Outline

 Fundamentals of Automation

 Industrial Automation Systems

 Sensors and Actuators

1. Introduction
 Programmable Logic Controllers (PLCs)
Industrial Automation

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What is Automation? What is Automation?

 Making products under the control of computers and

programmable controllers is known as automation.

 Manufacturing assembly lines as well as stand alone machine

tools and robotic devices fall into this category.

 It is delegation of human control functions to technical

equipment for increasing the productivity, quality, and
increasing the safety in working conditions thereby reducing
the manpower and cost.
Tesla

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What is Automation? Types of Automation

An Automated system is a system where  Home Automation

 the user provides the input
 the computer carries out the process  Office Automation
defined by the program
 the computer then provides the user with  Building Automation
the output
 Industrial Automation

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 Types of Automation Types of Automation
HOME AUTOMATION OFFICE AUTOMATION

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Types of Automation Industrial Automation

Industrial Revolution
INDUSTRIAL AUTOMATION
Industrial Automation is the use of various control Systems
for operating equipment such as machinery, processes in
factories, boilers and heat treating ovens, and so on…

1780 1870 1970 2011 2020

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Why Automation? How Automation?

 To Reduce Human Efforts.
 All automated systems are controlled by a
 To Reduce Production Time of Product.
program
 To Increase Productivity of Product.  Most systems use sensors to provide
feedback – this allows the program to react to
 To Improve Quality of Product. it’s working environment
 To Improve Safety in Working Condition.  The motion of an automated system is usually
performed by a motor
Automation systems can work accurately and
continuously, can repeat the same task over and over
with no need for rest.
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 Automation System Examples Automation System Examples

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Fundemental Elements of Automation Actuators

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Actuators Actuators
Electric Motors Pneumatic Actuators
HVAC Actuator Grippers Valves

Linear Electric Motor Compressors Hydraulic Actuators

Solenoid

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 Feedback / Sensors Sensors
Example of feedback
Picking up an egg.  Pressure
 Heat
 Light
If the gripper goes too far,  Magnetic
 Infrared
it breaks the egg.  Force
 Acceleration
If the gripper does not go far enough, it doesn’t
 Linear or rotational velocity
pick the egg up.  Torque
 Inductive/Position
If the gripper ”can feel” when it touches the egg, it  …….
can pick the egg up every time.
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Sensors Sensors
Automation refers to control and control requires measurement, so sensors are a must for SMART HEALTH APPs
industrial automation systems

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Sensors Sensors
CONVENTIONAL VEHICLE AUTONOMOUS VEHICLE

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 Sensors Sensors
Specs or Features of Sensors Analog

Features Specs An Analog signal is one which is continuously

 Analog or Digital  Working range variable between two limits.
 Current or voltage  Working frequency
That means it can have any value (within limits)
 Pulses  Repeatability/Linearity
 Normally Open or Close  Accuracy
at any time.
 Whether requires power supply  Working Conditions
 Whether requires calibration

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Sensors Sensors
Digital Analog/Digital Conversion

An digital signal is one which is changes in The big problem is the real world is essentially Analog and
discrete steps between two limits. computers work digitally. So, we need to convert
That means it can only have certain values at • from Analog to Digital
certain times. • to get data into the computer/CPU.
• from Digital to Analog
• to get information out of the computer/CPU.
This is one of the tasks carried out by the automation
systems

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Automation Tools Automation Tools

 SCADA - Supervisory Control and Data Acquisition
 PLC - Programmable Logic Controller

 HMI - Human Machine Interface

 DCS - Distributed Control System

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 PLC

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PLC PLC
PLC is the heart of the automation system. • PLCs are optimized for control tasks and the
PLC is a special form of microprocessor-based industrial environment.
controller. • PLCs are rugged and designed to withstand
PLC uses programmable memory to store vibrations, temperature, humidity, and noise.
instructions and to implement functions such as • PLCs have interfacing for inputs and outputs
logic, sequencing, timing, counting, and already inside the controller
arithmetic in order to control machines and • PLCs are easily programmed and have an
processes. easily understood programming language

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PLCs
Why are PLCs so common?
• They are cost-effective
• They are flexible, reliable and compact
• They have significant advantages over traditional
control systems based on relay or pneumatics

Where are PLCs used?

• In every industry where automation is involved, from
individual machines to whole processes

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 PLCs
Advantages Over Traditional Control Systems

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PLCs PLCs
Why 24V?
What tasks do PLCs perform?

• The logic control tasks such as interlocking, sequencing, timing and 1. Safety: 24 VDC is not deadly in case of short circuit. IEC 61131-2
standart
counting (previously undertaken with relays or pneumatics) 2. Eliminate high current in the system: All Electronic devices in "Programmable
industry have a minimum power consumption. it can be provided controllers - Part 2:
by using low voltage & high current / low current & high voltage. Equipment
• In addition, PLCs can perform a variety of calculation, communication requirements and
tests"
and monitoring tasks 3. Noise Prevention: To be able to tolerate voltage fluctuations you
need higher voltage running in your system.

4. Efficiency: The intrinsic safe concept of two wired analog devices

with floating supply is most efficient for 24VDC system.

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PLCs PLCs
Type of PLC - Compact Type of PLC - Modular

TECOMAT
TC600

Omron

Omron
Mitsubishi

Mitsubishi
Zelio
Eaton
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 PLCs PLCs
Type of PLC – Modular (Small) Basic PLC Structure
Outputs & Power Supply

Communication
Ports (RS-485)
courtesy ABB
courtesy Backmann

mounted on rail,
24V supply
cheaper
not water-proof,
no ventilator
Inputs
extensible by a parallel bus (flat cable or rail)

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BASIC ARCHITECTURE BASIC ARCHITECTURE

 CPU (microprocessor)
 Power Supply (AC to DC)
 Memory Unit (Data & Program)
 Inputs (Digital and Analog, Sensors)
 Outputs (Actuators)
 Communication Interface
 Programming Device (PC)
 Program (Ladder Diagram, Structural Text, etc.)
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BASIC ARCHITECTURE BASIC ARCHITECTURE

CPU/PLC

Internal Architecture
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 BASIC ARCHITECTURE of
BASIC ARCHITECTURE
Automation
CPU/PLC Input/Output Unit:
 The input/output unit provides the interface between
the system and the outside world, allowing for
connections to be made through input/output channels
to input devices such as sensors and output devices such
as motors and solenoids.
 Every input/output point has a unique address that can
be used by the CPU
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BASIC ARCHITECTURE PLCs

Input/Output Unit: Hardware of the PLC

 The input/output channels provide isolation and signal PLC Input Devices
 Push buttons
conditioning functions so that sensors and actuators can
 Switches (limit switches, level switches, etc.)
often be directly connected to them without the need  Sensors
PLC Output Devices
for other circuitry.  ...
 Relay contacts
 Electrical isolation  Solenoid valves
is usually by means of  Signal devices (such as lamps, alarms, etc.)
 Motors
optoisolators (optocouplers)
 …
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BASIC ARCHITECTURE BASIC ARCHITECTURE

Sourcing and Sinking: Input case Sourcing and Sinking: Output case
The terms sourcing and sinking are used to describe the way in  If the current flows from the output module to an output
which DC devices are connected to a PLC.
 With sourcing, an input device receives current from the input
load, the output module is referred to as sourcing
module, that is, the input module is the source of the current.  If the current flows to the output module from an output
 With sinking, an input device supplies current to the input load, the output module is referred to as sinking.
module, that is, the input module is the sink for the current.

Sourcing Sinking
Sourcing Sinking
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 BASIC ARCHITECTURE Relay & Transistor
Relay type of output
Input/Output (I/O) Modules
Input/Output Unit:  Output modules convert control signals from the CPU into
digital or analog values that can be used to control various
Outputs are specified as output devices.

 relay type (the signal from the PLC output is used to  Common output voltage is 24 V, outputs are often specified
as being of relay type, or transistor type .
operate a relay and is able to switch currents of the  With the relay type, the signal from PLC output is used to
order of a few amperes in an external circuit. ) operate a relay and so is able to switch currents of the order
of few amperes (i.e. 10 A) in an external circuit and can be
 transistor type (uses a transistor to switch current used for both AC and DC switching. Relays are, however,
relatively slow to operate.
through the external circuit. This gives a considerably  The transistor type of output uses a transistor to switch
Transistor form of output

faster switching action. ) current through the external circuit. This gives a faster
switching actioni, however transistor output can switch
max. 0.3A.
 triac type (can be used to control external loads that are
connected to the AC power supply )  Opto-isolators are used with transistor switches to provide
isolation between the external circuit and the PLC. The
transistor output is only for DC switching.

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PLCs PLCs
Transistor Output Modules
PLC Wiring: Relay Output
A transistor output is a solid-state device
that handles small to medium amount of
current. Most transistor outputs in our
PLC range can only handle DC current up
to the power supply voltage of the PLC.
(i.e. 24 VDC).

 One should connect the PLC

transistor output to an external relay,
to control large
loads/amps/voltages.

 Typically a PLC will have either NPN

or PNP transistor type outputs.

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PLCs PLCs
NPN and PNP PNP
NPN and PNP
NPN and PNP are directional attributes of solid-state transistors.

Devices connected to the PLC must be specified as NPN or PNP.

IOs can 'sink' current (also known as positive logic) and can 'source' current (also
known as negative logic).

Sinking type of IOs should be used with the PNP wiring

Sourcing type of IOs should be used with the NPN wiring

NPN

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 BASIC ARCHITECTURE of
PLCs
Automation
NPN and PNP
POWER SUPPLY

 Converts the incoming voltage to a useable

form for the internal electronics

 Protect the components from voltage spikes

 Operates either on 120vac/240vac/24vdc

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BASIC ARCHITECTURE of BASIC ARCHITECTURE of

Automation Automation
INPUT MODULE INPUT MODULE
Encoders Any Analog Sensors
Push Button Emergency

Switches Inductive
Proximity THERMOCOUPLE Any Digital Sensors

Relays Pots

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BASIC ARCHITECTURE of BASIC ARCHITECTURE of

Automation Automation
OUTPUT MODULE (Actuators) PROGRAM
MOTORS
PNEUMATICS
CONTROL VALVE

BOILERS LAMP

SOLENOID VALVE

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 PLCs
The signal chain within a PLC

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PLCs
Selecting a PLC - what matters?
• Inputs/Outputs • Functions required
– How many Inputs/Outputs? including – PID
embedded, local expansion, and networked I/O – PTO/PWM (Pulse Train Output/Pulse Width Modulated)
• 10, 16, 20, 32, 138, 156, >256 – Data Logging
– How many Discrete vs. – Messaging between PLC’s
Analog – Math Calculations

• Type of I/O • Memory Size

• AC, DC, Analog, • 1k, 6k, 8k 12k, 14k,
Thermocouple, sourcing,
sinking, etc. Thanks for your attention..
• Communications Networks
• DF1 Full Duplex, DF1 Half
Duplex, DF1 Radio Modem,
DH485, ModBus Master /
Slave
• DeviceNet, Ethernet
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