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Automatic Journey ?

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13 views46 pages

Automatic Journey ?

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Automation journey & its industrial revolution

(Industries- 4.0 & IOT)

1
HOW AN AUTOMATION SYSTEM
CHANGES THE WORLD

1. AUTOMATION JOURNEY STARTED FROM TRANSISTORS TO THE


DIGITAL FACTORY (MICRO PROCESSORS BASED)

2. AUTOMATION TECHNOLOGY IS THE BACKBONE OF INDUSTRIAL


PRODUCTION/QUALITY /ENERGY /CLEAN ENVIRONMENT

3. IT MAKES FACILITIES MORE PRODUCTIVE, EFFICIENT, RELIABLE, AND


FASTER
AUTOMATION JOURNEY

❑ MANUAL CONTROL
❑ PNEUMATIC CONTROL
❑ ELECTRICAL HARD WIRED LOGIC CONTROL
❑ ELECTRONIC CONTROL USING LOGIC GATES
❑ PLC control
❑ SCADA
❑ DCS ( Distribution control system)
❑ EXPERT PROCESS OPTIMIZATION (Rule based Fuzzy system)
❑ Robotics in Process & quality control
❑ Industries 4.0–IVth Industrial Revolution (Smart factory)
❖ Cloud competing
❖ AI ( artificial intelligent)
❖ MI ( machine learning )
❖ IOT sensors
❖ EDGE Computing (extension of cloud computing)
MANUAL CONTROL

All the actions related to process control are taken by the operators
(Human interface)

Drawbacks:

❑ It was more control by visualization with minimum parameters

❑ Likely human errors and consequently its effect on quality of final


product.

❑ The production, safety, energy consumption and usages of raw material


are all subject to the correctness and accuracy of human action.

❑ Total depends on person/operator capability

❑ No records/History of operation
PNEUMATIC CONTROL
Industrial automation, with its machine and process control, had its origin
in the 1920s with “Pneumatic Controllers”.

Actions were controlled by a simple manipulation of pneumatic valves,


which in turn were controlled by pneumatic relays, switches & electrical
switch gear

Drawbacks:
• Bulky and Complex System.
• Involves lot of rework to implement control
logic.
• Longer Project time .
• performance based on quality of air
• Difficult maintenance and troubleshooting.
ELECTRICAL HARD WIRED LOGIC
CONTROL
❑ The contactor and relays together with
hardware timers and counters were used in
achieving the desired level of automation.

❑ Mimic Based control desk for operation

ELECTRICAL SWITCH GEAR


DRAWBACKS:

❑ Bulky Panels.

❑ Complex wiring.

❑ Longer Project time.

❑ Difficult maintenance and troubleshooting.

MIMIC BASED CONTROL DESK


ELECTRONIC CONTROL USING LOGIC
GATES
In 1960s with the advent of electronics, the logic gates started
replacing the relay and auxiliary contactors in the control circuits.

The hardware timers & counters were replaced by electronic timers .

ADVANTAGES OVER ELECTRICAL HARDWERE CONTROL


• Reduced space requirements.

• Less maintenance & greater reliability.


PROGRAMMABLE LOGIC CONTROLLERS
(PLC)
❑ In 1970s - Mmicroprocessors and associated hardwires like Digital Input ,
Digital Output peripheral chips, the whole process of control and automation
underwent a radical changes.

❑ Instead of physical wiring of control devices, in PLC it is achieved through


application program /software.

❑ The programmable controllers have in recent years experienced an


unprecedented growth as universal element in industrial Automation.

❑ It can be effectively used in application ranging from simple control like


replacing small number of relays to complex automation problems.

PLC HARDWERE
PLC PANEL
PROGRAMMABLE LOGIC CONTROLLERS
(PLC)
PLC- Programmable Logical Controller : Programmable Logic
Controller (PLC) is a digital computer used for the automation of various
electro-mechanical processes in industries. PLC consists of a microprocessor
which is programmed using the computer language.

PLC configuration diagram


Features of PLC:
❑ Very High Accuracy
❑ Low Power Consumption (Energy
Saving)
❑ High Level human Safety
❑ Less Plan Running cost
❑ Small in Size (Required Lased space)
❑ Rugged Construction
❑ Easily programmable
❑ Easy Maintenance
❑ Economical & high Flexible
❑ Shorter project program
❑ Easy Documentation
SCADA- SYSTEM
Supervisory control and data acquisition (SCADA) is a system of
software and hardware elements that allows industrial organizations to:
❑ Control industrial processes locally or at remote locations
❑ Monitor, gather, and process real-time data
❑ Directly interact with devices such as sensors, valves, pumps, motors, and
more through human-machine interface (HMI) software
❑ Record events into a log file.
❑ This upgradation of PLC with HMI ( Operator station)

OBJECTIVES OF SCADA: BENEFITS OF SCADA:


❑ AUTOMATION ❑ CONTINUOUS MONITORING.
❑ MONITORING ❑ REAL TIME CONTROL.
❑ MEASUREMENT ❑ AUTOMATION AND PROTECTION.
❑ DATA ACQUISITION ❑ REMOTE CONTROL AND
❑ DATA COMMUNICATION OPERATION
❑ CONTROL ❑ PROCESS GRAPHICS
❑ VISUALIZE WHOLE PROCESS EQUIPMENTS LOG DATA
EVENTS/ ALARMS
❑ VISUALIZE OF LOG TRENDS OF ANALOG/DIGITALS
SIGNALS.
❑ COMMUNICATIONS WITH THIRD PARTY SOFTWARE
SCADA- SUPERVISORY CONTROL & DATA
ACQUISITION
❑ Dynamic process graphic

❑ Real-time and historical trending

❑ Alarms

❑ Device connectivity

❑ Script for logic development ( ladder /statement)

❑ Database connectivity

BENEFITS OF SCADA:
❑ Continuous monitoring of dynamic process value.

❑ Real time control.

❑ Automation and protection.

❑ Remote control and operation

❑ Process graphics
HMI-HUMAN MACHINE INTERFACE
• Human Machine Interface (HMI) systems use to communication
between machines and to the human operator.

• HMI provides control the machine, touch screen, decision making,


monitoring, managing and visualizing device processes etc.

HUMAN-MACHINE INTERFACE (HMI)


DCS- DISTRIBUTED CONTROL SYSTEM

❑ Distributed control system (DCS) is a computerized control system for a


process or plant usually with many control loops, in which process
controllers are distributed throughout the system with

❖ Multi-disciplined controllers for logic


❖ Sequential and process control
❖ Input /output ( analogue & digital)
❖ operation station ( supervisory control)
❖ Different type communication prosocial
❖ Custom applications software
❖ Business integration on one platform



The DCS concept increases


Reliability


Reduces installation costs by more communication protocol


Remote monitoring and supervision


Distributed process with common network & server
Area wise signal processing near to equipment & communicated on network by
using STAR /RING Tropology
DCS
WITHOUT SERVER/CLIENTARCHITECTURE
DCS
TYPICAL BLOCK DIAGRAM FOR DATA PROCESSING & CONTROL
24 V
DIGITAL
Power Supply
INPUT /OUTPUT
BOARD
+5V
Regulated
INPUT/OUTPUT ANALOG supply
DAQD
CURRENT TERMINAL PROCESSOR BOARD
VOLTAGE BOARD
RTD

DATA
BASE-1

( Battery PROCESSOR
ALGORITHM Back-1 Up) BOARD
CAT HOLD PROCESSOR
STATION

DATA
BASE -2

DATA HIGH (Battery


DATA Back Up)
MODEM PROCESSOR
HIGH WAY
SYSTEM CONFIGURATION DIAGRAM – FLS -DENMARK
SYSTEM CONFIGURATION DIAGRAM – SIEMENS

CENTRAL CONTROL ROOM PKG & CEMENT DISPATCH


OS #1 OS #2 MCS-1 MCS-2 EMS/MIS OS #3

FIRE WALL
OFFICE
LAN
SER. CCTV

ETHERNET SWITCH ETHERNET SWITCH

UTP CAT-5 CABLE


Ethernet Ring Laser B/
Laser B/ Laser B/ W
Deskjet
W W Printer
Colour
Printer Printer Printer
ENGG. Redundant
STATION Servers
ETHERNET SWITCH ETHERNET SWITCH ETHERNET S/W

Ethernet Ring

PC- PC- PC-


1 2 4
PROFIBUS-DP STP CABLE

PROFIBUS-DP STP CABLE


PROFIBUS-DP STP CABLE

I/O Panels I/O Panels I/O Panels

iMCC iMCC iMCC


Sub-Control Sub-Control Sub-Control
Systens Systens Systens

CLINKER, GYPSUM CEMENT MILL-1 PACKING & CEMENT


STORAGE & X’PORT, FLY DISPATCH
ASH STORAGE & X’PORT
DCS- BRIEF SPECIFICATION OF HARDWARE

SPECIFICATION FOR RACK SERVERS


• Make : DELL R430 ( redundant configuration)
• Memory : 16GB
• HARD DISK : 4x 300GB SAS, 15K RPM, Hot Plug, RAID 5
• RED CONTROLLER : H730

OPERATOR STATION ( HMI)


• Make : Dell
• Model :
• Processor : Intel Core i7-8700 (6 Cores/12MB/12T/up to 4.6GHz/65W
• Memory7 : 8 GB
• Hard Disk : 1 TB
• Operating : Windows 10 Pro English 64bit

WORK STATION
• Make : Dell
• Model: Dell Precision T3630
• Processor Intel Xeon E-2124, 3.4 GHZ
• Memory : 8x DVD+/-RW Drive
• Hard Disk : 1 TB
• Operating : Windows 10 Pro English 64bit
DCS- DISTRIBUTED CONTROL SYSTEM

In Industries, Automation and manufacturing processes requires transfer of


process and device data between widely distributed measurement and control
devices.

Process automation networks mostly use in

❑ 2 WIRE - Analog (4-20mA)


❑ HART Protocol ( hybrid Both Digital & Analogue)
❑ Foundation Fieldbus
❑ Profibus –PA
❑ Profibus DP
❑ Modbus
❑ OPC
❑ Ethernet
❑ DeviceNet
❑ CAN Bus
DCS- DISTRIBUTED CONTROL SYSTEM
2 WIRE - Analog (4-20mA)

HART Protocol
(Hybrid Both Digital & Analogue)
DCS- DISTRIBUTED CONTROL SYSTEM
Profibus –PA & DP connection diagram

IOT -TRANSMITTER
connection diagram
DCS- DISTRIBUTED CONTROL SYSTEM

OPC – CLIENT –SERVER


ARCHITECTURE

MODBUS –CONNECTIVITY
DCS- DISTRIBUTED CONTROL SYSTEM
Ethernet connectivity :Ethernet protocol is the traditional
technology for connecting devices in a wired local area network
(LAN) or wide area network (WAN) enabling them to communicate
with each other via a protocol -- a set of rules or common network
language.

Ethernet is a way of connecting computers together in a local area


network or LAN. It has been the most widely used method of
linking computers together in LANs .

The basic idea of its design is that multiple computers have access
to it and can send data at any time.

Advantage
• relatively low cost;
• backward compatibility;
• generally resistant to noise;
• good data transfer quality;
• speed;
• reliability; and
• data security -- common firewalls can be used
DCS- DISTRIBUTED CONTROL SYSTEM

Ethernet LAN Features

▪▪ Bus topology, Wired LAN in IEEE 802.3 physical layer standard

▪▪ 10 Mbps, 100 Mbps (Unshielded and Shielded wires) and 4 Gbps


(in twisted pair wiring mode)

▪▪ Broadcast medium Passive, Wired connections based.


Frame format like the IEEE 802.2

▪▪ SNMP (Simple Network Management Protocol)


Open system (therefore allows equipment of different specifications)

▪ Each one connected to a common communication channel in the network


Multi access is like in a Packet switched network Ethernet
TCP/IP Network 5 layers
1. Application HTTP
2. TCP
3. Internet
4. Data Link
5. Physical
DCS- DISTRIBUTED CONTROL SYSTEM

IMPORTANT FEATURES OF DCS


1. To handle complex processes

2. Server-client relationships.

3. A lot of predefined function blocks

4. More sophisticated operator station /HMI

5. Redundant servers, controllers and/or Networks

6. Synchronized alarming and security.

7. Historical data logging and trending.

8. Reduced engineering time.

9. Historical data and trending.

10. Alarms.

11. Operator features and security.


CONTROL ROOM FOR PLANT AUTOMATION
ENGINEERING & SERVER ROOM
ROBOTIC LAB FOR ON LINE QUALITY
CEMENT CONTROL
ROBOTIC LAB FOR ON LINE QUALITY
CEMENT CONTROL
SMART MANUFACTURING
smart manufacturing are part of the technological transformation
known as Industry 4.0 or the Fourth Industrial Revolution.
SMART MANUFACTURING

Benefits of a smart factory


❑ PRODUCTIVITY AND EFFICIENCY
❑ SUSTAINABILITY AND SAFETY
❑ PRODUCT QUALITY
❑ CLOUD CONNECTIVITY
❑ ARTIFICIAL INTELLIGENCE
❑ MACHINE LEARNING
❑ BIG DATA
❑ INDUSTRIAL INTERNET OF THINGS (IIOT)
❑ DIGITAL TWINS
❑ ADDITIVE PRINTING
❑ VIRTUAL REALITY (VR) AND AUGMENTED REALITY (AR)
❑ BLOCKCHAIN
❑ MODERN DATABASE:
THE PATH TO INDUSTRIES 4.0
WHAT IS INDUSTRY 4.0
WHAT IS INDUSTRY 4.0
Industry 4.0 is also referred to as the 4th Industrial Revolution. The term
covers the current trend of digitalization and data exchange in automation
and manufacturing technology.

Some of the important elements of Industry 4.0 are

❑ INTERNET OF THINGS (IOT/IOTT)

❑ CLOUD COMPUTING

❑ BIG DATA AND ANALYTICS,

❑ VIRTUAL TWINS,

❑ AUGMENTED REALITY,

❑ AUTONOMOUS ROBOTS,

❑ CYBER-PHYSICAL SYSTEMS.
What is the Internet of Things (IoT)?

How does it work?


THE INTERNET OF THINGS (IOT) IS THE CONCEPT

• CONNECTING ANY DEVICE TO THE INTERNET.

• IOT IS A GIANT NETWORK OF CONNECTED THINGS AND PEOPLE

• COLLECT AND SHARE DATA ABOUT THE WAY THEY ARE USED

HOW DOES IT WORK?

• CAPTURE THE DATA THROUGH SENSORS-

• SHARE THE DATA

• PROCESS THE DATA-

• ACT ON THE DATA


IOT (INTERNET OF THINGS)

The Internet of Things (IoT)


• network of physical objects or "things"
• embedded with electronics, software, sensors, and network connectivity,
• which enables these objects to collect and exchange data.
• IoT allows objects to be sensed and controlled remotely across existing network
infrastructure,
• creating opportunities for more direct integration between the physical world and computer-
35
IOT (INTERNET OF THINGS)

List of sensors in IOT


(Internet of things)
1. Pressure
2. Temperature
3. Flow
4. Vibration
5. Humidity
6. Speed
7. Current
8. Sound
9. Level
10. Proximity sensors

35
CONNECTING IOT SENSORS AND WIRED SENSORS

• Sensors in an Industry 4.0 system can be connected in various ways for data
transfer from the machine to the computer
• The sever can be on premise, meaning within the physical boundaries of
the organization, or on the cloud .
• There are a variety of connection options depending for IOT sensors, sensors
❑ with wired LAN
❑ sensors with WiFi LAN.
• ON-PREMISE SYSTEM:
❑ The sensors on machines send data to a server within organization.
❑ The connection between sensors and the server can be wired or WiFi LAN.
❑ Users can see reports if they are on the same LAN, from within the shop
floor.

35
CONNECTING IOT SENSORS AND WIRED SENSORS

Cloud based system: The sensors on machines send data to a Cloud server
outside your organization.

The connection between sensors on the machine can be direct IOT, via

❑ a mobile phone network


❑ by wired LAN
❑ or WiFi LAN.

Users can see reports from anywhere on earth, on the Web.


In the case of the direct IOT via the mobile phone network, there is no IT
infrastructure required on the shop floor for data transfer.

In the wired or WiFi LAN systems, you need LAN cabling, switches, access
points, repeaters, etc. In the on premise system, you additionally need a
server within the organization

35
CLOUD BASED SYSTEMS -IOT DIRECT TO
CLOUD

35
ON-PREMISE SERVER SYSTEMS
Wi-Fi LAN

35
ON-PREMISE SERVER SYSTEMS
Wired LAN

35
Industry 4.0 Solution – Mobile App

Key Features

❑ Connect to Individual Plant DCS or Historian using OPC UA or OPC DA

❑ Comprehensive Industrial IoT Platform for consolidated data aggregation and KPI Derivations.
❑ Secured access to various groups for relevant KPIs based on access control.

❑ Each Plant can access to only own data
❑ Corporate Team can access multiple plants
❑ No of plant - 14
35
❑ No. Control system 34 ( all Dalmia power & cement plant)
EDGE COMPUTING FOR IOT DEVICES
• Edge computing is a extension of cloud computing

• that brings computation and data storage closer to the location where it is
needed, to improve response times and save bandwidth.

• client data is processed near to the originating source .

• Edge allow data from IOT devices to be analysis at the edge of network
before being sent to data center or cloud

Banifits of Edge computing

❑ Speed

❑ Security.

❑ Scalability

❑ Versatility.
THANKS

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