Transcript plc[programmable logic controller]

ETAS PVT. LTD.
SEMINAR
PRESENTED
BY
ER. KAILASH TIWARI
ET AUTOMATION SERVICES
(AN ISO 9001-2008)
Existing for the last 2 Years
Executes Automation projects for all types of
process & manufacturing industries
Imparts automation training to Engineers /
engineering professional
 Imparted training to more than 5000 fresh
engineers & 100 professionals
WHAT IS AUTOMATION ?
Automation is basically the delegation of human control function
to technical equipment to automate the systems that produce
their goods or services in the most efficient manner
possible.
BENEFITS OF INDUSTRIAL AUTOMATION

Increasing Productivity

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Increased productivity = more units/day = more money
Products produced more consistently
increased consistency = higher quality = increased consumer
satisfaction
 Example - A bottled soft drink such as a Coke or a Pepsi
always tastes the same no matter where or when you purchase
it. Consumers count on this.

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Products produced more reliably


Decreased labor expenses


robots can run 24 hours/day without getting tired or bored
Automated systems reduce the amount of people needed to
produce the goods
Increasing Safety in working conditions
USE OF INDUSTRIAL AUTOMATION
Automation is encompassing virtually every
walk of life.
Automation solutions are required right from
agricultural to space technology.
Plant Automation is the necessity for the
manufacturing industry to survive in today’s
globally competitive market
HISTORY OF AUTOMATION
Programmable Logic Controller
Electronic Control using Logic Gates
Hard wired logic Control
Pneumatic Control
Manual Control
MANUAL CONTROL
All
the actions related to process control are taken by the
operators
Drawbacks
Likely
human
errors
and
consequently its effect on quality of
final product

The
production,
safety,
energy
consumption and usage of raw material
are all subject to the correctness and
accuracy of human action.

PNEUMATIC CONTROL
Industrial
automation, with its machine and process control, had its origin in
the 1920s with the advent of "Pneumatic Controllers".
Actions
were controlled by a simple manipulation of pneumatic valves, which in
turn were controlled by relays and switches.
Drawbacks
• Bulky and Complex System
• Involves lot of rework to implement control logic
• Longer project time
HARD WIRED LOGIC CONTROL
The
contactor and Relays together with hardware timers and
counters were used in achieving the desired level of automation
Drawbacks
• Bulky panels
• Complex wiring
• Longer project time
• Difficult maintenance and troubleshooting
ELECTRONIC CONTROL USING LOGIC GATES
In 1960s with the advent of electronics, the logic gates started
replacing the relays and auxiliary contactors in the control
circuits.

The
hardware timers & counters were replaced by electronic
timers
Advantages
•Reduced space requirements
•Energy saving
•Less maintenance & greater reliability
Drawbacks
•Changes in control logic not possible
•More project time
PLC[PROGRAMMABLE LOGIC CONTROLLER]
1. PLC is a solid state/ computerized industrial computer that
performs discrete or sequential
logic in the factory environment.
2. These are originally developed to
replace mechanical relays, timers
Counters and contactors.
3. The very first plc was developed
by modicon in later 1965.
ADVANTAGES OF PLC
1. Reliability in operation.
2.Flexability in control techniques
3.Flexibility in Programming and
Reprogramming in the Plant
4. Large quantity of contacts
5. Online offline modifications
6. Cost effective for controlling complex system
7. Small Physical size and shorter project time
8. Speed in operation
9. Ability to communicate with computer in the plant
10. Ease of maintenance/ troubleshooting
11. Documentation
12. Security
BLOCK DIAGRAM OF PLC
BASIC PARTS OF PLC


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

Input Module
Output Module
CPU (central processing unit)
Power Supply
Communication Bus
INPUT TO PLC
Input to the plc may be of following
1. Discrete/Digital input
2. Analog input
Discrete/Digital input:

A Discrete/Digital input is an input that has either ON( means closed
or1) or OFF( means open or 0) condition.
for examples : Push buttons, Toggle switches, Limit switches ,
proximity switches.
Analog input:

An Analog input is an input that has a continuous signal that may
vary from 4-20 mamp. Or 0-10 volt.
for examples: temperature, pressure, flow& level sensors are analog
input to PLC.
OUTPUT OF PLC
Output of the PLC may be of following
1.
Discrete/Digital output
2.
Analog output
Discrete/Digital output:
 A Discrete output is an output that is either in ON or
OFF condition.
 Solenoid coil, Indicator lamps, Alarm, Relay coils are
examples of discrete outputs.
Analog output:
 An Analog output is a output that has a continuous
signal that may vary from 4-20 mamp. Or 0-10 volt.
 Control valve, servo/stepper motors are the examples
of analog outputs.
CENTRAL PROCESSING UNIT


It is a micro-processor based circuitry. The
CPU consists of following blocks :
1. Arithmetic Logic Unit (ALU), Program
memory
2. Process image memory (Internal
memory of CPU)
3. Internal timers and counters
4. Flags
CPU performs the task necessary to fulfill
the PLC
functions. These tasks include Scanning,
I/O bus traffic control, Program execution,
Peripheral
and
External
device
communication, special functions or data
handling execution and self diagnostics.
POWER SUPPLY



The power supply gives the voltage
required for electronics module (I/O Logic
signals, CPU, memory unit and peripheral
devices) of the PLC from the line supply.
The power supply provides isolation
necessary to protect the solid state devices
from most high voltage line spikes.
As I/O is expanded, some PLC may require
additional power supplies in order to
maintain proper power levels.
COMMUNICATION BUS SYSTEM


It is path for the transmission of the signal . Bu system is
responsible for the signal exchange between processor and
I/O modules
The bus system comprise of several single line ie wires /
tracks
PLC SIGNAL FLOW
Input Module
Processor Memory
Output Modules
Data Output
Input
Image Table
Image Table
I:0/6
O:0/7
I:0/6
O:0/7
I:1/4
O:1/5
Input Devices
Output Devices
Ladder Program
I:1/4
I:0/6
O:0/7
I:1/4
O:1/5
O:1/5
Programming Terminal
PLC PROGRAMMING STANDARDS
The open, manufacturer-independent programming
standard for automation is IEC 61131-3. You can thus
choose what configuration interface you wish to use when
writing your application :
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Ladder Diagram
Instruction List
Function Block Diagram
Sequential Function Chart
Structured Text
CLASSIFICATION OF PLC
1.Depending upon the Physical assembly
a. Compact Type
b. Compact + Modular Type
c. Modular Type
2. Depending upon the no. of I/Os
a. small(<100)
b. medium(<10000)
c. large(>10000)
3. Depending upon the I/Os supported
a. Digital
b. Analog
VARIOUS BRANDS OF PLC

Allen Bradley ………………………………..USA

Siemens
…………………………Germany

Modicon
……………………………France

Mitshubishi
……………………………..Japan

GE Fanuc
………………………………..USA

Omron
……………………………..Japan
FEW MORE EXAMPLES OF AUTOMATION
1.
2.
3.
4.
5.
6.
Automation at Home Security
Automation at Bottling Plant
Automation at Coal Unloading
Robotic Arm Controlling
Brewing Batch Controlling
Conveyor_UPS Controlling
INDUSTRIAL AUTOMATION COMPONENTS



Field Instruments
Control Hardware
Control Software
Automation : Typical installation . . . .
SCADA Software
Communication Cable
Control Hardware
Control Panel
Field Cabling
Junction Box
Field Cabling
Sensors Placed in the field
SENSORS ( FIELD INSTRUMENTS )
Sensors with transmitters are the field devices
placed in the field who actually sense the
parameter and send the analog signal to the control
hardware.
The analog signals used are Ohm (RTD), mV
(Thermocouple), 4-20 mA, +/-10 V, etc
ROLE
OF
ENGINEERS IN INDUSTRIAL AUTOMATION
Designing of the Automation system
 Erection and Commissioning
 Maintenance and Troubleshooting of existing
system
Applied Engineers

Job Prospect for Fresher
Today management of almost all
manufacturing units are going for industrial
automation to survive in globally competitive
market. Most of these industrial units are
looking forward for trained engineers in the
field of industrial automation.
Since they are thinking about more accuracy,
productivity in less time & with minimum
manpower , It’s a
golden opportunity to
prepare yourself to take on this task.
JOB PROSPECTS FOR ENGINEERS

Manufacturing Industries like Reliance, Ceat, Godrej,
Colgate ….
Automation Solution Products manufacturer/developer like Rockwell, Siemens,
Grouppe Schneider, Yokogawa, ABB


System Integrators for Grouppe Schneider Rockwell, Siemens, etc

Consultants for Automation
Current Situation
Automation is a high growth sector globally hence it is
essential to all professionals and students to have practical
knowledge about the hardware and software used in
Industrial Automation.
How ETAS will Help You
Fortunately you have ETAS with you. Our practical and
professional training courses in diversified hardware and
software used in Industrial Automation are designed to fill
the vacuum between your practical knowledge and industry
demands.
Hundreds of Individuals have benefited by our courses.
They have increased their technical knowledge, thus leading
to better job opportunity.
THANK YOU FOR LITENING
ME
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