ppt presentation on industrial automation by raj nayak

S. R. THERMONIX TECHNOLOGIES

PPT PRESENTATION BY RAJ NAYAK

S. R. THERMONIX TECHNOLOGIES

Existing for the last 2 YearsExecutes projects of Full Power Plant Solution for all types of Industries Imparts automation training to Engineers & engineering professional Imparted training to more than 5000 fresh engineers & 100 professionals

Email: [email protected] Contact: +91-8527695764

mailto:[email protected]

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

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.

Products produced more reliably robots can run 24 hours/day without getting tired or bored

Decreased labor expenses 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 Email: [email protected] Contact: +91-8527695764


HISTORY OF AUTOMATION

Pneumatic ControlHard wired logic Control

Electronic Control using Logic Gates

Programmable Logic Controller

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 CONTROLIndustrial 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

Drawbacks

•Reduced space requirements•Energy saving•Less maintenance & greater reliability

•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, timersCounters and contactors.

3. The very first plc was developed by modicon in later 1965.



ADVANTAGES OF PLC1. Reliability in operation. 2.Flexability in control techniques3.Flexibility in Programming and Reprogramming in the Plant4. Large quantity of contacts5. Online offline modifications6. Cost effective for controlling complex system7. Small Physical size and shorter project time8. Speed in operation9. Ability to communicate with computer in the plant10. Ease of maintenance/ troubleshooting11. Documentation12. Security



BLOCK DIAGRAM OF PLC



BASIC PARTS OF PLC

Input Module Output Module CPU (central processing unit) Power Supply Communication Bus



INPUT TO PLCInput to the plc may be of following 1. Discrete/Digital input 2. Analog inputDiscrete/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 PLCOutput of the PLC may be of following1. Discrete/Digital output2. Analog outputDiscrete/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 0-10Volts. Control valve, servo/stepper motors are the

examples of analog outputs.Email: [email protected] Contact: +91-8527695764


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

Programming Terminal

O:0/7

O:0/7

O:1/5

Output Devices

Output ModulesProcessor MemoryInput Module

Input DevicesLadder Program

O:0/7

O:1/5

I:0/6

I:1/4

O:1/5

I:0/6

I:1/4

I:0/6

I:1/4

Data InputImage Table

OutputImage Table

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 :

Ladder Diagram Instruction List Function Block Diagram Sequential Function Chart Structured Text

CLASSIFICATION OF PLC1.Depending upon the Physical assembly a. Compact Type b. Compact + Modular Type c. Modular Type2. 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. Automation at Home Security2. Automation at Bottling Plant3. Automation at Coal Unloading4. Robotic Arm Controlling5. Brewing Batch Controlling6. Conveyor UPS Controlling



INDUSTRIAL AUTOMATION COMPONENTS

Field Instruments Control Hardware Control Software



Sensors Placed in the field

Automation : Typical installation . . . .

Junction Box

Field Cabling

Control PanelControl Hardware

SCADA Software

Communication Cable

Field Cabling

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 systemApplied 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 S. R. Thermonix will Help You

Fortunately you have S. R. Thermonix Technologies 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



ANY QUERY ?Email: [email protected] Contact: +91-8527695764


ppt presentation on industrial automation by raj nayak

Engineering