the year 1984. It is a 7-layer architecture with each layer having specific functionality
to perform.
SENDER RECEIVER
By Prateek Sharma

17. REAL TIME DATA PROCESSING
BATCH DATA PROCESSING
By Prateek Sharma

18. IIOT KEY TECHNOLOGIES
By Prateek Sharma

19. ARTIFICIAL INTELLIGENCE (AI) & MACHINE LEARNING (ML)
AI is where intelligent machines are developed and respond like humans. ML is where
machine
learning is a part of AI predicting and a more accurate outcome delivered without
programming.
By Prateek Sharma

20. CYBER SECURITY TECHNOLOGY
Cyber security technology becomes an important basic platform for IoT and IIoT enabling
disconnected machines to physically connect and communicate in a secure method
By Prateek Sharma

21. CLOUD COMPUTING
Cloud computing is the on-demand availability of computing resources as services over the
internet. It eliminates the need for enterprises to procure, configure, or manage resources
themselves, and they only pay for what they use.
By Prateek Sharma

22. EDGE COMPUTING
Edge computing is a distributed computing model bringing data storage closer to the location where it
is needed and optimizes sensors, industrial computers, and devices that are part of the IIoT system for
publishing and consuming data for faster processing.
By Prateek Sharma

23. DATA MINING
Data mining and analytics are about collating and examining large amounts of data stored from
various parts of the enterprise.
By Prateek Sharma

24. DIGITAL TWIN
A digital twin is a virtual representation referring to a digital replication of the actual companies’
physical assets, processes in place, automation systems, and devices. The twin uses real-time
data to enable learning and reasoning for improved decision making.
By Prateek Sharma

25. ORGANIZATION’S LAYERS OF SYSTEMS
An organization’s layers of systems starting with the plant floor transmitter, process PLCs,
operation HMI, and SCADA, reporting based on Database Administration, manufacturing
execution systems (MES) for warehouse control and Enterprise Resource Planning (ERP) for
accounting systems.
Now integrators are required to have expertise in machine learning, data science, and real-time
analytics.
By Prateek Sharma

26. IIOT BENEFITS
The benefits of IIoT in manufacturing, pharmaceuticals, agriculture, mining, Oil and Gas, and
retail are gaining ground and many companies are embracing this new paradigm for solutions
in optimizing operations and personnel productivity.
1. Predictive Maintenance (PdM)
2. Real-Time Data
3. Error Prevention
4. Enhanced Safety
5. Packaging Optimization
6. Smart Metering
By Prateek Sharma

27. SCADA VS. DCS VS. IIOT
By Prateek Sharma

28. FUTURE OF INDUSTRY 4.0
Industry 4.0, or the fourth industrial revolution it’s often called, is the future of
manufacturing. With the advent of the Internet of Things, virtual reality, blockchain,
drones, Big Data, robotics, augmented reality, and so much more, it’s clear that
digital technology plays a key role in manufacturing.
Discussion about industry 4.0 may have been overshadowed by the COVID-19
crisis, but many important elements are still set to be implemented this year. 5G
rollout is one of them. Artificial intelligence remains just as important as well and
many manufacturers depend on additive manufacturing.
There are many benefits to Industry 4.0, including how technologies can help
companies to react to the market more quickly (and easily), how work-life balance
of your employees can improve, how it’s innovation-centered and how it can lead to
fast designs and productions.
The industry is undergoing a massive digital transformation, which can help
businesses to remain competitive while driving innovation forward.
By Prateek Sharma

29. BIBLIOGRAPHY
1. ARTICLE ON IIOT , UNIVERSITY OF CAMBRIDGE
2. REALPARS (https://realpars.com/iiot/)
3. ELECTROCUS SOLUTION
4. SIEMENS (https://www.siemens.com/)
5. ELECTRICAL AND ELECTRONIC MEASUREMENTS AND
INSTRUMENTATION BY A.K SAWHNEY
6. https://www.geeksforgeeks.org/
By Prateek Sharma

30. By Prateek Sharma