INDUSTRIAL AUTOMATION
Day 1
What is Automation?
Industrial automation is the control of machinery and processes used
in various industries by autonomous systems through the use of
technologies like robotics and computer software. Industries
implement automation to increase productivity and reduce costs
related to employees, their benefits and other associated expenses,
while increasing precision and flexibility. With the Industrial
Revolution came mechanization, which brought cheaper and more
plentiful goods. Generally, the mechanical processes in industries
were faster and produced greater quantities of goods but still required
skilled workers. Not only did machines require operators but when
errors occurred, they would waste materials, cause production issues
and even damage equipment. With the arrival of automation, control
loops were added to machine operation. These can be open control
loops that allow for human input or closed loops which are fully
automated. Industrial control systems (ICS) allow for monitoring and
control locally and remotely. With these increasingly advanced
control mechanisms, industries can operate 24 hours a day.
Productivity has increased, errors are reduced and quality is
improved. However, automation does have some negative impact,
including high initial costs, reduced worker employment and the
elimination of some ethical human oversight. As automation
continues to advance and gain popularity in new industries, it is
possible to see these events increase.
Industrial Automation:
PLC implementation
Embedded development
IoT
AI Program
PLC Implementation
Measurement Device &Sensor
Control Device
PLC Interface & Programming
Field Implementation
Installation
Maintenance
Service
The above work proposal is in every automation process
DAY 2
P.L.C
Programmable logic controller
A programmable controller is currently defined as a digital
electronic device that uses a programmable memory to store
instructions and to implement specific functions such as logic,
sequence, timing, counting and to arithmetic to control machines and
processes.
Programming languages
A software program written into the user
memory provides a way for the user to communicate
with the PLC. The program is a control plan that tells
the processor what to do when certain conditions
exists. Several different forms of programming
languages have been developed by PLC manufacturer
to enable instructions to be written. The four most
common types of languages are:
Ladder diagram
Boolean algebra
High-level languages
State languages
We are learning in Ladder languages
Ladder language
This is still the premier language the PLC. The
ladder diagram has many advantages:
It is readily available understand and maintained by
skilled workers familiar with relay logic. It simplifies
training, Ladder language, however, generally lacks
good flow control instructions.
It provides graphical display of program execution by
showing power flow through ladder diagram, thereby
making it easier to debug.
Program is fast. It generates more readable for
sequence control.
Basic Ladder Logic Symbols:
A horizontal link along which Power can flow
(Press Alt + Right, Left, Up and Down)
Normally open contact (Press OK)
Normally closed contact (Press OK + Alt)
Output coil: if the power flow
to it is on then the coil state is on (Press OK)
In
Latch:
Used to hold the Supply during the ladder logic operation. I0
I1 Q0
Q0 (Latch)
When I0 is pressed Q0 get energized, the latch also get energized.Q0
will be turned off by pressing the I1 switch. (ie Closed to open ).
DAY 3
Day nine is fully working in PLC basic Programming
Logical AND
------[ ]--------------[ ]----------------( )
Key Switch 1 Key Switch 2 Door Motor
The above realizes the function: Door Motor = Key Switch
1 AND Key Switch 2
This circuit shows two key switches that security guards might use to
activate an electric motor on a bank vault door. When the normally
open contacts of both switches close, electricity is able to flow to the
motor which opens the door.
Logical AND with NOT
------[ ]--------------[\]----------------( )
Close Door Obstruction Door Motor
The above realizes the function: Door Motor = Close
door AND NOT(Obstruction).
This circuit shows a pushbutton that closes a door, and an obstruction
detector that senses if something is in the way of the closing door.
When the normally open pushbutton contact closes and the normally
closed obstruction detector is closed (no obstruction detected),
electricity is able to flow to the motor which closes the door.
Logical OR
--+-------[ ]-------+-----------------( )
| Exterior Unlock | Unlock
| |
+-------[ ]-------+
Interior Unlock
The above realizes the function: Unlock = Interior
Unlock OR Exterior Unlock
This circuit shows the two things that can trigger a car's power door
locks. The remote receiver is always powered. The lock solenoid gets
power when either set of contacts is closed.
Industrial STOP/START
In common industrial latching start/stop logic we have a "start" button
to turn on a motor contactor, and a "stop" button to turn off the
contactor.
When the "start" button is pushed the input goes true, via the "stop"
button NC contact. When the "run" input becomes true the seal-in
"run" NO contact in parallel with the "start" NO contact will close
maintaining the input logic true (latched or sealed-in). After the
circuit is latched the "stop" button may be pushed causing its NC
contact to open and consequently the input to go false. The "run" NO
contact then opens and the circuit logic returns to its quiescent state.
--+----[ ]--+----[\]----( )
| start | stop run
| |
+----[ ]--+
run
-------[ ]--------------( )
run motor
P.L.C Ladder logic
Ladder diagram description
Ladder diagrams and Boolean mnemonics’ are considered
basic languages. These basic languages are instruction sets that
perform the most fundamental control operations, such as On-Off
relay switching, timing, and Counting. The Functional Block and
English statements are considered high-level languages. These are
capable of executing more sophisticated control operations than the
basic languages, such as analog control, diagnostics. And report
generation.
The display unit ‘DO’ has the internal setting as follows
DO LO A
TRG XOO YO
[00] CHR
[UVW] [VOLTAGE HIGH]
Here the DO specifies the display unit executed by the PLC.
LO specifies the logical operation such as AND or OR LOGIC.
TRG represents whether the trigger is required or not.
XOO, YO gives the row and column position.
[OO] represents the Bit level of character.
CHR is the character specification.
Similarly the display units
D2- low voltage
D3 - current overload,
D4- temperature high
D5- speed high
are used for displaying the various parameter faults.
The timer ‘TO’ have the following internal settings.
TO X S A
TRG
RES 05.01
TO-timer
TRG-trigger
RES-reset
This reset option is used for giving the light indication after 5 seconds
of the fault.
The timer ‘T1’ has the following internal settings.
T1 S A
TRG
RES 10.01
This timer is used for giving the alarm after the fault has occurred and
continued up to 10 seconds from the time of fault occurrence.
The PLC comparator has the internal comparison setting as follows.
Ao
I4v >= 02.8v
This is used for giving the preset value as [Link] I4 input is used to
get the present value of temperature in terms of voltage.
The timer ‘T2’is used for giving one shot trigger in continuous
interval of time.
T2 O S A
TRG
RES 02.01
O represents one-shot trigger.
DAY 4
Day 10 is we working practical in PLC in ladder logic. Timer,
Counter, Display program in design and verify the output in PLC
OMRAN model.
DAY 5
This day we are design in ladder logic in Computer software in
Siemens and OMRAN the logic design and output verify.
DAY 6
Day 12 is control working of control devices in Relay, Circuit
breaker, TRAIC control circuit, MOSFET based inverter. We are
learning theory and working practical.
DAY 7
We working Circuit design software layout to convert Copper board.
Every industrial based drive circuit is design in PCB software. The
software layout is very difficult to design in copper board. This one of
the way in layout to PCB circuit making. The software layout is
printing the lasers printer.
