WHAT IS AUTOMATION ? Making products under the control of computers and programmable controllers is known as automation. Manufacturing assembly lines as well as stand alone machine tools and robotic devices fall into this category. It is delegation of human control functions to technical equipment for increasing the productivity, quality, and increasing the safety in working conditions thereby reducing the manpower and cost. 1

Home Automation Office Automation Building Automation Industrial Automation 2

HOME AUTOMATION FIG- 1 HOME AUTOMATION Home automation is becoming more and More popular around the world And is becoming a common practice. 3

OFFICE AUTOMATION Office Automation Refers To Various Computer Machinery And Software Used To Digitally Create,collect,store And Manupulate Office Information Needed For Accomplishing Basic Task And Goals. Fig-2 office automation 4

BUILDING AUTOMATION Building Automation System Is Often Refer To As An Intelligent Building “Smart Building” Or If Resident “Smarthome”. Fig-3 building automation 5

INDUSTRIAL AUTOMATION Industrial Automation is the use of various control Systems for operating equipment such as machinery, processes in factories, boilers and heat treating Ovens. Fig-4 conveyor system at industries 6

WHY AUTOMATION IS USED ? To Reduce Human Efforts. To Reduce Production Time Of Product. To Increase Productivity Of Product. To Improve Quality Of Product. To Improve Safety In Working Condition. 7

AUTOMATION IN DAILY LIFE There Are Following Example In Which Automation Is Used:- Lift Moves Up And Down Automatically After Push Button. Toll Plaza Gate Open/Close Automatically. Escalator Rotate Automatic In Metros/Shopping Malls. Traffic Light Control System. 8

AUTOMATION COMPANIES – IN INDIA 9

AUTOMATION COMPANIES(INTERNATIONAL) 10

AUTOMATION TOOLS Different types of automation tools exist are :- HMI - Human Machine Interface. DCS - Distributed Control System. SCADA - Supervisory Control and Data Acquisition. PLC - Programmable Logic Controller. 11

WHY PLC ? To Reduce Human Efforts. To Get Maximum Efficiency From Machine And Control Them With Human Logic. To Reduce Complex Circuitry Of Entire System. To Eliminate The High Costs Associated With Inflexible, Relay-controlled Systems. Fig-5 WORKERS OPERATING A MACHINE 12

UNDERSTANDING OF PLC (Example ) Machine can be controlled by PLC without human efforts 13

WHAT IS PLC ? 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 - Programmable Logic Controller 14

PLC – MICROLOGIX 1000 Fig-6 micrologix

Fig-7 Allen Bradely Micro Logix

BASIC ARCHITECTURE OF PLC Fig-8 BASIC ARCHITECURE OF PLC 17

Push Button Switches Relays RTD THERMOCOUPLE 18

The CPU Consists Of Following Blocks :- Arithmetic Logic Unit (ALU). Internal Memory Of CPU. Internal Timers,Counters And Flags. The Various Operations Performed Are :- Scanning I/O Bus Traffic Control. Program Execution. Peripheral And External Device Communication. Data Handling And Self Diagnostics. 19

CONTROL VALVE MOTOR SOLENOID VALVE LAMP 20

Converts The Incomming Voltage To A Useable Form For The Internal Electronics. Protect The Plc’s Components From Voltage Spikes. Operates Either On 120vac/240vac/24vdc. 21

Examples of PLC Programming Software:- Allen-Bradley – Rockwell Software RSLogix500 Modicon - Modsoft Omron – Syswin GE-Fanuc Series 6 – LogicMaster6 Square D- PowerLogic Texas Instruments – Simatic Telemecanique – Modicon TSX Micro 22

Ladder logic is a programming language used to develop software for PLC used in industrial control applications. RUNGES RAIL PLC PROGRAMMING 23

NORMALLY OPENNORMALLY CLOSED (CONTACT) COILS 24

TOOLS FOR LADDER PROGRAMMING Bit Instructions Timers Counters Compare Block Mathematical Operators 25

26 Input NC Bit Input NO Bit Output Bit

TIMERS Timer Is Basically Used To Add Some Delay In The Programming Circuit By Adding A Particular Time To Each Circuit. Types Of Timer:- TON TOFF 27

COUNTERS Counter Is Same As Timer. Counter Works On The Method Of Counting The Number Of Pulse. 28 COUNTER UP COUNTER DOWN

AN EXAMPLE OF PLC PROGRAMMING 29 FIG-9 PLC PROGRAMMING ON RS LOGIX 500

IMPLIMENTATION OF PLC PROGRAMME ON PANEL 30

Manufacturing / Machining Food / Beverage Textile Industry Travel Industry Aerospace Printing Industry AREAS OF APPLICATION FIG-10 AUTOMATIC BOTTLE FILLING AND CAPPING

Supervisory Control & Data Acquisition Systems

WHY SCADA? Previously Without SCADA Software, An Industrial Process Was Entirely Controlled By PLC, CNC, PID & Micro Controllers Having Programmed In Certain Languages Or Codes. These Codes Were Either Written In Assembly Language Or Relay Logic Without Any True Animation That Would Explain The Process Running. It Is Always Easy To Understand The Status Of The Process If It Is Shown With Some Animations Rather Then Written Codes. Hence Scada Software Came To Existence And With Some Exclusive Features It Became Internal Part Of Automation System

WHAT IS SCADA? SCADA Stands For Supervisory Control And Data Acquisition. As The Name Indicates It Is Not A Full Control System, But Rather Focuses On The Supervisory Level. A SCADA Program Normally Runs On A PC And Communicates With External Instrumentation And Control Devices. It’s An Optional Device Used In Automation For Continuous Monitoring. 34

FEATURES OF TYPICAL SCADA SOFTWARE 35 Dynamic Process Graphics. Real Time & Historical Trends. Alarms. Recipe Management. Security. Scripts.

36 OVERVIEW OF SCADA FEATURES

APPLICATION OF SCADA MANUFACTURING. BUILDING,FACILITIES & ENVIROMENT. WATER TREATMENT PLANT. FOOD INDUSTRIES. CHEMICAL INDUSTRIES. TRAFFIC SIGNAL. 37

Wonderware : InTouch Intellution : iFix (Earlier Fix DMACS) Allen Bradley : RS View (Earlier Control View) Siemens : WinCC (Earlier Coros LS /B ) GE Fanuc : Cimplicity Indusoft : I W S Movicon : Progea Wonderware : InTouch Intellution : iFix (Earlier Fix DMACS) Allen Bradley : RS View (Earlier Control View) Siemens : WinCC (Earlier Coros LS /B ) GE Fanuc : Cimplicity Indusoft : I W S Movicon : Progea

REFERENCES

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CONTENTS WHAT IS AUTOMATION ? WHY AUTOMATION IS USED? AUTOMATION IN DAILY LIFE TYPES OF AUTOMATION AUTOMATION COMPANIES AUTOMATION TOOLS WHY PLC ? WHAT IS PLC ? PLC MICROLOGIX 1000 HARDWARE FEATHERS OF PLC BASIC ARCHITECTURE OF PLC EXAMPLES OF PLC PROGRAMMING SOFTWARE LADDER LOGIC ELEMENTS OF LADDER LOGIC TOOLS FOR LADDER PROGRAMMING 42

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A SUMMER TRAINING PRESENTATION ON “AUTOMATION WITH PLC & SCADA” ( ) Submitted to: Prof. Hanuman Patel Submitted by: PRASHANT SINGH B.Tech 4 th Year Department of Electrical & Electronics Engineering VYAS INSTITUTE OF ENGINEERING & TECHNOLOGY JODHPUR (Raj.) 44