INDUSTRIAL AUTOMATION USING PLC

INDUSTRIAL AUTOMATION
USING
PLC

CONTENTS
• AUTOMATION
• TYPES OF AUTOMATION
• INDUSTRIAL AUTOMATION
• DEVELOPMENT OF CONTROL SYSTEM
• WHAT IS PLC
• WHY PLC?
• COMPONENTS OF PLC
• PLC OPERATION
• PLC PROGRAMMING
• APPLICATIONS
• ADVANTAGES AND DISADVANTAGES
• CONCLUSION

AUTOMATION
 Automation is basically the delegation of human control
functions to technical equipment aimed towards
achieving:
Higher productivity.
Superior quality of end product.
Efficient usage of energy and raw materials.
Improved safety in working conditions etc.

TYPES OF AUTOMATION
 Building automation
Example: lifts, smoke detectors
 Office automation
Example: printers, cctv cameras
 Scientific automation
Example: rocket launching
 Light automation
Example: street solar lightening
 Industrial automation
Example: automated bottle filling stations , steel factories etc

INDUSTRIAL AUTOMATION
 The use of Computerized or robotic devices to
complete manufacturing tasks.
PLANT
FIELD
INSTRUMENT
CONTROL SYSTEM
HARDWARE
CONTROL
SOFTWARE
CONTROL

DEVELOPMENT OF CONTROL SYSTEM
 Manual control
 Pneumatic control
 Hard wired logic control
 Electronics control
 PLC control.

PLC(PROGRAMMABLE LOGIC CONTROLLER)
 Programmable Logic Controller (PLC) is an industrial computer
that monitors inputs, makes decisions based on its program and
controls outputs to automate a process or machine.
 The automation of many different processes, such as controlling
machines or factory assembly lines, is done through the use of small
computers called a programmable logic controllers (PLCs).

WHY PLC?
 To reduce human efforts .
 To get maximum efficiency from machine and control them with
human logic .
 To reduce complex circuitry of entire system .
 To eliminate the high costs associated with inflexible, relay-controlled
systems.

UNDERSTANDING OF PLC (Example )
Machine can be controlled by PLC without human efforts

MAJOR COMPONENTS OF A PLC
PROCESSOR
POWER
SUPPLY
I M
N O
P D
U U
T L
E
O M
U O
T D
P U
U L
T E
PROGRAMMING
DEVICE
From
SENSORS
Pushbuttons,
contacts,
limit switches,
etc.
To
OUTPUT
Solenoids,
contactors,
alarms
etc.

PLC
INPUT OUTPUT
PUSH BUTTONS
1. INPUT MODULES accepts and converts signals from sensors into a
logic signal
Ex. : Switches, Pushbuttons.
2. OUTPUT MODULES that convert control instructions a signal that can
be used by actuators.
Ex. : lamps, alarm.
COMPONENTS (INPUT /OUTPUT)

3. CENTRAL PROCESSING UNIT(CPU)
It is the brain of PLC and governs the activities of the entire PLC systems
 The CPU consists of following blocks :
Arithmetic Logic Unit (ALU),
Internal memory of CPU
Internal timers ,counters and Flags .
 The various operations performed are :
Scanning I/O bus traffic control,
Program execution,
Peripheral and External device communication,
Data handling and self diagnostics.
PROCESSOR
4. MEMORY is the component that stores information, programs and data in
a PLC.
COMPONENTS (CPU ,MEMORY)
Types of memories used in PLCs are read only memory (ROM) and
random access memory (RAM).

5. POWER SUPPLY
Provides the voltage needed to run the primary PLC
components. POWER
SUPPLY
6. PROGRAMMING DEVICE
The programming terminal is used for programming
the PLC and monitoring/sequencing PLCs
operation.
PROGRAMMING
DEVICE
COMPONENTS (POWER SUPPLY, PROGRAMMING DEVICE)

 CHECK INPUT STATUS
First the PLC takes a look at each
I/O to determine if it is on or off.
 EXECUTE PROGRAM
Next the PLC executes the program
one instruction at a time.
 UPDATE OUTPUT STATUS
Finally the PLC updates the status of
the outputs .It updates the outputs
based on which inputs were on during
the first step.
PLC OPERATION

Ladder logic is a programming language used to develop software for
PLC used in industrial control applications.
RUNGES
RAIL RAIL
PLC PROGRAMMING

ELEMENTS OF LADDER LOGIC
NORMALLY OPEN NORMALLY CLOSED
(CONTACT) (CONTACT)
COILS

LADDER LOGIC EXAMPLE
OR OPERATION
A
B
C
In the above diagram, it can be seen that either
input A or B is be true (1), or both are true, then the
output C is true (1).

 Manufacturing / Machining
 Food / Beverage
Textile Industry
 Travel Industry
 Aerospace
 Printing Industry
AREAS OF APPLICATION

 Replacing Human Operators
Dangerous Environments
Beyond Human Capabilities
 Fast
 Easily programmed and have an easily understood
programming language.
 Improves Productivity
 Improves Quality
ADVANTAGES

 PLC Devices Are Proprietary
 Initial Costs Are High
 There's Too Much Work Required In
Connecting Wires
 Unemployment Rate Increases
DISADVANTAGES

 The PLC 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 a small number of relays to complex
automation problems.
 Today the PLCs are used for control & automation job in a
single machine & it increases up to full automation of
manufacturing / testing process in a factory.
CONCLUSION

INDUSTRIAL AUTOMATION USING PLC

INDUSTRIAL AUTOMATION USING PLC

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INDUSTRIAL AUTOMATION USING PLC