গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়

Gopalganj Science and Technology University

ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Q: What is automation?
Automation is the automatic operation of processes and machinery without human operators.

Page | 1

(a) (b)

(c) (d)
Fig. 1.1: Automation examples
Q: What is the importance of automation?
• High productivity
• Reduced costs
• Better quality and consistency
• Greater safety
• Improved flexibility
• Increased added value and human capacity
• New level of data support and production traceability
• Real-time monitoring and predictive maintenance

Q: How does automation happen?

Only closed-loop systems are the type of system that is applicable to automation. A closed-loop control
system is a type of control system where the input is varied depending on the feedback from the output.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 2

Fig. 1.2: A closed loop system.

As an analogy, we will use an example from our very own home.
Let’s say we wanted to turn on the lights whenever someone walks in front of our house. What would we
do? We may appoint a man who will check and inform you periodically whether anyone is walking in front
of the house or not.
• If the appointed person informs you that someone is walking in front of the house, then you will
turn on the lights.
• If the appointed person informs you that no one is in front of the house, then you will turn off the
lights
“How did that become a closed-loop system?”
The information provided by the appointed person is feedback, and you, who turn lights on and off, is the
switch. So the environment in front of the house, the appointed person, and you are forming a closed loop.
“How can this be applied to an automated system?”
We can use a sensor as a replacement of the appointed person and a relay as a replacement of you.
The sensors observe the environmental conditions in the front of the house and send two types of electrical
signals based on whether anyone is walking in front of the house or not.
• If someone is walking in front of the house, then the sensor sends one types of signal that activate
the relay. So it turns on the lights.
• If no one is walking in front of the house, then the sensor sends another types of signal that
deactivate the relay. So it turns off the lights.
Now we have an automated system that performs the same task that we done manually in previous.

Q: How does automation work?

Let’s consider a drilling system that drills workpieces for a certain dept one after another. It consists of the
following steps
• put the workpiece under the drill machine
• start lowering the drill when the workpiece is in position
• start drilling by applying pressure when the drill reaches the workpiece,
• stop drilling when the drill has produced the required depth of the hole,
• retract the drill, and then switch it off and
Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
• wait for the next workpiece to be put in position before repeating the operation.
Each step needs a control system. We can perform each of the control actions either manually or
automatically.
For example, one human can sit in front of the drill machine. He/she will take away the drilled workpiece
and will put the new workpiece for the drill. Besides managing the workpiece, he/she can perform control
Page | 3
actions needed for each step.

Fig. 1.3: Automatic drilling machine.

For the automatic drilling system, we could wire up electrical circuits in which the closing or opening of
relay contacts would result in motors being switched on or valves being actuated. Thus, as a result, we
might have a relay as shown in Fig. 1.3 closing or opening contacts which, in turn, switches on the current
to a motor and causes the drill to rotate Fig. 1.3.
• A sensor detects whether there is a workpiece or not under drill. If there is no workpiece then a
relay will be energized. So the motor of the conveyor belt will be switched on. So it will carry the
workpiece under the drill.
• When the workpiece is under the drill, it will be sensed by the sensor. Based on the sensed signal
two relays will be activated. One will stop the conveyor belt and another will start lowering the
drill when the workpiece is in position.
• When the drill touches the workpiece, it will be sensed by the sensor. Based on the sensed signal
two relays will be activated. One relay turns on a motor that starts rotating the drill and another will
activate the hydraulic valve, which results in pressure being switched to drive a piston in a cylinder
and so results in the workpiece being pushed into the required position.
• The depth of the drill is sensed by the sensor. When the required depth is achieved the
corresponding relays will be activated to stop the motors responsible for rotating the drill and
activating the hydraulic valve.
• After that the necessary relays will be activated to perform retract the drill and turn on the motor to
run the conveyor belt to remove the drilled workpiece.
• The process is continued,
Each step of the control function is initiated based on the feedback signal. The part responsible for
generating the feedback signal is called the controller. This made an automatic drilling system.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Q: What is a controller?
The controller is a hardware device or a software program that produces signals as input to the controlled
plant or process to obtain the desired output. The controller works based on logic.

Q: What is logic? Page | 4

Logic is a method of reasoning (making decisions) based on a series of statements (rules).
Example:
If the sky is cloudy
and
If it is raining
Or
If it is a sunny day
And
If the temperature is high
Then
Take an umbrella with you
Boolean logic: Boolean logic is a method of reasoning (making decisions) based on a series of TRUE or
FALSE statements under certain conditions studied in Boolean algebra.
Boolean logic is a type of algebra in which outputs are either TRUE or FALSE (known as truth values or
truth variables) based on inputs that are either TRUE or FALSE.
In Boolean, the basic logics are AND, OR, and NOT.
The logic AND is a type of Boolean logic whose output is true only when all of its inputs are true.
The logic OR is a type of Boolean logic whose output is true when any one of its inputs is true.
The logic NOT is a type of Boolean logic whose output is true when its input is false and vice versa.
A logic gate is an idealized or physical device or circuit that implements the Boolean logic.
In most modern computers, logic gates are built using transistors combined with other electrical
components like resistors and diodes.
Digital logic is the fundamental concept underpinning all modern computer systems. Put simply, it's the
system of rules that allows us to make extremely complicated decisions based on relatively simple
"yes/no" questions.
Logic in electrical:

(a) (b)
Fig. 1.4(a)
Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
If the switch is short then the bulb gives light.
If the switch is open then the bulb gives no light.
This switch may be made short or open in two ways:
• Manually
• Automatically
Page | 5
based on the necessity.

Relay logic: Relay is an automatic switch.

Fig. 1.4(b)
Relay logic is a method of reasoning (making output) based on a series of relay statuses. Relay logic consists
of relays wired up in a particular fashion to perform the desired switching operations. The circuit
incorporates relays along with other components such as motors, timers, actuators, contactors, etc.
Example:

Fig. 1.4(c)
If the relay A is activated
and
If the relay B is activated
Then
The bulb gives light
It is also known as the relay logic control (RLC) works efficiently to perform basic ON/OFF operations
by opening or closing the relay contacts.
When the coil of the relay A and the relay B is not energized they act as open circuits. So these relays are
known as normally open relays or normally open contacts, denoted as

Fig. 1.4(d)
The circuit shown in Fig. 5 made automatically on-off using relays can be represented symbolically below.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 6

Fig. 1.4(e)
The circuit of Fig. 5(c) and Fig. 5(e) is called a relay logic control circuit. A relay logic control circuit is
a schematic diagram that shows various components, their connections, inputs as well as outputs in a
particular fashion.
It contains two vertical lines, one on the extreme left and the other on the extreme right. These vertical lines
are called rails. The extreme left rail is at the supply voltage potential and is used as an input rail. The
extreme right rail is at zero potential and is used as the output rail.
The term logic is used because programming is primarily concerned with implementing logic and switching
operations; for example, if A or B occurs, switch on C; if A and B occur, switch on D.

Fig. 1.4(f)

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Q: Generations of controller circuits/Automation Systems
1. Generation 1 (Invention of steam engine)
2. Generation 2 (Invention of electricity and uses of Relay-Controlled Systems)
3. Generation 3 (Invention of Microprocessor and uses of Microprocessor-Controlled Systems)
4. Generation 4 (Internet of Things) Page | 7

Q: Generation 2
The 1st generation controller for automation was RLC. The particular symbols are used in relay logic circuits
to represent different circuit components. Some of the most common and widely used symbols are given
below.
1. NO contact

The given symbol indicates a normally open contact. If the contact is normally open, it would not allow
any current to pass through it and hence there will be an Open circuit at this contact.
2. NC contact

This symbol is used to indicate Normally Close contact. This allows the current to pass through it and acts
as a short circuit.
3. Push Button (ON)

This push button allows current to flow through it to the rest of the circuit as long as it is pressed. If we
release the push button, it becomes OFF and no longer allows the current to flow. This means in order to
carry the current the push button has to remain in the pressed state.
4. Push Button (OFF)

The OFF push button indicates an open circuit i.e. it does not allow the flow of current through it. If the
push button is not pressed, it stays in the OFF state. It can transit into the ON state to carry the current
through it once it is pressed.
5. Relay coil

The relay coil symbol is used to indicate the control relay or motor starter and sometimes even a contactor
or timer.
6. Pilot Lamp

The given symbol denotes a Pilot Lamp or simply a bulb. They indicate the machine's operation.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Q: Explain the working of the relay logic circuit with an example
The working of a relay logic circuit can be explained through the given figures-

Page | 8

Fig. 1.5(a): Relay circuit to control red and green lights.

This figure shows a basic relay logic circuit. In this circuit,
Rung 1 contains one Push button (initially OFF) and one control relay.
Rung 2 contains one Push button (initially ON) and one Pilot lamp.
Rung 3 contains one NO contact and one pilot lamp.
Rung 4 contains one NC contact and one pilot lamp.
Rung 5 contains one NO contact, one pilot lamp, and a sub-rung with one NC contact.
To understand the working of the given relay logic circuit, consider below figure

Fig. 1.5(b):
In rung 1, the push button is Off and hence it does not allow the current to pass through it. Therefore, there
is no output through rung 1.
In rung 2, the push button is On and therefore, current passes from the high voltage rail to the low voltage
rail and the pilot lamp 1 glows.
Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
In rung 3, the contact is NO, therefore pilot lamp 2 remains Off and there is no flow of current or output
through the rung.
In rung 4, the contact is NC, allowing the current to pass through it and giving an output to the low-voltage
rung.
In rung 5, no current flows through the main rung as the contact is NO but due to the presence of the sub-
Page | 9
rung, which contains a normally close contact, there is a flow of current and hence the pilot lamp 4 glows.

Q: Example (RLC)
Draw the RLC ladder diagram for a motor that will start when both a presser switch and a temperature
switch are closed or when a push button is closed.
Solution:
The RLC ladder diagram is shown in Fig. 1.6.

Fig. 1.6: RLC ladder diagram.

Q: Example (RLC)
Draw the RLC ladder diagram to operate a motor at any pressure but not unless the specified temperature
setting has been reached.
Solution:
The RLC ladder diagram is shown in Fig. 1.7.

Fig. 1.7: RLC ladder diagram.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Q: Example (RLC)
Draw the RLC ladder diagram to control a relay being used to operate a hydraulic valve, this then results
in pressure being applied to drive a piston to move a workpiece.
Solution:
The RLC ladder diagram is shown in Fig. 1.8. The vertical lines represent the power rails and the horizontal Page | 10
lines to systems connected between them. The sequence of events is read from the top horizontal line
downwards.

(a) (b)
Fig. 1.8: RLC ladder diagram
Fig. 1.8(a) shows a simple ladder diagram. Thus, in the top line of Figure 1.8(a), when the push button is
closed, relay 1 is activated. This closes the contacts on the second line. So the solenoid valve is switched
on. When the push button is released the relay is deactivated. This opens the contacts on the second line
and so the solenoid valve is switched off.
Fig. 1.8(b) shows a more usual ladder diagram. This has the relay 2 switched on by a momentary press of
push-button switch. So the relay 2 is activated. This closes two sets of contacts in the second and third lines.
Contacts on the second line latch the push button switch. So that when the push stops there is still a
connection of power to the relay 2. Contacts on the third line switch on the solenoid valve. The solenoid
valve remains on as long as the power supply is available.
Now if we press the stop button the relay 2 is deactivated. This opens two sets of contacts in the second and
third lines. Contacts on the second line deactivate the latching of the push button. Contacts on the third line
switch off the solenoid valve.
The solenoid valve remains off until the start push button is pressed again. as long as the power supply is
available.

Q: Example (RLC)
Draw the RLC ladder diagram to control green and red light.
Solution:
The RLC ladder diagram is shown in Fig. 1.9.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 11

Fig. 1.9: Relay circuit to control red and green lights.

Before pushing the start button, all horizontal lines or rungs are incomplete except rung 2. So the green
light is ON.
When the start push button is closed, the relay coil is switched on and latches the push button. So the relay
remains on until the stop push button is pressed. So the relay closes the ‘NO’ contacts and opens the ‘NC’
contacts of rung 3 and 2, respectively. As a result, the green light is switched OFF and the red light is
switched ON.
When the stop push button is pressed, the current to the relay coil is switched off. So the relay closes the
‘NC’ contacts and opens the ‘NO’ contacts of rung 2 and 3, respectively. So the green light goes ON and
the red light comes OFF.

Q: Basic logic gates using relay logic

Basic digital logic gates can also be realized using relay logic and have a simple construction using the
contacts as given below.
OR Gate:
The truth table for the OR gate is:
A B Output

0 0 0

0 1 1

1 0 1

1 1 1
This table is realized using the relay logic circuit in the following manner –

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 12
In this, the Pilot lamp will turn on whenever any one of the inputs becomes one which makes the contact
associated with that input as normally close. Otherwise, the contact remains normally open.
AND Gate:
The truth table for AND gate is:
A B Output

0 0 0

0 1 0

1 0 0

1 1 1
Relay logic realization of AND gate is given by –

The contacts are connected in series for AND gate. This means that the pilot lamp will turn ON if and only
if both the contacts are normally close i.e. when both the inputs are 1.
NOT Gate:
The truth table for NOT gate is:
A Output

0 1

1 0
The equivalent relay logic circuit for the given NOT gate truth table is as follows –

The pilot lamp lights up when the input is 0 so that the contact remains normally close. As the input changes
to 1, the contact changes to normally open and hence the pilot lamp doesn’t light up giving the output as 0.
NAND Gate: The NAND gate truth table is:
A B O/P

0 0 1

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

0 1 1

1 0 1

1 1 0
The relay logic circuit as realized for the given truth table is as – Page | 13

As two normally close contacts are connected in parallel, the pilot lamp lights up when one or both the
inputs are 0. However, if both the inputs become 1, both the contacts become Normally Open and hence
the output becomes 0 i.e. the pilot lamp doesn’t light up.
NOR Gate:
The truth table for the NOR gate is:
A B Output

0 0 1

0 1 0

1 0 0

1 1 0
The given truth table can be implemented using the relay logic as follows –

Here, two normally close contacts are connected in series which means the pilot lamp will light up only if
both the inputs are 0. If any one of the inputs becomes 1, that contact changes to normally open, and hence
the flow of current is interrupted, thereby causing the pilot lamp not to light up, indicating 0 output.

Q: Problems of RLC
In the “traditional” form of the RLC control system, wiring is made based on the rules governing the control
system. For a large control system, a huge amount of wiring is needed. When the rules used for the control
actions are changed, the wiring has to be removed and has to be made a new wiring.
For example, let’s draw the RLC ladder diagram for a motor that will start when both a presser switch and
a temperature switch are closed or when a push button is closed.
The RLC ladder diagram is shown below.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 14

Figure 1: RLC ladder diagram.

Now, the changes require that the manual pushbutton control should be permitted to operate at any pressure
but not unless the specified temperature setting has been reached. The new RLC ladder diagram is shown
below.

Figure 2: The modified RLC ladder diagram for the modified process.
So we have to remove the connection and need to make a new connection. This rewiring in RLC is
extremely difficult for a large control system.
Besides, if a fault occurs in wiring then it is extremely difficult to identify and repair.

(a) (b)
Fig. 4

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Q: Generation 3
The fundamental component of the 3rd generation automation is the microprocessor. After the invention of
the microprocessor, a new era of control systems opened. We can connect the input and output devices to
the microprocessor. We just need to write a program to instruct the microprocessor how to react to each
input signal from, say, switches and give the required outputs to, say, motors and valves. Now we can make Page | 15
control in any control rules just changing the control program. For example,
A push button, a temperature sensor (switch), and a pressure sensor (switch) are connected to a
microprocessor as input devices. Besides, a motor is connected to the same microprocessor as the output
device.

Fig. 5(a)
Let’s we want to turn on the motor when both the presser switch and the temperature switch are closed
based on the condition satisfied or when a push button is closed. We have to write the control program with
the following logic and load to the microprocessor memory.

Fig. 5(b)
Now, the changes require that the manual pushbutton control should be permitted to operate at any pressure
but not unless the specified temperature setting has been reached.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
In this case, we just need to rewrite the program in the following way and load it to the microprocessor
memory.

Page | 16

Fig. 5(c)
So, there is no need to change the hardwire connection. For any control rule, we just have to rewrite the
control program.
By changing the instructions in the program, we can use the same microprocessor system to control a wide
variety of situations.
A microprocessor by itself is not a computer. Additional components such as RAM, ROM, PROM, and
peripheral interfaces are required to make it operational. However, the microcontroller, which is a close
relative of the microprocessor, does contain all the computer functions on a single IC. Microcontrollers
have their compactness is ideal for many control applications. For examples
• Vending machines use a microprocessor system
• Modern domestic washing machines use a microprocessor system
In these machines, the required written program is loaded in the microprocessor memory, and the
microprocessor is installed inside the machine.
In the washing machine, inputs to it arise from the dials used to select the required wash cycle, a switch to
determine that the machine door is closed, a temperature sensor to determine the temperature of the water,
and a switch to detect the level of the water. On the basis of these inputs, the microprocessor is programmed
to give outputs that switch on the drum motor and control its speed, open or close cold and hot water valves,
switch on the drain pump, control the water heater, and control the door lock so that the machine cannot be
opened until the washing cycle is completed.
However, the limitations of a microprocessor-based control system are that it can handle only a limited
number of inputs and outputs and is not suitable for an industrial rush environment.

To overcome the limitations of the microcontroller-based automation systems, the programmable logic
controller (PLC) is designed. A programmable logic controller (PLC) is a special form of microprocessor-
based controller that uses programmable memory to store instructions and to implement functions such as
logic, sequencing, timing, counting, and arithmetic in order to control machines and processes.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 17
Figure 1.7: A programmable logic controller.
PLCs are specially hardened industrial computers. The first PLC was designed in 1969.

Q: What is a PLC?
• PLC stands for Programmable Logic Controller.
• PLC is an industrial-grade digital computer designed for industrial process control.
• Programmable logic controllers, also called programmable controllers or PLCs, are solid-state
members of the computer family, using integrated circuits instead of electromechanical devices to
implement control functions.
• PLCs can be thought of in simple terms as industrial computers with specially designed architecture
in both their central units (the PLC itself) and their interfacing circuitry to field devices
(input/output connections to the real world).
• A PLC is a computer specially designed to operate reliably under harsh industrial environments –
such as extreme temperatures, wet, dry, and/or dusty conditions.
• PLC is an industrial-grade computer that is capable of being programmed to perform control
functions.
• PLCs are used to automate industrial processes such as a manufacturing plant’s assembly line, an
ore processing plant, or a wastewater treatment plant.
• Programmable logic controllers are now the most widely used industrial process control
technology.

Q: Explain the advantages of PLC over RLC with an example

Input devices (sensors and switches) and output devices (motors, valves, etc.) in the system being controlled
are connected to a PLC. The operator then enters a sequence of instructions, program, into the memory of
the PLC. The PLC controller then monitors the inputs and outputs according to this program and carries
out the control rules for which it has been programmed.
Two input devices and one output device are connected to a PLC as shown in Fig. 1(a). Now we can control
the output device for different control rules without rewiring. We just need to update the control program
as shown in Fig. 1(b), Fig. 1(c), Fig. 1(d), and Fig. 1(e).

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 18

(a)

(b) (c)

(d) (e)
Fig. 1
On the other hand, an RLC is shown in Fig. 2(a) which is implemented using two relays. We can
control the output device under different control rules. But for different control rules we have to
rewire the connection as shown in Fig. 2(b), Fig. 1(c), and Fig. 2(d).

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 19

(a)

(b) (c)

(d)
Fig. 2

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
This rewiring is very difficult for large control system.
PLCs have the great advantage that the same basic controller can be used with a wide range of control
systems. The input devices among themselves, the output devices among themselves, and input devices
with output devices are connected through softwire. So to modify a control system, all that is necessary is
for an operator to change the control program. There is no need to rewire. The result is a flexible, cost-
Page | 20
effective system that can be used with control systems, which vary quite widely in their nature and
complexity.

Q: Compare with an example the method by which the process control operation is changed in a
relay-based system to the method used for a PLC-based system.
In PLC:
Draw the PLC ladder diagram for the following condition: A motor will start when both a presser switch
and a temperature switch are closed or when a push button is closed.

Figure 1: The required PLC ladder diagram.

Coil 0/1 is energized when contacts I/1 and I/2 are closed or when contact I/3 is closed. Either of these
conditions provides a continuous path from left to right across the rung that includes the coil.
Now,
The changes require that the manual pushbutton control should be permitted to operate at any pressure but
not unless the specified temperature setting has been reached.

Figure 2: The modified PLC ladder diagram.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
If a PLC is used, no rewiring is necessary. The input and output are still the same. All that is required is to
change the PLC program.
In RLC:
Draw the RLC ladder diagram for the following condition: A motor will start when both a presser switch
and a temperature switch are closed or when a push button is closed.
Page | 21

Figure 1: The required RLC ladder diagram.

Now,
The changes require that the manual pushbutton control should be permitted to operate at any pressure but
not unless the specified temperature setting has been reached.

Figure 2: The modified RLC ladder diagram for modified process.

In RLC rewiring is needed, which is very difficult for a large number of control rules.

Q: Explain the advantages of PLC over RLC with an example

Let’s look at an example to better understand this advantage.
Imagine you have a light connected to a switch. In general, the light operates under two conditions – ON
and OFF. Now you are given a task that when you turn ON the switch, the light should glow only after 30
seconds. With this hard-wired setup – we’re stuck. The only way to achieve this is to completely rewire our
circuit to add a timing relay. That’s a lot of hassle for a minor change.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Page | 22

Light Switch
This is where a programmable logic controller comes into the picture, which doesn’t require any additional
wiring and hardware to make sure of a change. Rather it requires a simple change in code, programming
the PLC to only turn on the light 30 seconds after the switch is turned ON. So, by using a PLC, it is easy to
incorporate multiple inputs and outputs.

Q: PLC Market/Manufacturers
The programmable logic controller (PLC) market was valued at USD 3897.36 million in 2019 and is
expected to reach USD 4292.66 million by 2025.

Some major manufacturers are

• Allen Bradley
• Siemens
• Mitsubishi PLC
• Hitachi PLC
• Delta PLC
• General Electric PLC
• Honeywell PLC

We (BSMRSTU-EEE) have Siemens PLC in our lab.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Model: S7-1200
S7-1200 is a relay type PLC.

Page | 23

Fig. 1.10: S7-1200 PLC

Q: PLC Applications
PLCs have a variety of applications and uses, including:
1. Process Automation Plants (e.g. mining, oil &gas)
2. Glass Industry
3. Paper Industry
4. Cement Manufacturing
5. In boilers – Thermal Power Plants

Q: Advantages of using PLC over RLC (Hugh Jack 2.1 and Petruzella-2)
• Increased reliability
• More flexibility
• Lower cost
• Communications capability: A PLC can communicate with other controllers and computer
equipment.
• Faster response time
• Easier to troubleshoot
• There are no physical connections between the field input devices and output devices, as in
hardwired systems. The only connection is through the control program (softwiring), which can be
easily altered.

Q: Difference between Relay and PLC (only 6)

Both relay and PLC are the devices that are used for industrial automation, however, several differences
between them are given in the following table
Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Basis of Difference Relay PLC

Definition A relay is an electrically operated A PLC is a semiconductor-based
switch that is used to turn ON/OFF switching device that is used to control
a high-power circuit by using a the industrial process automatically.
low-power signal. Page | 24
Types The relays are broadly The PLCs are also classified into two
classified into two types types namely compact PLC and
namely electromagnetic relays modular PLC.
and solid-state relays.
Construction An electromagnetic relay consists A typical PLC consists of an input
of an electromagnet, an armature, module, a processing element, an
a set of input terminals, and a set application (PLC program), a power
of control terminals. supply, and an output module.
Operation In the case of the relay, when a When the input signal is received from
low power control signal is the input devices like sensors, the
provided at the input terminals, processing device makes a decision
the armature of the relay moves and releases an output signal through
under the influence of the the output module.
magnetic field of the
electromagnet to turn on and
off the circuit.
Name of control The control system designed by The control system in which PLC is
system using relays is known as relay used is known as programmable logic
logic control. It is also called a control.
hard-wire control system.
Programming Relays do not require PLCs are programmed to work. There
programming to work. are different programming languages
available for PLC programming.
Modification in Very difficult Very easy
circuit design
Memory Relay does not have memory. PLC has a memory module to store the
program.
Fault determination It is difficult to detect the fault It is very easy to determine the fault in
in a relay circuit. a PLC-based circuit by using software.
Flexibility Relay provides a less flexible The flexibility of a PLC base system is
control system. comparatively more.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh

Input-output A relay has relatively less I/O PLC has more I/O capability.
capability capability.
Advanced A relay performs only a fault PLC can also be programmed to
functionality detection function. And it does perform several advanced functions
not have any other advanced like timer, counter, etc. Page | 25
functions.
Wiring It requires a lot of wiring Very little wiring when compared to
relay logic
Rewiring Rewiring is required to change Logic can be easily changed by
the logic changing the program
Environmental Relays can’t handle humidity, PLCs can handle vibrations,
effect vibrations, and temperature as temperature, humidity, etc
good as PLC’s
Physical appearance

Q: Disadvantages of RLC over PLC

1. Complex wiring
2. More time to implement
3. Comparatively less accuracy
4. Difficult to maintain
5. Fault detection is hard
6. Provide less flexibility

Q: PLC versus PC (only important six)

The differences between PC and PLC are summarized below.
PC PLC
Computers are optimized for calculation and PLCs are optimized for control tasks and the
display tasks industrial environment.

Personal computers are more liable to crash than PLCs have greater reliability
PLCs

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Personal computers are so good at long-term They are not as good at long-term data storage and
data storage and analysis analysis as personal computers.
Programming PCs need expertise. As a PLCs are easily programmed and have an easily
consequence, they are not user-friendly. understood programming language that is primarily
concerned with logic and switching operations. As a
Page | 26
consequence, they are more user-friendly.
PCs are not flexible to expand to tackle a larger PLCs in a rack format are easy to expand to tackle a
number of input/output devices. larger number of input/output devices.
The common input devices of PCs are The common input devices of a PLC are switches,
keyboards and mouse connected to the input and sensors connected to the respective input
ports. modules.
The common output devices of a PC are a The common output devices of a PLC are control
monitor, and printer connected to the output valves, VFD drives, and solenoid valves connected
ports. to the respective output modules.
PC requires clean space and sometimes air- Operates in an industrial environment. PLC is
conditioned room for its lifetime operation. The designed in such a way that it can withstand
common personal computer is not designed for industrial environments like different ambient
harsh environments. temperatures, humidity, and electrical noise.
PLCs are rugged and designed to withstand
vibrations, temperature, humidity, and noise.
Capable of executing several programs Most PLCs, on the other hand, execute a single
simultaneously, in any order. program in an orderly and sequential fashion from
the first to the last instruction
Have hard drive Have no hard drive

Similarity:
PLCs share many features of the personal computer you have at home.
• PLC and PC share the same architecture.
• They both have a power supply,
• They both have a CPU (Central Processing Unit),
• They both have inputs and outputs (I/O), memory,
They both have operating software (although PLC has a different operating software).

Compare the PLC and PC with regard to:

a. Physical hardware differences
b. Operating environment
c. Method of programming
d. Execution of program
a.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation

 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
PLC and PC share the same architecture. But PCs are optimized for input devices such as keyboards and
mouse connected to the input ports. And PLCs are optimized for input devices such as switches, and sensors
connected to the respective input modules. PC also have hard disk for long time data storage. On the other
hand PLCs do not have such storage.
b.
Page | 27
PC PLC
PC requires clean space and sometimes air- Operates in an industrial environment. PLC is
conditioned room for its lifetime operation. The designed in such a way that it can withstand
common personal computer is not designed for industrial environments like different ambient
harsh environments. temperatures, humidity, and electrical noise.
PLCs are rugged and designed to withstand
vibrations, temperature, humidity, and noise.

c.
PC PLC
Programming PCs need expertise. As a PLCs are easily programmed and have an easily
consequence, they are not user-friendly. understood programming language that is primarily
concerned with logic and switching operations. As a
consequence, they are more user-friendly.

d.
PC PLC
Capable of executing several programs Most PLCs, on the other hand, execute a single
simultaneously, in any order. program in an orderly and sequential fashion from
the first to the last instruction

Q: Generation 4 of Automaton
The key technology and fundamental component of fourth-generation automation is the Internet of Things
(IoT). It is not easy to separate IoT and automation because automation is a tremendous driver for the
development of IoT devices. Automation has given applicable purposes to many IoT technologies.
Internet of Things (IoT):
In traditional Internet using traditional computing devices (such as desktops, laptops, smartphones, and
tablets), one people exchange data with other peoples. So we can say that the traditional Internet is the
“Internet of Peoples”.
When one “Thing (Physical object)” can exchange data, at anytime and anywhere, with another “Thing
(Physical object)” then it is called the “Internet of Things (IoT).”
For IoT, three factors must be secured
• Things
• Connectivity
• Cloud
Things: An embedded (microprocessor) system with sensors and actuators.
Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation
 গগোপোলগঞ্জ বিজ্ঞোন ও প্রযুবি বিশ্ববিদ্যালয়
Gopalganj Science and Technology University
ইগলবিক্যোল অ্যোন্ড ইগলিবনক্ ইবঞ্জবনয়োব িং বিভোগ Dept. of Electrical and Electronic Engineering
ইবঞ্জবনয়োব িং অ্নুষদ Faculty of Engineering
গগোপোলগঞ্জ-৮১০০, িোিংলোগদশ Gopalganj-8100, Bangladesh
Connectivity: Bluetooth, Wi-Fi, LTE, etc.
Cloud: Thinger.io
So the IoT extends Internet connectivity beyond typical computing devices (such as desktops, laptops,
smartphones, and tablets) to any range of non-Internet-enabled physical devices and everyday objects to
sense, communicate, and interact with each other. Embedded with the microprocessor, these devices can
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communicate and interact over the internet, sharing their internal states or the external environment, and
can be remotely monitored and controlled. In general, Internet of Things (IoT) devices are nonstandard
computing hardware. Typically, non-IoT devices include PC, mobile phones, tablets, laptops, or landlines.
Why IoT:
In agriculture, one Thing-A will measure the humidity of the soil and send data to the cloud through
connectivity. Another Thing-B takes data from the cloud, analyzes it, and turns on the water pump if needed.
Another Thing-C collects the data about insect attack to the agriculture field and sends it to the cloud.
Another Thing-D collects data from the cloud and takes necessary actions based on the analyzed data. So
via cloud, Things are communicating and exchanging data with one another for better results.
In home, “Thing-A” collects the humidity data and sends it to the server. The “Thing-B” collects the
analyzed data from the cloud and activates the actuator to keep humidity within a comfortable range. Here,
two Things are communicating and exchanging data. Similarly, “Thing-C” collects the temperature data
and sends it to the server, where “Thing-D” collects the analyzed data from the cloud and activates the
actuator to keep the temperature within a comfortable range. Similarly, “Thing-E” collects the data about
the mode and sends it to the server, where “Thing-F” collects the analyzed data from the cloud and plays
music (actuator) matched to the mode. In this way, all Things communicate and exchange data to make life
comfortable in IoT.
In industry, Industrial devices like sensors, connectors, actuators, interfaces, motion controllers, lightbulbs,
locks, etc., each act as an IoT device. So they will have the capability to share information about their
condition and performance in the cloud.
Combined with cloud computing and advanced data analytics, automation IoT software can manage these
devices and learn to adapt accordingly to accommodate new ones as necessary. When data generated by
IIoT devices can be analyzed with appropriate techniques, we can leverage to improve efficiency,
productivity, visibility, and more. The Internet of Things (IoT) in industrial automation is also known as
the Industrial Internet of Things (IIoT). It refers to the use of Internet of Things technology (connected
machines, devices, and sensors) in industrial applications. IIoT networks typically support machine-to-
machine (M2M) communication and the regular transmission of data between the central system (cloud)
and all IIoT-integrated devices. It enables building self-managing production processes requiring cloud
computing and communications standards that allow sensors, controllers, people, machines, equipment,
logistics systems, and products to communicate and cooperate directly.

Dr. Md. Rabiul Islam, Associate Professor ∥ [email protected] ∥ Introduction to Automation