Introduction Industrial Automation

● Automation is required in every walk of life.

● Automation solutions are required right from
agricultural sector to high technology sector like
space.
● Plant Automation is the necessity for the
manufacturing industry to survive in today’s
globally competitive market

What is industrial Automation

?
Automation is basically the delegation of human control
function to technical equipment for
i. Increasing Productivity
ii. Increasing Quality
iii. Reducing Cost
iv. Increasing Safety in working conditions
 Advantages of the Industrial Automation

History of Automation

● Programmable Logic Controller

● Electronic control using logic gates
● Hard wired logic control
● Pneumatic control
● Manual control
 History of industrial automation
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 a 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
i. Longer project time
v. 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
Disadvantages
Changes in control logic not possible
More project time
 Programmable Logic Controllers
In 1970s with the coming of microprocessors and associated
peripheral chips, the whole process of control and automation
underwent a radical change.
Instead of achieving the desired control or automation through physical
wiring of control devices, in PLC it is achieved through a program
or say software.
It can be effectively used in applications ranging from simple control
like replacing small number of relays to complex automation problems

Advantages of PLCs
➢ Reduced space
➢ Energy saving
➢ Ease of maintenance
➢ Economical
➢ Greater life & reliability
➢ Tremendous flexibility
➢ Shorten the project execution time
➢ Easier storage, archiving and documentation
 Industrial Automation Components

Input Junction Junction

Controller Output
box box
Inputs Junction Controller Junction
Switches PLC Output
box box
Toggle Microcontroller i. Alar
Optocoupler -HMI Relay
Push button ADC -SCADA Contactor
m
Sensors ADC ii. Horns
-Temperature DAC iii. Led
sensors Inverter iv. Motor
-Proximity sensor VFD v. Buzz
-Reed switch
-Metal detector
er
-Pressure sensor

SENSORS AND TRANSDUCERS

• Displacement Sensors,
• Position and Proximity Sensors
• Velocity and Motion Sensors
• Force and Fluid pressure Sensors
• Liquid flow and Liquid level Sensors
• Temperature and light sensors
• Selection of sensors.
 Conventional Relays
A relay is an electromagnetic switch that has a coil and a set of associated contacts.
This electromagnetic field generates a force that pulls the contacts of the relay,
causing them to make or break the controlled external circuit connection
It is more practical to have a low power electrical relay circuit control the high-
power relay contacts than to wire a high-power electric switch directly from the
control area to the motor and its independent power supply.

Relay with two

contacts normally
open (NO) and
normally
closed(NC)

Simple relay circuit for controlling a bell using a single pole, single-through
(SPST) switch

A relay is typically used to control a device that requires high voltage or draws
large current.
The relay allows full power to the device without needing a mechanical switch
that can carry the high current.
A switch is normally used to control the low-power side, the relay-coil side.

Simple relay circuit

Notice that there are two separate circuits:
The bottom uses the direct-current (dc) low power, whereas the top uses the
alternating current (ac) high power.
The two circuits are only connected through electromagnetic field coupling.

Simple relay circuit

Relay Logic
Relay logic systems are System
control structures appropriate for both industrial and
municipal applications.
Hardwired is the operations/processes that will be controlled by relay logic
systems.

These systems are

Inflexible and can be
Difficult to modify after deployment.
Because the operation of relay logic
controllers is built directly into the
device, it is not easy to troubleshoot
the system when problems arise.
Such control systems are developed with
fixed features for specific applications
 It was a large complicated electrical electronics circuit full of
many small and big devices.
The logic was designed through wires with the help of electrical
and electronic devices such as
a) Relay,
b) Contactor,
c) Hardware timer/ counter,
d) Diode
e) Resistor,
f) Capacitor etc.
it was complicated but automatic system.

Shows two relay circuits for implementing two inputs:

The implementation of AND and OR logic functions by using coil relay
Relay has two magnetic coils and an associated normally closed (NC) set of
contacts.
Two inputs are connected to one side of each of the two coils
The other end of the coil is connected to the ground
Schematic diagrams for relay logic circuits are often called logic diagrams.
A relay logic circuit is an electrical diagram consisting of lines/networks/rungs
in which each must have continuity to enable the intended output device

A typical circuit consists

of a number of networks,
with each controlling an
output

Relay logic line diagrams

Each output is controlled through a combination of input or output

conditions (e.g., switches and control relays) connected in series, parallel,
or series-parallel to obtain the desired logic to drive the output.
Relay logic diagrams represent the physical interconnection of devices

In ladder-logic diagrams,
an electromechanical relay coil is shown as a circle
and the contacts actuated by the coil as two parallel lines.
Given this notation, the relay logic line diagrams for the AND and OR logic
functions are
L1 L2
Indicator L1 Indicator L2
А AORB CR1 AANDB
A CR1

CR2
B
CR2
CR1 Indicator

CR2 CR1 CR2 Indicator

The L1 and L2 designations in this logic diagram refer to the two poles of a 120-
Vac supply.
L1 is the hot side of the supply, and L2 is the ground/neutral side.
Output devices are always connected to L2.

Any device overloads that are to be included must be shown between the output
device and L2;
the output device must be the last component before L2.
Input devices are always shown between L1 and the output device.
Relay contact control devices may be connected either in series, parallel, or a
combination of both called series-parallel.
Control Relay Application
Figure shows the line diagram for a common application of electromechanical
relay dc motor-control circuitry
A momentary NO push-button switch starts the motor, and another NC push-
button switch stops the motor.
The control relay contact is used to latch the Start push button after it is released.
Another contact associated with the same relay is used to start the motor.
Pressing the Stop push button at any time will interrupt the flow of electricity to
the motor and cause it to stop

Dc motor controls
The line diagram illustrates how a hardwired relay is used to control two pilot
lights. The desired control is accomplished using two push-button switches; PB1
starts the operation, and PB2 terminates it at any time.

With no power applied to the control

relay, the contacts are in a normal state.
The NO contacts are open, and
The NC contacts are closed.
The green pilot light receives power
and turns on as indicated by the
green fill light.
The red pilot light is off as shown.

Relay controlling two pilot lights.

 Rung 1:
Once the START PB1 is pressed, coil CR1 becomes energize; this, in turn,
makes contacts CR1-1 close and maintains power to CR1 through the NC
STOP push button PB2.
When CR1 energizes the switch state of the contacts,
The NO contacts close, and
The NC contacts open.
This will turn off the green light on rung 2 and
Turn on the red light on rung 3.
When the STOP push button is pressed,
The control relay loses power, and
The contacts switch to the normal state.
This results in turning the green light on and the red light off

Motor Magnetic Starters

A magnetic starter is used to control the high power to the motor.
Three of the motor magnetic starter contacts are used to connect the three phases of the high-
voltage supply.
In addition, overload relays are physically attached for the motor overload protection

Figure shows the low power motor starter circuit. START and STOP push-button switches
start and stop the motor through the control of its magnetic starter. Magnetic starter
contact M-4 is used to latch the motor start action.

Figure High-power motor circuit Figure Low-power motor starter circuit

Figure presents a line diagram of a magnetic reversing starter controlled by forward
and reverse push buttons.
Pressing the forward push button completes the forward coil circuit from L1 to L2.

Energizing coil F, in turn,

energizes two auxiliary contacts
F-1 and F-2. F-1 provides a
latch around the forward push
button maintaining coil F
energized.
The NC contact F-2 will prevent
the motor from running in the

Figure Control of reversing motor starter

PLC programming
 Programmable Logic Controllers
( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic apparatus which uses a

programming memory for the internal storage of instructions for
implementing specific functions such as logic, sequencing, timing,
counting and arithmetic to control through digital or analog
modules, various types of machines or process.
A Programmable Logic Controller (PLC) is a type of computer-based
industrial control system that uses a programmable memory to store
instructions and execute specific functions in response to input from
sensors or other devices.
PLCs are commonly used in industrial control systems, such as
manufacturing lines and automated processes, to control and automate
machines and equipment.

They can be programmed to perform a wide range of tasks, such as

monitoring inputs, controlling outputs, and making decisions based on
input conditions.
PLCs are typically used in environments where reliability and
durability are important, such as factories and other industrial settings.

A Programmable Logic Controller (PLC) is a type of computer that

is used to control and automate industrial machines and processes.
It uses a programmable memory to store instructions and make
decisions based on input from sensors or other devices.
This allows it to control and monitor different parts of a manufacturing
line or other industrial system.
 What is the programmable logic controller (PLC)?
A programmable logic controller (PLC) is an industrial grade computer that is capable of
being programmed to perform control functions
PLC is a digitally operating system designed for use in an industrial environment which
uses a programmable memory for its internal operation of user –oriented instructions for
implementing specific functions such as
a. logic,
b. sequencing,
c. timing,
d. counting and
e. arithmetic
PLC control through digital or analog inputs and outputs in the various types of machines
or processes.
A programmable logic controller (PLC) is an industrial computer that receives inputs from
input devices and then evaluates those inputs in relation to stored program logic and
generates outputs to control peripheral output devices

Major Components of a Common PLC

Power supply:
a) To work on any electronic device we
need to power it on.
b) PLC provides terminals to connect
power cables to it.
c) The power supply is either AC or DC
power to PLC.
d) AC power supply is directly L, N and
earth terminals of PLC will be connected
to the socket.
e) DC power supply needed then it will be
24 V DC. An SMPS (Switch Mode
Power Supply) will be the power source
and the PLC terminals + - will be
connected to it.
 Low voltage:
This low voltage is for PLC’s internal use and it is converted by PLC
itself from its power supply.
This low voltage is 5 or 3.3 V DC in old and new PLC respectively.
As PLC is a digital device, its internal work takes place on 0/ 1.
PLC also converts power supply into 24V DC as low voltage for its I/O
wiring purpose.

CPU: Central Processing Unit is the brain of PLC.

It is a microprocessor which monitors and controls the logic
and communication execution.

I/ O:
input/ output in block diagram refer to input output terminals not the
physical I/Os like push button, sensors, motor, relay etc.
There is two types I/Os
a) Relay and
b) Transistor.
Memory location:
PLC has two memory locations, program and data memory location.
The memory location where program is saved is program memory.
Memory location where all addresses (addresses that we use in our
program) are pre located is data memory.
It is EEPROM. PLC RAM and EEPROM is battery backed.
Communication port:
It is used to communicate PLC with other devices such as laptop/
computer, HMI/ SCADA PC/ Drives etc.
On branded PLC you can find RS 232, RS 422, RS 485 etc.

In summary main parts

PLC
POWER SUPPLY
Provides the voltage needed to run the primary PLC components
I/O MODULES
Provides signal conversion and isolation between the internal logic
level signals inside the PLC and the field’s high-level signal.
PROCESSOR
Provides intelligence to command and govern the activities of the entire
PLC systems.
PROGRAMMING DEVICE
used to enter the desired program that will determine the sequence of
operation and control of process equipment or driven machine.
 I/O interfaces

● PLC input/output terminals are not directly connected to

PLC CPU.
● Signal is sent through light from terminal to CPU and from
CPU to terminals through Opto couplers that is why PLC
CPU last long.
● When wrong connection is made from field device then the
PLC CPU will be isolated optically

PLCs provide many other benefits

including:
a. Increased Reliability.
b. More Flexibility.
c. Lower Cost.
d. Communications Capability Relay fixed Modular PLC
e. Faster Response Time PLC
f. Easier to Troubleshoot

PLC communication
High-speed module Relay based control PLC-based control
counting panel
Relationships between the inputs and outputs re determined by the user
program.

All the logic is contained in the PLC’s

memory
There are two ways in which I/Os (Inputs/Outputs) are incorporated into
the PLC:
Fixed and
Modular.

Fixed I/O
PLC’s with fixed I/O typically come in a complete unit that
contains the processor, I/O section, and power supply
Disadvantage of fixed I/O
lack of flexibility; you are
limited in what you can
get in the quantities and
types dictated by the
packaging

Fixed I/O
is typical of small PLCs that come in one package with no separate, removable units.
The processor and I/O are packaged together, and the I/O terminals will have a fixed
number of connections built in for inputs and outputs.
Modular I/O
is divided by compartments into which separate modules can be plugged.
This feature greatly increases your options and the unit’s flexibility.

is modular in nature, more flexible than fixed I/O units. The I/O rack or
chassis is a framework or housing into which modules are inserted.

Voltage Signal
The purpose of this interface is to condition the various signals received from or
sent to external field devices.
To electrically isolate the internal components from the input and output
terminals, PLCs commonly employ an optical isolator, which uses light to couple
the circuits together .

Input/ output Interface types

Input interface
DC voltage digital input circuit
A.C voltage digital input circuit
Pulse counter circuit
ADC interface
DC voltage digital input circuit
This interface uses DC source which is normally 24V
It can be connected into forms
With the sink input interface when the input device turned on connect the circuit
to 0V line of the DC supply.
With the current sourcing interface when the input device turned on connects the
Circuit to the positive polarity of the supply

AC voltage digital input circuit

This interface uses AC source which is normally 12/24/120/220V.
It comprises rectifier and filter circuit
 Analogue to digital converter circuit
it uses to accepts an analogue input signal and converts into output binary
value that corresponds to the level of the analogue input.

Output interface Relay output circuit

a) Relay output circuit
b) Transistor output
circuit
c) Triac output circuit
d) DAC interface

Transistor output circuit

Triac output circuit

 Current Signal
In the field of industrial instrumentation and control, 4-20mA
is a commonly used standard for current loop signaling.

a) To immune to electrical noise and can be transmitted

over long distances using twisted pair cables, which are
inexpensive and widely available.
b) 4-20mA signals can be easily converted to other forms
of measurement, such as voltage or resistance.
c) It is very easy to identify if the cable is broken.
 Programming Methodology
a) Ladder logic diagram
b) Block diagram
function
c)
a) Statement
Ladder logiclist
Ladder diagram
diagrams are specialized schematics commonly used to document industrial control
logic systems.
They are called “ladder” diagrams because they resemble a ladder, consist
i) two vertical rails (supply power) and
ii) many “rungs” (horizontal lines) as there are control circuits to represent.

a simple ladder diagram showing a

lamp that is controlled by a hand
switch
Fig. simple ladder diagram showing a lamp

Ladder
Logic
•Parallel contacts are equivalent to an OR gate.
•Series contacts are equivalent to an AND gate.
•Normally-closed contacts are equivalent to a NOT gate
(inverter).
Things to note
•Parallel contacts are logically equivalent to an
OR gate.
•Series contacts are logically equivalent to an
AND gate.
•Normally closed (N.C.) contacts are logically
equivalent to a NOT gate.
•A relay must be used to invert the output of a
logic gate function, while simple normally-closed
switch contacts are sufficient to represent inverted
gate inputs

Permissive and Interlock Circuits

•Switch contacts installed in a rung of ladder logic designed to interrupt a circuit
if certain physical conditions are not met are called permissive contacts,
because the system requires permission from these inputs to activate the output.
•Example of Permissive circuits
A practical application of switch and relay logic is in control systems where
several process conditions have to be met before a piece of equipment is allowed
to start.
A good example of this is burner control for large combustion furnaces.
 The burners in a large furnace to be started safely,
the control system requests “permission” from several process switches,
including
● High and low fuel pressure,
● Air fan flow check,
● Exhaust stack damper position,
● Access door position, etc.
Each process condition is called
a permissive, and each
permissive switch contact is
wired in series, so that if any one
of them detects an unsafe
condition, the circuit will be
opened:
If all permissive conditions are met, CR1 will energize, and the green
lamp will be lit.
In real life, more than just a green lamp would be energized:
Usually, a control relay or fuel valve solenoid would be placed in that
rung of the circuit to be energized when all the permissive contacts were
“good:” that is, all closed.

If any one of the permissive conditions are not met, the series string of
switch contacts will be broken, CR2 will de-energize, and the red lamp
will light.

Note that the high fuel pressure contact is normally-closed.

This is because we want the switch contact to open if the fuel pressure
gets too high.

Since the “normal” condition of any pressure switch is when zero (low)
pressure is being applied to it, and we want this switch to open with
excessive (high) pressure, we must choose a switch that is closed in its
normal state.

Interlocks
witch contacts designed to prevent a control system from taking two incompatible
actions at once (such as powering an electric motor forward and backward
simultaneously) are called interlocks

A practical application of relay logic is in

control systems where we want to ensure
two incompatible events cannot occur at
the same time.
An example of this is in reversible motor
control, where two motor contactors are
wired to switch polarity (or phase sequence)
to an electric motor.
The forward and reverse contactors should
not be energized simultaneously:
When contactor M1 is energized, the 3 phases (A, B, and C) are connected directly
to terminals 1, 2, and 3 of the motor, respectively.
However, when contactor M2 is energized, phases A and B are reversed, A going to
motor terminal 2 and B going to motor terminal 1.
This reversal of phase wires results in the motor spinning the opposite direction.

Motor Control Circuits for forward and Reverse

These parallel auxiliary contacts are sometimes referred to as seal-

in contacts, the word “seal” meaning essentially the same thing as the
word latch.
 To prevent this occurrence from happening, the circuit can be designed so that the
energization of one contactor prevents the energization of the other.
This is called interlocking, and it is accomplished using auxiliary contacts on each
contactor, as such:

Application examples
1. Develop a simple ladder logic program that will turn on switch if inputs A and B ,
or input C is on.
Solution
Let input A , B and C stand for I1, I2 and I3 respectively
2. Develop a simple ladder logic program that will operate the machine in auto and manual mode
Solution
The ladder diagram for a given problem will have two switches (I1 for auto mode while I2 for
Manual mode)
Also interlock contact is needed to avoid both mode to operate at the same time

Auto mode

Manual mode

3. Develop a ladder logic program that will operate two motors M1 and M2 which are required to
to turn ON one after another .First motor M1 start by pressing switch I2 and then by pressing
switch I2, M2 should start. But condition is like that when M2 starts M1 remains OFF. .
Solution
4. Develop a ladder logic program that will be used to find and check bottle cap from a
bottling plant

5. Write a ladder diagram for forward movement of motor by pushing the forward push
button. On pushing the reverse push button motor should start in reverse direction. Motor
should stop before changing the direction of motion. Insert a stop the motor at any time
PHYSICAL WIRING
L
220-230V
AC
N

L N N I1 I2 I3 I4 I5 I6 I7 I8

412-AC-RC
PORT
Q1 Q2 Q3 Q4

M CONTACTOR LAMP BUZZER

SOLENOID

L N + - L N + -