Industrial Control Systems

Lecturer: Haytham Yassin

T.A: Omnia Ahmed

Date: 9 October 2023

Course Code: MENG426
With or Against Automation
Reasons for Automation

• Shortage of labor

• High cost of labor

• Increased productivity

• Lower costs
• reduced scrap rate
• lower in-process inventory
• superior quality
• shorter (compact) lines
Reasons for not automating

• Labor resistance
• Cost of upgraded labor
• Chrysler Detroit plant - 1 million hours
of retraining
• GM Wilmington assembly plant - $250
hours/person/year
• Initial investment
• Management of process
improvements
• Appropriate use of technology
• A systems approach to automation is
important
• Equipment incompatibilities
Skills shift

• What are the

main categories of
workforce skills?
 Skill Shift
Impact of Automation & AI of Future workforce

• Mckinsey & Company

• 5 main categories of Skills
• 25 skills were defined

Workforce Skill Model

• 25 skills were defined

Workforce Skill Model

• 25 skills were defined

Workforce Skill Model

Automation and AI will accelerate the shift in skills that the workforce needs
Automation and AI will accelerate the shift in skills that the workforce needs
Industry 4.0

Mass customization
References
• Programmable logic controllers: Frank d.
petruzella
• Programmable logic controllers: W. Bolton
Content
1. PLC Introduction & Overview
2. PLC Hardware Components and Applications
3. Number Systems & Codes
4. Fundamentals of Logic Operations
5. Basics of PLC Programming
6. Memory and PLC Programming Essentials
7. PLC Programming Basics
8. PLC Wiring Diagrams and Ladder Logic Programs
9. Programming Timers
10. Programming Counters
11. Program Control Instruction
12. Data Manipulation
13. Math Instructions
14. Sequence and Shift Register instructions.
15. PLC Installation, Practices, Editing, and Troubleshooting
Competency-based learning
Intended Learning Outcome
1. Understand PLC Fundamentals: Demonstrate a solid
understanding of PLC basics, including hardware components,
number systems, and logic operations.
2. Handling PLC Programming: Develop proficiency in PLC
programming, including ladder logic design, memory usage, and
program control instructions.
3. Efficiently Implement Timers and Counters: Create timer and
counter programs to manage timing and counting functions in
industrial control systems.
4. Data Handling and Math: Effectively manipulate data and apply
mathematical instructions within PLC programs.
5. Manage Sequences: Utilize sequence and shift register
instructions to control sequential processes and data shifting.
6. Install and Troubleshoot: Demonstrate the ability to install,
practice, edit, and troubleshoot PLC systems, ensuring reliable
industrial control.
Course Program Competencies
• A3: Develop and conduct appropriate experimentation and/or simulation,
analyze and interpret data, assess and evaluate findings, and use statistical
analyses and objective engineering judgment to draw conclusions.
• A4: Utilize contemporary technologies, codes of practice and standards, quality
guidelines, health and safety requirements, environmental issues and risk
management principles.
• A7: Function efficiently as an individual and as a member of multidisciplinary
and multi-cultural teams.

• B4 : Adopt suitable national and international standards and codes to: design,
build, operate, inspect and maintain mechanical equipment and systems

• C5: Design a mechatronic system using systems approach to meet a given

specification and requirements.
• C6: Integrate a wide range of analytical tools, techniques, equipment, and
software packages to design and develop mechatronic systems.
• C7: Exercise creative approaches to the analysis and solution of problems in
mechatronic engineering.
Grade Distribution
• Final Exam (Theoretical & Practical) 40
• Theoretical 30
• Practical 10
• Midterm (Theoretical & Practical) 20
• Theoretical 15
• Practical 5
• 3 Quizzes (Theoretical / Practical) Best of 3 total of 20
marks
• Lecture assignments & engagements 5
• Lab 15
• Reports , Assignments & Practical 10
• Professional attitude 5
Lecture -01Content
• Control Process
• Automation systems
• What is PLC?
• History of PLC
• PLC Advantages
• Parts of PLC - Hardware
• General Architecture of PLC
• I/O Incorporation into PLC
• Principles of Operation- PLC Operating
Cycle
Control Process: What does it mean
to control?
Control consists of some activities:
• Observe: the phenomena (speed of machine,
pressure of steam, temperature of water, etc.)

• Compute: (decide) the needed activity (growing or

reducing the amount of fuel ).

• Action: set the appropriate device (modify the setting

of fuel valves ).

During evolution machines became more powerful,

quicker, and more precise, thus human control doesn't
fit their tasks. It became necessary to control machines
with other machines. This control is the automation
Control Process
• Physical Quantity is sensed in the form of
small current/voltage e.g. Temperature,
Pressure, Flow, Level etc (Sensor)

• This Electrical Signal is amplified to a certain

level (Amplifier)

• Then amplified analogue output is converted

into digital form. (Analogue to Digital
Converter i.e. A/D)

• This digital output is fed to the controller of

the system to control the various physical
quantities with the help of different devices.
(PLC, Microcontroller, DSP etc…)
Control Process – Block Diagram
Amplified
Analogue output

Physical Quantity Amplifier A/D

(Temperature, Pressure etc..)

Digital

Controller
Analogue output (PLC, Microcontroller etc…)
in mA/mV

Control signals
Digital /Analogue

Devices
(Motors etc…)
Automation Systems
What’s meant by Automation

• Method of making a machine, a

process, or a system work without
being directly controlled by a person

It is a technology dealing with the

application of:
• Mechanical
• Electronics
• Computer-based systems
For the production of goods & and
services.
Automation Systems

Manually Controlled Systems

 Automation Systems
1. Controlled System components:
• Mechanical Components (conveyor belts,
arms, rotary discs, etc.)
• Actuators (motors, solenoid valves, relays,
heating elements, etc.)
• Sensors (tactile switches, opto-switches,
proximity switches, etc.)
2. Controller
• A unit that reads the state of the sensors
and activates the actuators according to
the control program
3. Control Panel
• Interface between the operator and the
system.
Buttons, switches, lamps, displays, touch
screens etc.
 What is PLC
• A digitally operating electronic Device which uses a
programmable memory for internal storage of
instructions

• Implement specific functions, such as logic,

sequencing, timing, counting and arithmetic

• Control various types of machines or process

through digital or analogue input/output. PLC Controlled System

• A Programmable Logic Controller (PLC) is a

microprocessor-based control system, designed for ABC ABC

use in an industrial environment, programmed to

sense, activate and control industrial equipment Control Panel
2
Start
1 3
Stop Run Empty Done
Size
History Of PLC
 History Of PLC – Old Rely Control System
• The early history of the PLC is fascinating!
• Started with a fifty foot long cabinet filled with
relays whose function in life is to control a
machine
• Wires run in and out of the system as the relays
click and clack to the logic
• Now imagine, there is a problem or a small design
change and you have to figure it all out on paper
and then shut down the machine, move some
wires, add some relays, debug and do it all over
again
• Imagine the labor involved in the simplest of
changes
• This is the problem that faced the engineers at the
Hydra-matic division of GM in the late 1960's
 History Of PLC
In 1968 the GM engineers developed a design criteria
for a "standard machine controller“ to replace relays
but it also had to be:
1. A solid-state system that was flexible like a
computer but priced competitively with a like
kind relay logic system.
2. Easily maintained and programmed in line with
the all ready accepted relay ladder logic way of
doing things.
3. It had to work in an industrial environment with
all it's dirt, moisture, electromagnetism and
vibration.
4. It had to be modular in form to allow for easy
exchange of components and expandability.
 History Of PLC
In 1968 the GM engineers developed a design criteria
for a "standard machine controller“ to replace relays
but it also had to be:
1. A solid-state system that was flexible like a
computer but priced competitively with a like
kind relay logic system.
2. Easily maintained and programmed in line with
the all ready accepted relay ladder logic way of
doing things.
3. It had to work in an industrial environment with
all it's dirt, moisture, electromagnetism and
vibration.
4. It had to be modular in form to allow for easy
exchange of components and expandability.
 Advantages of a PLC Control System
1. Eliminates much of the hard
wiring that was associated
with conventional relay control
circuits.
 Advantages of a PLC Control System
Increased Reliability:
• Once a program has been written
and tested it can be downloaded to
other PLCs.

• Since all the logic is contained in

the PLC’s memory, there is no
chance of making a logic wiring
error.
 Advantages of a PLC Control System
More Flexibility
• Original equipment manufacturers
(OEMs) can provide system
updates for a process by simply
sending out a new program.
• It is easier to create and change
a program in a PLC than to wire
and rewire a circuit.
• End-users can modify the program
in the field.
 Advantages of a PLC Control System
Lower Costs:
• Originally PLCs were designed to
replace relay control logic.

• The cost savings using PLCs have

been so significant that relay
control is becoming obsolete,
except for power applications.
 Advantages of a PLC Control System
Communications Capability:
• A PLC can communicate with other
controllers or computer
equipment.
• They can be networked
to perform such functions
as: supervisory control, data
gathering, monitoring devices and
process parameters, and
downloading and uploading of
programs.
 Advantages of a PLC Control System
Faster Response Time
• PLCs operate in real-time which
means that an event taking place in
the field will result in an operation
or output taking place.

• Machines that process thousands of

items per second and objects that
spend only a fraction of a second in
front of a sensor require the PLC’s
quick response capability.
 Advantages of a PLC Control System
Easier To Troubleshoot:
• PLCs have resident diagnostic and
override functions that allows
users to easily trace and correct
software and hardware problems.

• The control program can be

watched in real-time as it
executes to find and fix problems
PLC Parts
Parts of PLC - Hardware
Central Processing Unit (CPU):
• The 'brain' of the PLC,
executing logic and controlling
communication.
Input/Output (I/O) Section:
• Interface for connecting field
devices.
Power Supply:
• Supplies power to various
modules.
Programming Device:
• Used to enter the program
into the memory of the
processor.
Parts of PLC - Structure of a PLC (CPU Structure)

CPU consists of three main parts

• Processor
• Memory
• Power Supply
Parts of PLC - Structure of a PLC (CPU Structure)

 This figure illustrates a simplified version of a microprocessor, which represents the heart of
a microcomputer.
 A microprocessor consists in the main of an arithmetic unit, control unit and a small number
of internal memory units, so-called registers.
General Architecture of PLC
Open Architecture:
• Easily connected to
devices and programs
made by other
manufacturers.
Closed Architecture:
• Proprietary design,
making it more difficult to
connect to other systems.
General Architecture of PLC

NOTE:
When working with PLC
systems that are proprietary
in nature you must be sure
that any generic hardware
or software you use is
compatible with your
particular PLC.
 I/O Incorporation into PLC

Fixed I/O:
• Typical of small PLCs with a fixed number of
connections for inputs and outputs.
• The processor and I/O are packaged together.
• Lower in cost – hut lacks flexibility.
 I/O Incorporation into PLC

Modular I/O:
• Allows flexibility by plugging
separate modules into
compartments.

• Click on Video
I/O Incorporation into PLC

• I/O system: Interface for

connecting field devices
to the controller
• Purpose: Condition
signals to/from external
devices (inputs and
outputs).
• Electrical Isolation:
Achieved using optical
isolators for component
safety.
Principles of Operation - PLC Operating Cycle
Principles of Operation - PLC Operating Cycle
One cycle through the program is called
a scan time:
• Reading the inputs from the other
modules
• Executing the logic based on these
inputs
• Updating the outputs accordingly
The scan time happens very quickly (in
the range of 1/1000th of a second).
 PLC VS DCS

• Your are required to present a comparison between PLC & Computers

• Explains memory size in PLCs and factors affecting memory
requirements.
Thank you for your attention!

Any Questions?