WHAT IS AUTOMATION

Delegation of Human Control functions to technical Equipment aimed towards

achieving .

 Higher productivity
 Superior quality of end product
 Efficient usage of raw materials and energy
 Improved safety in working condition .
HISTORY OF CONTROL AND AUTOMATION

MANUAL CONTROL

HARDWIRED LOGIC
CONTROLS

ELECTRONICS CONTROL
WITH LOGIC GATES

PLC
MANUAL CONCEPTS

In This, The Control and Automation are done by Manual Operations

The Major Drawbacks are,

Human Errors Subsequently affect quality of end product

HARD WARE LOGIC CONTROLS

In This, Contactor and relays together with timers and counters were used in

Achieving desired level of automation.

 The Major Drawbacks are,

 Bulky and Complex Wiring.

 Involves lot of rework to implement changes in control logic.

 The Work can be started only when the takes is fully defined and this leads
To longer project time.

ELECTRONICS CONTROL WITH LOGIC GATES

In This, Contactor and relays together with timers and counters were replaced with

Logic gates and electronic timers in the control circuits.

The Major Benefits :

 Reduced Space Requirements.

 Energy Saving.

 Less Maintenance and Hence Greater reliability

The Major Drawbacks :

Implementation of changes in the control logic as well as reducing the project

lead-time was not possible.

 PROGRAMMABLE
LOGIC
CONTROLLER

Definition :

A Plc can be defined as in industrialized computer that includes the hardware

and software required to automatically control production equipment ,machinery
,processes ,
And other types of mechanical ,electrical ,and electronics devices typically found in
industry.
It also includes the flexibility to reprogram the software as often as needed . The plc is the
Key element behind today ‘s industrial automation.
 Plc uses:
Most likely you encounter plc based controls every day
without event realization it .where ? In simple
applications such as car industry ,car washes, elevators,
Food industry ,amusement parks to more complex
applications such as…

Amusement
parks

Car washes

Car industry

Food
industry

Elevators
 and more:
Water and Waste Water treatment plats ,
manufacturing assembly line , machinery ,and bottling
line ,Oil and Gas.

Oil and Gas

Water treatment plants

Assembly line

Bottling lines
machinery
The Major Benefits :

 Reduce Space
 Energy
Saving
 Easy of Maintenance

 Modular Replacement, easy Trouble Shooting, error Diagnostics programmer

 Short Project Time
 Tremendous Flexibility
 Greater Life and reliability

 Economical
The Compatibilities of PLC’S:

 Logic Control

 PID Control
 Coordination and Communication

 Operator Control
 Signaling and Listing
Examples of Industries where PLC’S are Used for Control and Automation Purpose :

 Oil and Gas

 Water treatment plant

 Robotics

 Power generation

 Automobiles

 Steel Plants

 Printing Industry
 PLC HISTORY:

Although PLCs evolved concurrently by different

organizations, it is recognized as first being introduced by Bedford Associates in
1968.It was the product of choice to meet GM’s Hydra –Matic Division’s
specifications as a replacement for traditional relay –based machine control
systems. The Modicon as it was called ,being
An electronic device, also allows quicker to the equipment’s control behavior.
 WHAT DO THE INDIVIDUAL WORDS MEAN?
IT MAY MAKE MORE SENSE TO LOOK AT THE WORDS IN REVERSE
ORDER.

CONTROLLER-
This is the key word. A PLC monitors various conditions, and based on these
conditions, it determines an outcome . In other words it has the ability to ‘
control ’ the outcome based on the status of different inputs such as sensors ,
switches,& numeric values from analog signals etc.

LOGIC- How the PLC determines an outcome is based on the logical rules it has
been taught. A simple example: it is night time ,AND the door is open then
turn on the light .

PROGRAMMABLE: The PLC is taught the rules to how it should use the input
conditions to create an outcome though its programming software. Being
programmable makes it versatile ,so or conditions change , the PLC be
reprogrammed to meet these changes.
 PLC I/O:

The input and output connections interface to the real world devices as seen in
the schematic example. Conditions and status of the inputs are monitored ,
decisions made by the user’s control program executing via the CPU, and
outputs activated based on the outcome.
 PLC OVERVIEW
Four internal areas:
 CPU - Decision making , controls other areas.

 MEMORY - User’s control program stored in nonvolatile

section of memory . Also I/O status & data is kept in memory.

 COMMUNICATIS PORTS - Load user’s program from PC ,

also exchange data with external devices, including other PLCs.

 INPUT/OUTPUT- handles interface of signals to real world devices.

 PLC LADDER LOGIC:

A PLC is programmed using application software running on a PC .The most

widely used programming method , carried over from relay-based control
systems, is Ladder Logic. Made up of contacts , coils , and other functions that
are arranged as rungs on ladder.
Shown here is a simple example of three ladder logic rungs . Externally wired
input ‘X001’ OR internal control relay ‘C1’ actives output ‘Y001’,which is
wired to a real world device . The ‘END’ coil tells the program ‘scan’ to start
over.
 PROGRAM SCAN:

It is helpful when programming a PLC to

understanding how the Ladder Logic program is
‘scanned’. Once the PLC is in RUN mode ,the CPU
executes in the order shown in the flow diagram.

 Status of the inputs devices are read and stored in

data registers.

 Housekeeping of any peripheral devices.

 ‘Scan’ the user’s ladder logic left to right , sequencing

through the ‘rungs’.

 Compute the results and write updates to the outputs.

 Do diagnostics and if all is well . repeat the scan.

 PLC INPUTS:

are devices that supply a signal/data to a PLC.

Typical examples of inputs are push buttons, switches, and measurement
devices.
Basically, an input device tells the PLC, "Hey,
something’s happening out here…you need to check this out to see how it affects the
control program."
 DIGITAL INPUTS

A discrete input, also referred to as a digital input, is an input that is either in an ON or

OFF condition.

Pushbuttons, toggle switches, limit switches, proximity switches, and contact

closures are examples of discrete sensors which are connected to the PLCs discrete or
digital inputs.

In the ON condition a discrete input may be referred to as a logic 1 or a logic high. In the
OFF condition a discrete input may be referred to as a logic 0 or a logic low.
 DIGITAL OUTPUT

A discrete output is an output that is either in an ON or OFF condition.

Solenoids, contactor coils, and lamps are examples of actuator devices connected
to discrete outputs. Discrete outputs may also be referred to as digital outputs.
In the following example, a lamp can be turned on or off by the PLC output it is
connected to.
 ANALOG INPUT

is a continuous, variable signal. Typical analog inputs may vary from 0 to 20

milliamps, 4 to 20 milliamps, or 0 to 10 volts. In the following example, a level transmitter
monitors the level of liquid in a tank.
Depending on the level transmitter, the signal to the PLC can either increase or decrease as
the level increases or decreases.
 ANALOG OUTPUTS

is a continuous, variable signal.

The output may be as simple as a 0-10
VDC level that drives an analog meter.
Examples of analog meter outputs are speed, weight, and temperature.
The output signal may also be used on more complex applications such as a
current-to-pneumatic transducer that controls an air-operated flow-control valve.
LOGIC GATE AND LADDER DIAGRAM
LOGIC GATE AND LADDER DIAGRAM
 TIMERS

Timers are represented by boxes in ladder logic.

When a timer receives an enable, the timer starts to time.
The timer compares its current time with the preset time. The output of the timer
is a logic 0 as long as the current time is less than the preset time.
When the current time is greater than the preset time the timer output is a logic
three types of timers:

1.On- Delay (TON),

2.Retentive On-Delay (TONR), and
3.Off-Delay (TOF).
 COUNTERS
Three type of counters

1.Up Counter.
2.Down Counter.
3.Up/Down Counter.
Up/Down Counter

Down Counter

Up Counter: