AUTOMATION

 What is AUTOMATION ?

• As the name suggest “Automation” means to

perform automatic operations by means of different
kinds of machines.

• Automation is the use of control systems and

information technologies to reduce the need for
human work in the production of goods and services.
In the scope of industrialization, automation is a step
beyond mechanization.

• It is used to reduce human interference and an efforts.

 AUTOMATION
 Tools of Automation

• Programmable Logic Controller (PLC)

• Supervisory Control And Data Acquisition (SCADA)

• Human Machine Interface (HMI) or Touch Screen (TS)

• Variable Frequency Drive (VFD)

 AUTOMATION

 ADVANTAGES : ~
• Replacing human operators in tasks that involve
hard physical or monotonous work.

• Replacing humans in tasks done in dangerous

environments.

• Performing tasks that are beyond human

capabilities of size, weight, speed, endurance, etc.

• Economy improvement: Automation may improve

in economy of enterprises, society or most of
humanity.
 AUTOMATION

 DISADVANTAGES : ~

• Unemployment rate increases due to machines

replacing humans and putting those humans out of
their jobs.

• Technical Limitation

• Security Threats

• High initial cost.

 PLC
 What is PLC ?

• PLC - programmable logic controller

• A Programmable Logic Controller, or PLC for short,

is simply a special computer device used for
industrial control systems. They are used in many
industries such as oil refineries, manufacturing lines,
conveyor systems and so on.

• PLC implements logic control functions by means of

a program.
 PLC
 How does a PLC differ from a computer ?
• A computer is optimized for calculation and
display tasks.

• A computer is programmed by specialists

• A PLC is designed for (logic) control and

regulation tasks.

• A PLC is programmed by non-specialists

• A PLC is well adapted to industrial

environment.
 PLC
 Components of PLC : ~
 PLC
 Components of PLC : ~

1. Inputs Circuits
2. Outputs Circuits
3. CPU (Central Processing Unit )
4. Memory for program and data storage
5. Programming device
6. Communication Device
7. Power Supply
 PLC
1. PLC inputs : ~
ANALOG inputs DIGITAL inputs

• Pressure Transducer Push buttons

• Flow meter Sensors

• Thermocouples Selector switches

 PLC

 PLC outputs : ~
ANALOG outputs DIGITAL outputs
• Mass flow controller • LED’s

• Pressure regulator • Small motors

• Position controller • Relays

 PLC

 Memory for program and data storage : ~

Memories used: -

• RAM – Random access memory

 Volatile
 Made up of metal oxide semiconductor
 lose it's information if power is removed.
• ROM – Read only memory

 Non-volatile
 don't need an external power source to
keep information
 PLC
 Power Supply : ~

• A power supply of 120v ac is typically used to drive

the PLC (some units operate on 240v ac).
• The power supply converts the 120v ac into dc
voltages of +5v.
• These low voltages are used to operate equipment
that many have much higher voltage and power
ratings than the PLC itself.
 PLC
 Programming In PLC :~
Languages used in PLC for the purpose of programming are

1. Ladder language
2. Functional Block Diagram (FBD)
3. Instructional List (IL)
4. Drive Functional Block (DFB)
5. Structural test language
 PLC
 Ladder language used in PLC programming
There are two PLC in which ladder programming
is used : -
• ZELIO PLC : - It uses Zelio soft 2 software for
the programming.

• DELTA PLC : - It uses WPL soft software for

their programming.
 PLC
 ZELIO PLC

The software’s used for different types of Zelio PLC’s are

as follows:-

• Zelio 1- non expandable- zelio soft 1

• Zelio 2- non expandable- zelio soft 2
• Zelio 3- expandable- zelio soft 2
 PLC
 Parameters used in Zelio and delta PLC in
ladder programming

Parameters ZELIO plc DELTA plc

Inputs In Xn

Outputs Qn Yn

NC of input

NO of input

Timer Tt1, t1 command has to be provided

(e.g.- TMR T0 k150)
 PLC
 Zelio soft 2 ladder programming

The various parameters used in zelio soft 2 while

operating ladder program and their relationship
amongst them are as follows:-
• INPUT CONTACT
• OUTPUT CONTACT
• INTERLOCKING
• MEMORY COIL
• LATCHING
• TIMER
• COUNTER
 PLC

 INPUT AND OUTPUT CONTACT

• Inputs in Zelio soft 2 is represented by I1, I2, I3,I5,I6.

• Inputs are further classified as: -

 NORMALLY CLOSED

 NORMALLY OPEN
 PLC

 Examples for Normally open contact

 PLC

 Example of Normally closed contact

 PLC

 INTERLOCKING

• Interlocking means to interlock something by placing

NC of coil or input in front. The concept of interlocking
reduces the complexity in PLC programming

• Interlocking in ladder programming means whenever

we want to off some output by input or any type coil,
then we have to place NC of that input or a coil in front
of output which we want to off.
 PLC

 Example of Interlocking
 PLC

 MEMORY COIL

• Memory coil in ladder programming is used for

reversing the contacts whenever coil is get
energized.
• In ladder programming memory coil is represented
by M1 and its contact is represented by m1.
• When memory coil M1 gets the signal it gets
energized and then it reverses the terminal of its
contact m1 which reverses the operation.
 PLC
 Example of Memory coil
 PLC
 When memory coil gets energized
 PLC

 LATCHING

• Latching is the process in which once output or a coil

is energized it remains energized forever. Latching is
done by the contact of output or coil which we want
to switch ON permanently.
 PLC
 When contact I1 is turned ON
 PLC
 TIMER

• Timer is basically used add some delay in the

programming circuit by adding a particular time to
each circuit.
Types of timers : -

• ON delay timer

• OFF delay timer

 PLC
 Example of Timer
 PLC
 COUNTER

• Counter is same as timer. Counter works on the

method of counting the number of pulse.
Types of counter : -

• UP counter- UP counter counts in increment order.

Ex . 1, 2, 4….n.

• DOWN counter- DOWN counter counts in

decrement order. Ex. 5,4,3,2,1
 PLC
 DELTA PLC

• It is high-speed, stable and highly reliable PLC's are

applied in various automation machines.

• it is totally similar to zelio plc programming but the

specifications of DELTA plc are different from zelio plc
as shown above.

• In DELTA plc memory space has been allotted

according to the types of plc.
 PLC
 Timers in Delta PLC

Timers in DELTA plc are used to add some delay in the

circuit, timers can be of two types as follows: -
• ON delay timer.
• OFF delay timer.
Commands for applying timer are as
follows: -

TMR<space>t0<space>k100
 PLC
 Example of delta PLC
 PLC
 WIRING OF PLC

• The operating voltage of plc is 220v (Ac) / 24v

(dc)/10v (dc). The operating voltage of plc is 220v
(Ac) / 24v (dc)/10v (dc).

Components used in wiring of plc are: -

• SMPS- Switch Mode Power Supply
• OUTPUT- Y0 ,C0
• SOURCE/SINK (S/S)- S0,S1.........
 PLC

 COMPONENTS

• SWITCH MODE POWER SUPPLY: -

SMPS is used to provide power supply to plc; SMPS
can be of different power supply mode. Ex - 220v (Ac) / 24v (dc)/10v
(dc).
• OUTPUT: -
Output Y0 actually connected to C0 the pair of Y0 C0 is responsible
for working of plc.
C0

Y0
C1

Y1
 PLC
 Example of wiring of PLC
 PLC
 Applications of PLC

• Gate Control : -

• PLC can sense a vehicle at the entrance or exit, and open

and close the gate automatically.
• The current vehicle count is easily determined by
programming a simple counter.
• Gate control system can also be used for domestic purpose.
 PLC
 Applications of PLC

• Conveyor System: -

• PLC can be used to start/stop latching logic for motor

control
• Counters can be used for monitoring product amounts
• Conveyor system using plc can be used in car washing
system
 VFD
 VARIABLE FREQUENCY DRIVE (VFD)
• VFD or Variable Frequency Drives are used
to run the motors of single phase or three
phase supply.
• VFD is used to accelerate and deaccelerate
the speed of motor with in a particular time.

Drives commands: -
• Start/Stop
• Speed reference
• Acceleration/ deacceleration
 VFD
 Parameters of VFD
P = 2—00 = 0 (digital keypad)
= 3 (potentiometer on drive)
P = 2—01 = 0 (digital keypad)
= 1 (external terminal) / keypad stop/enable
= 2 (external terminal)/keypad stop/disable
START/STOP command
= 0 (on board)
= 1 (ext M0=forward, M1= reverse)
= 3(M0=forward, M1= reverse, M2=stop)
P = 1—09 = acceleration time
P = 1—10 = deacceleration time
 VFD
 Advantages of VFD

• Dynamic braking : -Dynamic braking stops the

system more quickly than coasting
• Highly efficient
• Low power consumption
• Small space consumption
• Low cost
• Easy to use
• Highly specific
 SCADA
 SCADA System
• SCADA is “Supervisory Control and Data Acquisition” –
real time industrial process control systems used to
centrally monitor and control remote or local industrial
equipment such as motors, valves, pumps, relays, etc
• A SCADA system gathers information (such as where a
leak on a pipeline has occurred), transfers the information
back to a central site, then alerts the home station that a
leak has occurred, carrying out necessary analysis and
control, such as determining if the leak is critical, and
displaying the information in a logical and organized
fashion.
 SCADA
 Why SCADA?

• Saves Time and Money

• Less traveling for workers (e.g. helicopter
ride)
• Reduces man-power needs
• Increases production efficiency of a
company
• Cost effective for power systems
• Saves energy
• Reliable
• Supervisory control over a particular system
 HMI
 HUMAN MACHINE INTERFACE (HMI)

• A human machine interface (HMI) is an interface

which permits interaction between a human being
and a machine.
• . Human machine interfaces vary widely, from
control panels for nuclear power plants to the
screen and input buttons on a cell phone.
• Two components are needed in a human machine
interface. The first is an input. A human user needs
some way to tell the machine what to do, to make
requests of the machine, or to adjust the machine.
Examples of input devices include keyboards,
toggles, switches, touch screens,