Project Report On "Industrial Automation": Submitted in Partial Fulfillment of The Requirement For The Degree of
Project Report On "Industrial Automation": Submitted in Partial Fulfillment of The Requirement For The Degree of
Bachelor of Engineering
In Electronics and Communication Engineering
I/We hereby declare that this Report will contain literature survey and
original work by undersigned candidate/candidates, as part of their
bachelor studies.
I also declare that, as required by these rules and conduct, I will be fully
cited and referenced all material and results that are not original to this
work.
Acknowledgment
4
PREFACE
2
AUTOMATION
Introduction:-
Example of automation
Industrial robots
Industrial Robots
feedback control systems
TYPES OF AUTOMATION
Fixed automaton
Programmable automation
Flexible automation
Fixed automation
The primary drawbacks are the large initial investment in requirement and
the relative flexibility.
Programmable automation
INDUSTRIAL AUTOMATION
PLANT
Field instrument
This type of instrument mainly used to get the feedback any type of
process carried our so they mainly plant used
Proximity Sensor.
Intelligent controller
This device are basically micro control based or micro controller device mainly
intelligent controller are:
Programmable logic controller (PLC)
PID Controller
Distributed controller system (DCS)
Computer Numerical controller (CNC
PLC
This type of device to control whole plant just in a setting in control room,
so mainly control device are
Need of Robot:-
Robots are typically used to do the tasks that are too dirty, dangerous, difficult,
repetitive or dull for humans. This usually takes the form of industrial robots used
in manufacturing lines.
History:
Manipulators: Robot manipulators are created from a sequence of link and joint
combinations. The links are the rigid members connecting the joints, or axes. The
joints are the movable components of the robotic manipulator that cause relative
motion between adjoining links. The mechanical joints used to construct the
robotic arm manipulator consist of five principal types. Two of the joints are linear,
in which the relative motion between adjacent links is non-rotational, and three are
rotary types, in which the relative motion involves rotation between links.
Usually Robots are made up of Servo motors with feedback network .Speed and
torque can be operated differently as it works on variable angular rotation.Torque
will change input power at constant speed.
Jogging of robots:
Joint by joint: we can move each &every point and exit anywhere.
Linear: when we working with one coordinate axis others are constant, eg. We can
use one point at a time.
Laws of robots:
First law: It may not injure human or through inactions allow human being come to
harm.
Second law: It must obey orders given to it by humans expect orders which
contradicts with first law.
Third law: It must protect its own existence.
Robot base:-
Fixed base: Manipulators are fixed. They cant fix their base away from work
being done.
Movable base: Its platform is wheel or track attached or legs employed.
What is relay?
ADVANTAGES
PLC not only capable of performing the same tasks as hard-wired control, but are
also capable of many more flexible application. In addition, the PLC program and
electronic communication lines replace much of the interconnecting wires require
hardwire control. Therefore, hard wiring, thought still required to connect field
device, is less intensive. This also makes correcting errors and modified the
application easier.
P h o t o g r a p h s h o wi n g s e v e r a l i n p u t a n d o u t p u t mo d u l e s
o f a s i n g l e Al l e n - Bradley
INSIDE PLC
The Central processing Unit (CPU), contains and internal program that tells the
PLCs how to perform the following functions:
The cpu:
RAM
RAM or Random Access Memory is a volatile memory that would lose its
information if power were removed. This is why some processors units
incorporate a battery back-up. CMOS RAM is used for storage of the users
program (ladder logic diagrams) and storage memory.
ROM
ROM or Read only memory is a non volatile memory. This means you dont need
external power source to keep information. In this type of memory, information
can be read, but not changed
EEPROM:
INPUT MODULE
There are many types of input module to choose form. Some example input are
limit switches, electric eyes, and pushbuttons. DC input, such as thumbwheels
switches, can be used to enter integer values to the manipulated by the PLC, DC
input cards are used for this application.
Allen-Bradley is the brand-name of a line of Factory Automation Equipment
manufacturer.
* LOGIC 1, LOGIC 0
In the function block diagram, the function and blocks are represented graphically
interconnected into networks. The function block diagram originates from the logic
diagram for the design of electric circuits.
LADDER LOGIC
Ladder Logic, Ladder programs is the most common programming language used
to program a PLC.
Ladder Logic was one of the first programming approaches used in PLCs because
it borrowed heavily from the relay diagram that plant electricians already knew.
If input is on (or true)- power (logic) completes the circuits from the left rail-
and output turns ON(or true)
If output is off (or false)- then the circuit is not complete and logic does not
follow to the right- and output 1 is OFF
This can be used to represent any discrete output from the control logic
When solve if the logic to left of the coil is TRUE, the referenced OUT is
ON (logic1)
SCADA stands for Supervisory Control And Data Acquisition any application
can gets data about a system in order to control the system is a SCADA application
it is a purely software package that is positioned on top of hardware to which it is
interfaced , in general via Programmable logic controller (PLCs), or other
commercial hardware modules.
Systems Concepts
The terms SCADA usually refer to a central system that monitors and controls a
complete site. The bulk of the site control is actually performed automatically by a
Remote Terminal Unit (RTU) or by a programmable Logic controller (PLC). Host
control functions are almost always restricted to basic site over- ride or supervisory
level capability.
EX: A PLC may control the flow of cooling water through part of an industrial
process, but the SCADA system may allow operators to change the set points for
the flow, and enable alarm condition, such as loss of flow and high temperature, to
be displayed and recorded. The feedback control loop passes through the RTU or
PLC while the SCADA system monitors the overall performs of the loop.
TAGS (POINTS)
Trends:
it is used for graphical representation of process
Two types
Real times trends
Historical Times trends
Classification of tags
Direct tags
Indirect tags
Direct tags
These tags are directly used by the programmer to represent the value of
plant or variable
Indirect tags
These tags are used by the another tags to show or represent the value of plant or
variable
Direct tags
Memory tags : these tags having no connection with process the plant.
ALARM
Benefits HMI/SCADA:
1. Powerful monitoring and control over your production
2. Ease of use for New and experienced users.
3. Robust connectivity to other software, system and devices
4. True client /server Architecture for ease Scale ability.