Introduction to Industrial

Automation
Dr. Swati Madhe, Prof. Manisha Narwane
Instrumentation and Control Department,
Cummins College of Engineering, Pune
INDUSTRIAL REVOLUTIONS
Introduction
● Industrial automation of a plant/process is the application of the process control and information
systems.
● Industrial automation is a vast and diverse discipline that encompasses process, machinery,
electronics, software, and information systems working together
What is Automation?
• The technology by which a process or procedure is
accomplished without human intervention.
• Industrial automation is a vast and diverse discipline that
encompasses process, machinery, electronics, software,
and information systems working together toward a
common set of goals – increased production, improved
quality, lower costs, and maximum flexibility.
Automation Technology Includes….
● Automatic assembly machines
● Feedback control and computer process control
● Computer system for planning, data collection, and
decision making to support manufacturing activities.
● Do the process control and demonstrate the excellence in
the regulatory and discrete control.
Reason For Automating
● To increase labour productivity
● To reduce labour cost
● To improve worker safety
● To improve product quality
● To mitigate the effects of labour shortages
● To reduce/eliminate routine manual & clerical tasks.
● To reduce mfg. lead time
● To accomplish processes that cannot be done
manually
Results of successful automation:

• Consistency:
• Reliability:
• Lower costs:
• Flexibility:
Automation Pyramid
Field Level
● The field level is the production
floor that does the physical work
and monitoring.
● Electric motors, hydraulic and
pneumatic actuators to move
machinery, proximity switches
used to detect that movement or
certain materials, photoelectric
switches that detect similar things
will all play a part in the field level.
Field Level Devices
 Control Level
● The control level PLC, PID and other
controllers to control and “run” the
devices in the field level that actually
do the physical work.
● They take in information from all of
the sensors, switches, and other input
devices to make decisions on what
outputs to turn on to complete the
programmed task.
Supervisory Level

● SCADA(Supervisory Control and

Data Acquisition System) is
essentially the combination of the
previous levels used to access
data and control systems from a
single location.
● It usually adds a graphical user
interface, or an HMI, to control
functions remotely.
● The important thing to remember
about SCADA is that it can monitor
and control multiple systems from
a single location.
Planning Level
● This level utilizes a computer
management system known as MES
or manufacturing execution system.
● MES monitors the entire
manufacturing process in a plant or
factory from the raw materials to the
finished product.
● This allows management to see
exactly what is happening and
allows them to make decisions
based on that information. They can
adjust raw material orders or
shipment plans based on real data
received from the systems we talked
about earlier.
Management Level
● Utilize the companies integrated
management system-ERP or
enterprise resource planning.
● This is where a company’s top
management can see and control
their operations.
● This allows the business to be able to
monitor all levels of the business
from manufacturing, to sales, to
purchasing, to finance and payroll,
plus many others.
● The integration of the ERP promotes
efficiency and transparency within a
company by keeping everyone in the
same page.
Types of Automation
● Hard Automation:
○ Controllers are built for specific purposes and could
not be altered easily.
○ Modification is time consuming and expensive.
○ Modifications can be done only when equipement sits
idle.
Types of Automation
● Soft Automation:
○ Reprogrammable
○ It is possible to reprogram and test them while they
work.
○ Lost time while hardware change is less than hard
automation.
Types of Automated Manufacturing System:
● Fixed Automation:
○ A system which the sequence of processing of
operation is fixed by the equipment configurations.
○ Each operation in the sequence is usually simple.
○ High initial investment
○ High production rates
○ Inflexible
○ Example: Automated assembly machines
Flexible Automation
● An extension of programmable automation.
● Capable of producing a variety of parts/products with
virtually no time lost for changeovers from one part style to
the next.
● Examples, flexible manufacturing systems for performing
machining operations.
The Features of Flexible Automation:
● High investment for custom engineered system.
● Continuous production of variable mixtures of products.
● Medium production rates.
● Flexibility to deal with product design variations.
Types of Automated Manufacturing System:
● Programmable Automation:
○ The production equipment is designed with the
capability to change the sequence of operations to
accommodate different product configurations.
○ New programs can be prepared and entered into the
equipment to produce new products.
○ Physical setup of the machine must be changed for
each new product. This changeover takes time.
○ Example: Numerical control tools, Batch production.
The Features of Programmable Automation:
● High investment in general purpose equipment.
● Lower production rates than fixed automation.
● Flexibility to deal with variations and changes in product
configuration.
Relationship Between Product Variety & Quantity
 Automation
AUTOMATION Tools
TOOLS Used in Industry
1.Programmable Logic Controller (PLC)
2.Human Machine Interface (HMI)
3.Supervisory Control and Data Acquisition (SCADA)
4.Distributed Control System (DCS) – Monitoring
networks
5.Artificial Neural Network (ANN) – Responsible in
processing information
6.Robotics
 PLC’s Are ...
● A modern controller device used extensively for sequence
control today in transfer lines, robotics, process control, and
many other automated systems.
● A special purpose industrial microprocessor based realtime
computing system, which performs the following functions:
− Monitor Input/Sensors
− Execute logic, sequencing, timing, counting functions for
Control/Diagnostics
− Drives Actuators/Indicators
− Communicates with other computers
 Evolution of PLC
● Before the advent of microprocessors, industrial logic and
sequence control used to be performed using elaborate
control panels containing
− electromechanical or solid-state relays
− contactors
− Switches
− indicator lamps
− mechanical or electronic timers and counters etc,
− all hardwired by complex and elaborate wiring.
 Advantages of PLC Over Conventional Control
Panel
● Programming the PLC is easier than wiring physical components
● Can be reprogrammed
● Require less space
● Installation and maintenance of PLCs is easier
● The PLC can be connected to a distributed plant automation system,
supervised and monitored.
● Any manufacturingApplications
application of PLC
that involves controlling
repetitive, discrete operations is a potential candidate for PLC
usage. Some typical industrial areas that widely deploy PLC
controls are

Chemical/ Petrochemical Metals Manufacturing/Machining

Batch process Blast Furnace Material Conveyors, Cranes

Pipeline Control Continuous Casting Assembly

Weighing, Mixing Rolling Mills Milling, Grinding, Boring

Finished Product Handling Soaking Pit Plating, Welding, Painting

Water/ Waste Treatment Steel Melting Shop Molding/ casting/forming

PLC Architechture
 CPU

CPU

Microprocessor Memory

System Memory Program Memory

CPU Memory
● System Memory:
− Flags ( internal relays), timers and counters
− Operating system data
− Process image for the signal states of binary inputs and outputs.
● Program Memory:
− User program is saved in program memory
− During each program scan, the processor reads the statement in the program memory
and executes the corresponding operations.

● The program and data needed for execution are stored in RAM or EPROM sub modules.
● These sub modules are plugged into the processors.
● Additional RAM memory modules can also be connected.
Input/Output Modules
● Digital Input Modules:
− convert the signals from the process(0-24v Dc) to the internal digital
signal level (5V or 3.3 V) of programmable controllers
● Digital Output Modules:
− convert the internal signal levels (5V or 3.3 V) of the programmable
controllers into the signal levels required externally by the process (0-
24v Dc)
● Analog Input Modules:
− convert the analog signals from the process into digital values which are
then processed by the programmable controller
Input/Output Modules
● Analog Output Modules:
− convert digital values from the programmable controller into the analog
signals required by the process.
● Special Purpose Modules:
− Include special units for
● High speed counting

● High accuracy positioning

● On-line self-optimizing control

● Multi axis synchronisation, interpolation

Programmer Unit
● Used to download programs into the program memory of the CPU.
● The external field programmers provide several software features that
facilitate program entry in graphical form.
● The programmers also provide comprehensive aids for debugging and
execution monitoring support logic and sequence control systems.
● Printer can be connected to the programmers for the purpose of
documenting the program.
Introduction to IEC 61131-3
What is IEC 61131-3?
• Define IEC 61131-3 as part of the broader IEC 61131 standard
which deals with programmable logic controllers (PLCs).
• Explain that it specifies programming languages and guidelines
for PLCs, aiming to standardize how PLCs are programmed and
operated globally.
Importance:
• Emphasize its role in ensuring interoperability between different
PLC systems and making programming more standardized and
efficient.
Objectives of IEC 61131-3

Standardization Goals:
Compatibility and Interoperability: Ensure different PLCs and
programming environments can work together.
Maintenance and Scalability: Make PLC systems easier to
maintain and scale by providing a standardized approach.
Support for PLCs: Facilitate the development and use of PLC
systems by providing a common framework for programming.
Structure of IEC 61131-3
Parts of the Standard:
General Overview: Description of the standard’s scope and its
application.
Definitions and Terminology: Explanation of key terms and
definitions used in the standard.
System Design and Application Considerations: Guidelines on
designing PLC systems and considerations for practical
implementation.
Programming Languages Defined in IEC 61131-3
Languages:
Ladder Diagram (LD): Graphical representation resembling relay
logic.
Function Block Diagram (FBD): Block-based visual language for
representing functions.
Structured Text (ST): High-level textual language similar to
programming languages like Pascal.
Instruction List (IL): Low-level textual language (note that this
language is deprecated in the latest revision of IEC 61131-3).
Sequential Function Charts (SFC): Graphical language for
managing sequences of operations.
Data Types and Variables

Standard Data Types:

• BOOL: Boolean values (true/false).
• BYTE: 8-bit integer.
• INT: 16-bit integer.
• REAL: Floating-point numbers.
• Variable Declaration and Usage:
• Show how to declare and use these data types in different
programming languages defined by IEC 61131-3.
Interfacing and Communication
Communication Standards:
Explain how IEC 61131-3 supports communication between PLCs
and other systems.
Data Exchange Protocols:
Overview of commonly used protocols like OPC (OLE for Process
Control) and Modbus, which enable data exchange between PLCs
and external systems.
Benefits of IEC 61131-3 Compliance

Advantages:
• Interoperability: Ensures different PLC systems can work
together seamlessly.
• Maintenance and Scalability: Simplifies system upgrades
and maintenance due to standardized programming
practices.
• Broader Acceptance: Facilitates adoption by providing a
universally recognized framework.
Common Implementations and Tools

Software Tools:
List examples of software tools and development environments
that support IEC 61131-3, such as Siemens TIA Portal or
Rockwell Studio 5000.

Case Studies:
Provide real-world examples of successful implementations to
illustrate practical applications of the standard.

INTERNATIONAL STANDARD IEC 61131-3 Manual:

https://d1.amobbs.com/bbs_upload782111/files_31/ourdev_56965
3.pdf
THANK YOU