PROGRAMMABLE LOGIC

CONTROLLER
UEC1605
Objectives
Be familiar with factory automation
Be exposed to programmable logic controllers
Learn to programme PLC
Be exposed to HMI systems
Learn to install and maintain procedures for PLC
Be exposed to applications of PLC
 SYLLABUS
UNIT – I INTRODUCTION TO FACTORY AUTOMATION 9

• History and developments in industrial automation. Vertical integration of industrial automation, Control elements in industrial automation, PLC introduction.

UNIT – II PROGRAMMABLE LOGIC CONTROLLERS 9

• Basics of PLC, Advantages, Capabilities of PLC, Architecture of PLC, Scan cycle, Types of PLC, Types of I/O modules, Configuring a PLC, PLC wiring.

UNIT – III PROGRAMMING OF PLC 9

• Types of Programming - Simple process control programs using Relay Ladder Logic - PLC arithmetic functions - Timers and counters –data transfer-comparison and manipulation instructions,
PID instructions, PTO / PWM generation.

UNIT – IV HMI SYSTEMS 9

• Necessity and Role in Industrial Automation, Text display - operator panels - Touch panels - Panel PCs - Integrated displays, interfacing PLC to HMI.

UNIT – V INSTALLATION 9
• Installation and maintenance procedures for PLC - Troubleshooting of PLC, PLC Networking- Networking standards & IEEE Standard - Protocols - Field bus - Process bus and Ethernet.
Applications of PLC Case studies of Machine automation, Process automation, Selection parameters for PLC. Introduction to Programmable Automation Controller.
TEXT BOOKS
COURSE OUTCOMES
Understand the basics of programmable logic
controllers for industrial applications

Apply the engineering knowledge to Program PLC

Design HMI systems

Apply the knowledge for the design of different

display units.

Apply the contextual knowledge of PLC for

societal applications
INTRODUCTION TO FACTORY
AUTOMATION

UNIT 1
CONTENTS OF UNIT 1

History and Vertical Control

developments integration of elements in PLC
in industrial industrial industrial introduction.
automation. automation automation
History and developments in industrial automation
Industrial Automation can be defined as
the use of control systems and technology to the
processes of procurement,
material handling,
manufacturing,
process Industry,
quality control
with the objective of ensuring minimal human
intervention.
History of Automation
11th century when miners used waterwheels to drain out
water from underground tunnels and shafts.
modern form of automation took shape during the Industrial
Revolution in the 1800s when automated processes and tools
were used to increase factory productivity
Use of electricity in the1920s led to faster production
process at the factory changing the factory floor
dynamics.
The application of feedback controllers by the industry during
the 1930s and 40s was a significant step towards modern
automation in manufacturing.
By 1980s the world saw new levels of automation with many sectors from
manufacturing and retail to pharmaceutical and consumer goods embracing
some or the other form of technology to further productivity
Early 2000
PRESENT 2020
TECHNICAL AUTOMATION

Manual Control

Pneumatic Control.

Hard wired logic Control.

Electronic Control using Logic Gates.

Programmable Logic Controller.

 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.

1
 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 lot of rework to implement control logic.
• Longer project time.

2
 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
• Longer project time
• Difficult maintenance and troubleshooting

2
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.

Drawbacks.
• Reduced space requirements.
• Energy saving.
• Less maintenance & greater reliability.
• Changes in control logic not possible.
• More project time.

2
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.
 The programmable controllers have in recent years experienced
an unprecedented growth as universal element in Industrial
Automation.
 It can be effectively used in applications ranging from simple
control like replacing small number of relays to complex
automation problems

10
Advantages of PLCs

Reduced
Shorter space
project time

Tremendous Energy
flexibility saving

Ease of
Greater life
maintenanc
& reliability
e

Economical
History of industrial revolution

1.0 •1780 - Mechanization

2.0 •1870 - Electrification

3.0 •1970 - Automation

3.5 •1980 - Globalization

4.0 •Today - Digitalization

5.0 •Future - Personalization

VERTICAL INTEGRATION OF
INDUSTRIAL AUTOMATION
VERTICAL INTEGRATION

Vertical integration is a
strategy that allows a
Vertical integration in
company to streamline
an automation system
its operations by taking
collects data at the The significant initial
direct ownership of
lowest level and capital investment
various stages of its
enables that required.
production process
information to travel to
rather than relying on
the highest level.
external contractors or
suppliers.
 Owning the Supply Chain

A typical company's supply chain or sales process begins with the purchase
of raw materials from a supplier and ends with the sale of the final product
to the customer.

Vertical integration requires a company to take control of two or more of

the steps involved in the creation and sale of a product or service. The
company must buy or recreate a part of the production, distribution, or
retail sales process that was previously outsourced.

Companies can vertically integrate by purchasing their suppliers to reduce

manufacturing costs. They can invest in the retail end of the process by
opening websites and physical stores. They can invest in warehouses and
fleets of vans to control the distribution process.

All of these steps involve a substantial investment of money to set up

facilities and hire additional talent and management. Vertical integration
also ends up increasing the size and complexity of the company's
operations.
Types of Vertical Integration
There are a number of ways
that a company can achieve
vertical integration. Two of
the most common are
•backward integration
•forward integration.
 Backward Integration
A company that chooses backward integration moves the ownership
control of its products to a point earlier in the supply chain or the
production process.
This form of vertical integration is aptly named as a company often
strives to acquire a raw material distributor or provider towards the
beginning of a supply chain. The companies towards the start of the
supply chain are often specialized in their distinct step in the process
(i.e. a wood distributor to a furniture manufacturer). In an attempt to
streamline processes, the furniture manufacturer would try to bring
the wood sourcing in-house.
Amazon.com, Inc. started as an online retailer of books that it
purchased from established publishers. It still does that, but it also
has become a publisher. The company eventually branched out into
thousands of branded products. Then, it introduced its own private
label, Amazon Basics, to sell many of them directly to consumers.
Forward Integration
A company that decides on forward integration expands by
gaining control of the distribution process and sale of its
finished products.
A clothing manufacturer can sell its finished products to a
middleman, who then sells them in smaller batches to
individual retailers. If the clothing manufacturer were to
experience forward vertical integration, the manufacturer
would join a retailer and be able to open its own stores. The
company would aim to bring in more money per product,
assuming it can operate its retail arm efficiently.
Forward integration is a less common form for vertical
integration because it is often more difficult for companies to
acquire other companies further along the supply chain. For
example, the largest retailers at the end of the supply chain
often have the greatest cashflow and purchasing power.
Balanced Integration
A balanced integration is a vertical integration approach in which a
company aims to merge with companies both before it and after it
along the supply chain. A company must be "the middleman" and
manufacture a good to engage in a balanced integration, as it must both
source a raw material as well as work with retailers to delivery the final
product.
Consider the supply chain process for Coca-Cola where raw materials
are sourced, the beverage is concocted, and bottled drinks are
distributed for sale. Should Coca-Cola choose to merge with both its
raw material providers as well as retailers who will sell the product,
Coca-Cola is engaging in balanced integration.
Though most costly and most risky due to the diversified nature of
business operations, balanced integration also poses the greatest upside
as a company is more likely to have greater (if not full) control over
the entire supply chain process.
FORWARD vs BACKWARD
Forward integration occurs when a vendor attempts to
acquire a company further along the supply chain (i.e.
acquire a retailer).
Backward integration occurs when a vendor attempts
to acquire a company prior to it along the supply chain
(i.e. a raw material provider).
Advantages and Disadvantages of
Vertical Integration
Vertical integration can help a company reduce
costs and improve efficiency. However, when
executed poorly, vertical integration may have
negative consequences on the company.
Advantages
The primary goal of vertical integration is to gain greater control over
the supply chain and manufacturing process. When performed well,
vertical integration may lead to lower costs, economies of scale, and a
lower reliance on external parties.
Vertical integration may lead to lower transportation costs, smaller
turnaround times, or simpler logistics if the entire process is managed
in-house. This may also result in higher quality products as the
company has direct control over the raw materials used through the
manufacturing line.
Sometimes, companies are at the whim of suppliers who have market
power. Through vertical integration, companies can circumnavigate
external monopolies. In addition, a company may gain insights from a
retailer on what goods are selling best; this information may be very
useful in making manufacturing and product decisions.
Disadvantages
Companies can't vertically integrate overnight; it is a long-term process that
requires widespread buy-in. This also includes heavy upfront
capital expenditure requirements to acquire the proper company, integrate
new and existing systems, and ensure staff are trained across the entire
manufacturing process.
By vertically integrating, companies do sacrifice a little bit of flexibility.
This is because they are committing capital to a specific process or product.
Instead of being able to decline purchasing from an external vendor, a
company will likely have committed money that can not be easily
recovered. In addition, a company may lose the opportunity to gain unique
knowledge through different external vendors.
Vertical integrate may also have several social impacts. Companies may end
up trying to do too much and lose focus of their ultimate goal. In addition,
customers may not support the culture of a large manufacturer also
interfacing directly with customers.
Vertical Integration
Advantages
May result in long-term cost saving due to favorable pricing and minimal
supply chain disruptions
Often results in economies of scale which increase efficiency
Reduces or eliminates the need to rely on external parties/suppliers
Leads to greater control over the product, inputs, and process which may
lead to superior products
Disadvantages
Often requires large upfront capital requirements to implement
May reduce a company's ability to be flexible in the long-term
May cause a company to lose focus on their primary objective or
customer
May result in displeased customer base who would prefer to work with
smaller retailer
 CHALLENGES FOR VERTICAL
INTEGRATION
Lack of communication: Horizontal integration assumes that a factory has devices and software capable of collecting
production data and sharing that data with other systems. To begin integration, you’ll need to either purchase new IoT-
enabled equipment or change existing equipment to allow interconnectivity. Strategies for IoT enabling legacy systems
include retrofitting them with sensors and connecting programmable logic controllers (PLCs) to the Internet using
converters. 
Knowledge silos: Knowledge silos occur when a factory's different information systems are incapable of sharing data
with one another, trapping information in one part of the machinery, production process or organization. If your
architecture is already compatible and relatively new, you may be able to eliminate knowledge silos by simply
integrating existing systems, setting them up to share data freely. In other cases, you may have to address incompatible
architecture before you can share production data with the rest of the business.
Asset management: Once you've integrated machines, data systems and devices in your Smart Factory, you must
continue to manage these assets to assure security and productivity. Implementing continuous network monitoring and
choosing industrial software with robust security features can help with asset management.
Supply chain management: For horizontal and vertical integration to impact resource efficiency, supply chain
management must be included in the network. Whether networking with external suppliers or integrating the internal
supply chain, manufacturers need to leverage data-driven technology to ensure smooth collaboration and sound
decision-making.
Economies of scale: Different shop floors must be horizontally and vertically integrated individually. Surveys have
shown that small and medium-sized businesses spend an average of $250,000 implementing Smart Factory technology,
and large businesses are likely to spend even more. The lack of economy of scale means manufacturers must make a
serious investment in technology, including new software for planning, controlling, visualizing and analyzing the
operational performance. The investment usually pays off, though, as the integration results in more cost-effective
production, consolidated management and reduced overhead costs.
Examples of Vertical Integration
The fossil fuel industry is a case study in vertical integration. British
Petroleum, ExxonMobil, and Shell all have exploration divisions that
seek new sources of oil and subsidiaries that are devoted to extracting
and refining it. Their transportation divisions transport the finished
product. Their retail divisions operate the gas stations that deliver their
product.
The merger of Live Nation and Ticketmaster in 2010 created a
vertically integrated entertainment company that manages and
represents artists, produces shows, and sells event tickets. The
combined entity manages and owns concert venues, while also selling
tickets to the events at those venues.4
This is an example of forward integration from the perspective of
Ticketmaster, and backward integration from the perspective of Live
Nation.
EXAMPLE
Netflix, Inc. is a prime example of vertical integration. The
company started as a DVD rental business before moving into
online streaming of films and movies licensed from major
studios. Then, Netflix executives realized they could improve
their margins by producing some of their own original content
like the hit shows Grace & Frankie and Stranger Things. It also
produced some bombs, like 2016's The Get Down, which
reportedly cost the company $120 million.
1 Today, Netflix uses its distribution model to promote its original
content alongside programming licensed from studios.
2 Instead of simply relying on the content of others, Netflix
performed vertical integration to become more engaged in the
entertainment development process earlier.
 What Is the Difference Between Vertical
Integration and Horizontal Integration?
Vertical integration is the practice of acquiring
different pieces along a supply chain that a company
does not current manage. On the other hand, horizontal
integration is the practice of acquiring similar
companies to further master what it already does.
Vertical integration makes a company more broad,
while horizontal integration may help it penetrate a
specific market further.
Control elements in industrial
automation
An automated control system consists of three
basic elements: Input Sensors, PLC, and
output actuators.
Industrial Automation
Components

Field Instruments.

Control Control
Software. Hardware.
Sensors ( Field Instruments )

 Sensors with transmitters are the field devices placed in the

field who actually sense the parameter and send the
analog signal to the control hardware.
 The analog signals used are Ohm (RTD), mV(Thermocouple),
4-20 mA, +/-10 V, etc

50
 Widely used Sensors
( Field Instruments )
RTD : Output in Ohms (Temperature)
Thermocouples : Output in mV (Temperature)
Pressure Transmitters : 4-20mA, 0-10 V …..
Flow Transmitter : 4-20mA, 0-10 V …..
Level Transmitter : 4-20mA, 0-10 V …..
Conductivity meter : 4-20mA, 0-10 V …..
Density meter : 4-20mA, 0-10 V …..
pH transmitter : 4-20mA, 0-10 V …..
51
Leading Manufacturers in Sensors
( Field Instruments )
Fisher Rosemount.
 Yokogawa.
 Anderson & Housers.
 Radix.
 ToshBro.

52
 Control hardware

Proportional–integral–derivative
(PID controllers)

Programmable Logic Controllers

(PLC)

Distributed Control System

53
Standalone PID Controllers

•These are the independent small hardware units which caters

requirement of closed loop controls in the process.
•These hardware can be installed in field or in control room.
•These hardware can be connected on the network.
•Currently the controllers are available with 100s of segment
and programming patterns.

54
PLC INTRODUCTION
 Programmable Logic controller
A PLC is a digital operating electronic apparatus which
uses a programmable memory for internal storage of
instruction for implementing specific function such as
arithmetic, logic, sequencing, comparing, timing and
counting to control through analog or digital input/output
modules various types of machines or process.
The other name of PLC is nothing but the Industrial grade
computer
 Programmable Logic controller
Features of PLC over other Controller:
Multiple field devices – (Car Manufacturing Line)
Extended temperature ranges – (Process control
Industries)
Resistance to humidity, pressure and vibration –
(Automation Installation inside the sea shore)
Easier to recover the program – (Master/Slave)
Rugged designed (External Damages)
Realtime control system (Output can be updated only
depends on the input condition)
RELAY LOGIC
 Evolution of PLC
Revolutionized the automation industry
Factory equipment to vending machines
1968 New years day for PLC
How before?
Machines inside the industry was fully controlled using relays (Power relays)
Relays has been placed between the power source and motor
To switch on/off the relays has to be energized or de energized (Where the switching time
will be controlled by the control relay)
Nearly 100 motors will be used in the industry which makes the control cabinet to be filled
by the power and control relays
Problem Pointed out by the personnel's:
Have to be properly hardwired (To understand the logic)
Troubleshooting would take an hours to identify the failure (Unlaced and criscros manner)
Strict maintenance schedule (Weekly/Monthly schedule 24*7)
Size of the cabinet (The electrical controller cabinet will be of 6*4 feet high if I use 50 to
100 relays)
Additional changes to be difficult (Changes the place of I/O devices)
Timing and counting actions cannot be done
 Evolution of PLC
Controller Cabinet
 Evolution of PLC
Hydramatic division of GE motors faces the above issues (Alto,
Celerio, Brio, Grand 10, Zest etc..,)
GM Engineers (Conversations about the concept of computer control
)
 With the list of requirements from GE engineers
Dick Morley and his team Bedford and Associates were invented the
first PLC in the year 1969 and named it as Modicon and presented to
the GM to meet their criteria
1968s-125 words memory size, Response time of the system was
slow
The first PLC was developed and it has an ability to work with I/O
signals, relay coil, contact, Internal logic, timers and counter
Initially the cost was high
Later on the other types of modules were interfaced
 Programmable Logic controller
Evolution
Year Development

1968 Programmable concept developed with 125 words of memory

1969 Hardware CPU controller, with logic instructions, 1 K of memory and 128
I/O points

1974 Use of several (multi) processors within a PLC - timers and counters;
arithmetic operations; 12 K of memory and 1024 I/O points

1976 Remote input/output systems introduced

1977 Microprocessors - based PLC introduced

1980 Intelligent I/O modules developed Enhanced communications facilities

Enhanced software features (e.g. documentation) Use of personal
microcomputers as programming aids

1983 Low - cost small PLC’s introduced

1985 Networking of all levels of PLC, computer and machine using SCADA
onwards software
OVERVIEW OF UNIT 1

History and Vertical Control

developments integration of elements in PLC
in industrial industrial industrial introduction.
automation. automation automation
APART FROM SYLLABUS

APPLICATION SLIDES
 Role of Engineers In Industrial
Automation
Designing of the Automation system.

Erection and Commissioning.

Maintenance and Troubleshooting of existing system.

69
 Job Prospect for Fresher
• Today management of almost all manufacturing units are
going for industrial automation to survive in globally
competitive market. Most of these industrial units are
looking forward for trained engineers in the field of
industrial automation.
•Since they are thinking about more accuracy, productivity in
less time & with minimum manpower , It’s a golden
opportunity to prepare yourself to take on this task.

70
 Job prospects for Engineers In
Industrial Automation
• Manufacturing Industries like Reliance, Ceat, Godrej,Colgate ….

•Automation Solution Products manufacturer/developer like

Rockwell, Siemens, Grouppe Schneider, Yokogawa, ABB.

• System Integrators for Grouppe Schneider Rockwell,

Siemens,
Etc.
• Consultants for Automation.
71
 Current Situation

•Automation is a high growth sector globally hence it

is

essential to all professionals and students to have practical

knowledge about the hardware and software used in

Industrial Automation.

72
 Architecture of industrial automation
system
 An Industrial Automation System consists of numerous elements
that perform a variety of functions related to Instrumentation,
Control, Supervision and Operations Management related to the
industrial process.
 These elements may also communicate with one another to
exchange information necessary for overall coordination and
optimized operation of the plant/factory/process. Below, we
classify the major functional elements typically found in IA systems
and also describe the nature of technologies that are employed to
realize the functions.
73
The Architecture of Elements: The
Automation Pyramid

74