Fundamentals of Industrial Automation

Fundamentals, Components, Process measurement, Programming, Communication, Process control.

DATE: 28/03/2025

Submitted By :
ATHULRAJ K M
Industrial Automation
Industrial automation is the use of technology, like computers, robots, and
control systems, to automate industrial processes and machinery, aiming
to improve efficiency, quality, and safety while reducing human
intervention.
 SAP S/4 HANA, Oracle ERP

PAS-X, AVEVA, Siemens Opcenter, Sap MES

Ignition, Wonderware(AVEVA), Siemens WinCC

SAP S/4 HANA, Oracle ERP

SAP S/4 HANA, Oracle ERP

Programmable Logic Controller (PLC)
A programmable logic controller is a type of tiny computer that can receive data through its inputs
and send operating instructions through its outputs. Fundamentally, a PLC’s job is to control a
system’s functions using the internal logic programmed into it. Businesses around the world use
PLCs to automate their most essential processes.

Ref: https://www.youtube.com/watch?v=g-XfoK-Og5c
PLC scan cycle
In general, a PLC scan cycle is a
repeatable list of executable tasks. The
list can vary in size and the tasks can
vary in nature, and the cycle time varies
based on performance and configuration.

Ref: https://instrumentationtools.com/understanding-the-scan-cycle-of-siemens-plc/
https://theautomization.com/plc-working-principle-and-plc-scan-cycle/
IEC 61131-3 standard programming
language for PLCs.
1. Ladder Diagram (LD): A graphical language that uses a ladder-like structure
to represent logic, similar to traditional relay ladder logic.
2. Sequential Function Chart (SFC): A graphical language used for describing
and implementing sequential control processes.
3. Function Block Diagram (FBD): A graphical language that uses function
blocks to represent logic, allowing for modular and reusable code.
4. Structured Text (ST): A textual, high-level programming language similar to
languages like Pascal or C.
5. Instruction List (IL): A textual, low-level language that uses a list of
instructions.
What is Control Systems?
A control system is a set of devices that are used to build a system that
generates the desired output.

Ref: https://instrumentationtools.com/feedback-control-system/
https://easytrical.wordpress.com/2015/05/19/comparison-of-open-loop-and-closed-loop-systems/
 Components of Automation Systems
Component Function Example
Sensors Detects physical changes Temp: PT00, Pressure: PT03, Flow: YF-S201

Actuators Converts signals into action Motors, Valves, Solenoids

Controllers Processes logic & decisions PLCs, DCS, Industrial PCs

HMI User interface for control Touchscreens, SCADA Displays

SCADA Supervisory control, monitoring Remote Control Systems

Communication Connects system components Modbus, Profibus, OPC UA

Power Supply Provides energy to components 24V DC Power, UPS

Robotics & AI Automates complex tasks Industrial Robots, AI Systems

Control Signals
In industrial automation, standard signals include analog signals (4-20mA current and 0-10V
voltage) and digital signals (like ON/OFF states), each used for different purposes in controlling
and monitoring processes.

Ref: https://instrumentationtools.com/what-are-analog-and-digital-signals-differences-examples/
Scaling of analogue signals
Analogue signal scaling refers to the process of converting or assigning analogue signals to specific values
that can be interpreted a PLC or a control system.

For example:

An analogue signal from a temperature sensor might range

from 0 to 10V, where 0V corresponds to -20°C, and 10V
corresponds to 100°C.

The mapping allows the control system to understand the

input and take the necessary action, such as adjusting a
heating or cooling process. Temp = (mA output – mA min) * [(max Temp – min Temp) / (mA max – mA min)] + min Temp

Essentially, analogue signal mapping helps the system

interpret real world physical values in a way that can be
used for control and automation.
Ladder Logic
PLC Ladder logic is a programming language used with PLCs.
Abbreviated as LD, it is also known as a ladder diagram, and it is one of the
most widely used visual programming languages for PLCs.

Here's a more detailed explanation:

• Rungs:
Ladder logic consists of "rungs" (horizontal lines) that represent logical conditions.

• Left to Right:
Each rung is evaluated from left to right.

• Top to Bottom:
The PLC's CPU scans the ladder logic programme rung by rung, top to bottom.

• Inputs and Outputs:

Inputs (contacts) represent the status of sensors, while outputs (coils) represent
the actions the PLC will take.

• Logic Flow:
The PLC evaluates the logic on each rung, and if the conditions are met, the
REF: https://www.edrawmax.com/article/ladder-diagram-symbols.html
Ladder Diagram Symbols Explained
Symbol Name Description
When the condition is true, then the contact is closed and the output logic flow is
Normally Open Contact (NO) Symbol enabled. When the condition is FALSE, then the contact is OPEN and the output
logic flow is blocked.
When the condition is true, then the contact is OPEN and the output logic flow is
Normally Closed Contact (NC) Symbol blocked. And when the condition is FALSE then the contact is CLOSED and output
logic flow is enabled.
When the input condition is true then the timer begins. And when the present
Timer Delay on Symbol time set point has been reached the output turns ON. If the input condition goes
FALSE at any stage, the timer stops and the output is OFF.

When the input is true, then the output turns ON. If the input condition goes
Timer Delay off Symbol
false, the timer begins, and when the preset time set point has been reached the
output turns OFF. If the input condition goes TRUE, at any stage, the timer stops
and the output turns ON as well.
A PID Controller is used to control the process value. The process variable is
PID Controller measured from the primary element (Input), and the output is manipulated to
maintain the process variable value at the set point input value.
When input is True from False, then the counter increases by 1 from the last
Counter Up stored value. When this stored value reaches the preset value, the output will go
True and the stored value is set again to 0.
When input is True from False, then counter decreases 1 value from the last
Counter Down stored value. When this stored value reaches 0 value, the output will go True and
the stored value is set again to preset value.
Industrial Communication Protocol
PLC communication protocols are sets of rules that define how data is
transmitted and received between PLCs and other devices in
industrial automation systems, enabling communication and control.
Common protocols include Modbus, Profibus, Ethernet/IP, PROFINET
and OPC-UA.
Networks, Nodes and Topologies
• Network: An interconnected group of computers and/or controllers,
and devices that interact with computers and controllers.

• Node: A computer or other device in a network.

• Topology: It refers to the type of network being implemented.

Ex. Line, Tree, Star and Ring
Network Topology
Bus Topology: All devices share a single communication line,
and data travels in both directions.

Point-to-Point Topology: A direct connection between two

devices for dedicated communication.

Ring Topology: Devices are connected in a circular manner, and

data travels in one or both directions.

Star Topology: All devices connect to a central hub or switch,

making communication efficient.

Tree Topology: A hierarchical structure with multiple star

networks connected to a central backbone.

Hybrid Topology: A combination of two or more different

network topologies for flexibility and scalability.
Industrial Process Control - PID
A PID (Proportional-Integral-Derivative) Controller is a closed-loop control system used in industrial
automation to maintain a desired output by continuously adjusting control inputs based on error
values. It consists of three components:
Proportional (P): Reacts to the current error by applying a
correction proportional to the magnitude of the error. A
higher gain results in faster response but may cause
oscillations.

Integral (I): Addresses accumulated past errors by summing

them over time, eliminating steady-state errors but
potentially causing overshoot.

Derivative (D): Predicts future errors by considering the rate

of change, improving stability and reducing overshoot.

By tuning these parameters, a PID controller ensures

accurate and stable system performance in applications like
temperature control, robotics, and process automation.

Ref: https://ctms.engin.umich.edu/CTMS/index.php?example=Introduction&section=ControlPID
A PLC PROGRMME and SIMULATION
I have created a PLC program using Ladder Logic for a can filling system and tested it using
Simumatik.
1. Press the Start button on the HMI to begin the process.

2. The stopping plate moves back, and a can drops onto the first
conveyor.

3. The first conveyor starts when its first sensor detects the can.

4. The can moves forward until it reaches the filling station, detected
by the first sensor of the third conveyor.

5. The conveyor stops, and the actuator holds the can in place.

6. The filling system starts and fills the can for 5 seconds.

7. The actuator releases the can, and the conveyor starts moving again.

8. The can moves forward, and a new can drops onto the conveyor.

9. The process repeats for the next can.

Bottle filling system using CODESYS
and Simumatik
Please click the link below ….
Google Drive Link Click Here
Shared Folder Click Here