Industrial automation involves delegating human control functions to technical equipment to enhance productivity, quality, and safety while reducing costs across various industries, from agriculture to space technology. Programmable Logic Controllers (PLCs) play a crucial role in automating processes, having evolved to replace older systems like mechanical relays, and are now integral in sectors including manufacturing, aerospace, and research. The implementation of automation systems simplifies complex controls, improves efficiency, and enhances the ability to monitor and adjust processes in real-time.

1. Industrial Automation
Automation is basically the delegation of
human control
function to technical equipment for
•Increasing Productivity
• Increasing Quality MACHINE
• Reducing Cost
• Increasing Safety in working conditions
CONTROL SYSTEM
INFORMATION TECHNOLOGY

2. What is Industrial Automation ..?
Automation is encompassing virtually every
walk of life.
Automation solutions are required right from
agricultural to space technology.
Plant Automation is the necessity for the
manufacturing industry to survive in today’s
globally competitive market

3. Don’t Surprise
IT IS ALSO AUTOMATION
Processor (Brain)
Feedback(Eyes)
Output
controlling unit(Hand) action unit
(Leg)
When Human Operator can operate the machine ,taking Feedback of a
Machinery performance and he can change or adjust according to requirement,
that why it also called as Automation.
Thus ,we can define Automation
Any systematic operation required intelligence and as well as
monitoring action.

4. Scope of Automation in industries
• Power & Steel plant
• Chemical
• Paint
• Gas & oil
• Automobile Industries
• Mobile manufacturing industries
• Textile industry
• Medicine

5. Industrial Automation
• PLC
• SCADA
• PID Controller
• Industrial Instrumentation
• Motor(AC)
• Relay & Contactor ,electrical device’s symbols
• Drives (AC)
• HMI
• Networking

6. ELECTRONIC CONTROLLER
TIMER
It is used for time delay generation
for the operation of different
Machinery
COUNTER PID Controller
It is used for counting the
no. of event

7. Thermocouple
PID Controller Analog Input Signal (FEEDBACK)
Frequency controlled
Power supplied to
Regulated Controlled Signal ( Output) Blower Motor
Blower
Temperature
controlling
by the use of PID
controller in VFD
Industry

8. Limitation of Electronic Controller in a Industry
In industry where large number of a Timer
, Counter, PID, Relay, Switches and etc ,which all makes the entire
system costly and complicated .
Thus, there is need of One Controller which can monitor the entire
system
And also generate delay and count a event
Easy to be program , modify whenever needed
All this feature are add up in a one controller PLC (Programmable
Logic Controller)

9. History of Automation
• Manual control system
• Pneumatic control system
• Hard wired logic control system
• Electronic control using logic gate
• PLC (Programmable logical controllers)

10. Programmable Logic Controller
A PLC is a micro processor based solid state / computerized industrial
computer that performs discrete or sequential logic in a factory environment.
It was originally developed to replace mechanical relays, timers, counters.
PLCs are used successfully to execute complicated control operationsin a
plant.

11. History of PLC
The PLC was invented in response to the needs of the American automotive
manufacturing industry.
Programmable logic controllers were initially adopted by the automotive industry where
software revision replaced the re-wiring of hard-wired control panels when production
models changed.
In 1968 GM Hydramatic (the automatic transmission division of General Motors) issued a
request for proposal for an electronic replacement for hard-wired relay systems. The winning
proposal came from Bedford Associates
of Bedford, Massachusetts.
The first PLC, designated the 084 because it was Bedford Associates' eighty-fourth project,
was the result. Bedford Associates started a new company
dedicated to developing, manufacturing, selling, and servicing this new product:
Modicon, which stood for Modular Digital Controller. One of the people who worked on that
project was Dick Morley, who is considered to be the "father" of the PLC. .

12. Global Player in a Automation Industry
1. Siemens
2. Allen Bradelly
3. Mitsubhisi
4. GE
5. ABB
6. Delta
7. Yokogawa
8. Omran
9. National Instrument
10. Schinider Electric
11. honeywell

13. Programming In a PLC
User have a multiple Choice for programming a PLC
Ladder logic Functional Block Diagram
Instruction List

14. Ladder Logic Programming
It is a easier way of Programming the PLC.
So that Engineer must be concerned only on procedure and functional of the
machinery design
For this knowledge of basic Electronic Circuit is sufficient.
For Example
Basic Gate Logic
A
Output
OR Gate
B
Electrical Circuit
A Output
Ladder Logic
B

15. AND Gate A B Output
Electrical
Circuit
A B Output
Ladder Logic
Output
NOT gate
Electrical Circuit
A
A Output
Ladder Logic

17. Motion Control System
We can operate these
Drive through
Keypad , external
Switch and also
through PLC
VFD
Induction Motor
Stepper Drive
Stepper Motor
Servo Drive Servo motor

18. Industrial Robotic is also the part of Automation Industry
Industrial robotic is the finest example of motion control system, One
robot required one controller for the specific operation but when
multiple robot working together thus we required no. of PLC
connected together by Master PLC, so that entire process can be
synchronized

19. SCADA
Supervisory Control and Data Acquisition
Data Acquisition
mean collecting
Control means Controlling data Information from
Supervisory means Monitoring the entire System such as Different
entire system through ON/OFF operation , controller, Sensor
GUI representation Speed , Drives , Motor which
of working Status ,of the controlling, temperature are connected at
entire system Controlling distance through wire
, Ethernet , wireless

20. PLC is just like a Black Box, internal operation of its
user can`t see until the entire process complete or halt the
System…Thus we required GUI(Graphical User Interface)
Representation of the entire process……..

21. Main feature of SCADA
•GUI is designed by simple Drag and Paste concept.
•Tagging and Coding is done by considering programming bit .
•On SCADA ,we can monitor Real Time operation and Historical Trend .
•Alarm triggering which also used in this system , it trigger when certain
task complete or sudden brake of a system.
•Recipe management ,it provide the operator multiple choice for mixing the
variety of chemical and solution.

22. We can also monitor the Real time operation and the
process on Graph .

23. In Industry SCADA were designed on Computer
System , and display may be on computer
screen, LCD Display or Projector
Here we can see, all the sensor , chemical tank, filling process , temperature ,ON
/OFF status of Motor .All this thing, it has being monitor on the PC screen and big
LCD Screen or projector.

24. HMI
Human Machine Interface
It have some major feature of SCADA ,HMI it is basically a control
display screen were operator can monitor and control the machinery
and it is portable and can easily installed on the Machine itself
HMI It was designed
for the specific task
operation on the
machine
and SCADA is for
entire Plant
operation

25. Industrial Networking
Eternet, Device net,Modbus , Profibus cable are used for
connecting entire Controller , Sensor , PLC and SCADA

26. Industrial Sensor
It is basically are of two type
Digital Sensor
it has switching b/w ( 0,24V)
Analog Sensor
It is basically are of two type
Current type analog Sensor
(4mA—20mA)
Voltage type analog Sensor
(0—10V)

27. Advantage of Implementation of
automation in Industry
Increase In Production
Reliability in operation
Flexibility in control techniques
Flexibility in programming and reprogramming in the plant
Large quantity of I/O s are connected
Online/ offline modifications
Cost effective for controlling complex systems
In-house simulation & testing of project
Speed in operation
Ability to communicate with computer systems in the plant.
Ease of maintenance / troubleshooting

28. SCOPE OF AUTOMATION
In Aeronautic and Space
Application, where large amount of a
Controlling unit are used for
connecting different device that are
working systematic manner
Smooth functioning of the Delhi Metro train is a
example of a motion control system .

29. SCOPE OF AUTOMATION
In the Research Lab such as
CERN,NASA,ISRO,DRDO and etc
Where very small unit of machine to
the very heavy Machinery Unit
designed are interlink together , A
to Z controlling in came under
In Heavy industry such as Steel ,Automobile
industrial Automation.
, and Food industry where the man are not
able to work in a such hostile condition ,thus
sensor, controller & PLC are diploid there and
monitoring & controlling is done from SCADA
based control room

30. In Industry and Research Lab
Industrial Automation is the End Consumer of the
Engineering field.
All the Mechanical machinery from small to large such as
Mechanical Hydraulic system, pneumatic system, Induction motor are
consumes in the Automation industry
Relay ,Contactor and large Amount of Switch
Electrical
Gear(MCB,MCCB,OLR ,Push Button) are also consumes in this
industry
Instrumentation Industrial sensor (Proximity ,IR Sensor , Level sensor) &
instrument (Pressure Switch , limit Switch, Flow Meter)
are also consumes in this
Electronic Embedded product such counter , timer, PID controller and
electronic Regulator and PLC are also consumes in the
automation
For connecting different device , controller , PLC and SCADA
Information Technology so that they can communicate with each other thus
Industrial networking requirement is essential

31. Role of Engineers In
Industrial Automation
• Designing of the Automation system
• Erection and Commissioning
• Application Engineering
• Maintenance and Troubleshooting of existing
system