industrial automation using plc
DESCRIPTION
The use of Computerized or robotic devices to complete manufacturing tasks.TRANSCRIPT
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INDUSTRIAL AUTOMATIONUSING
PLC
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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
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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.
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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
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INDUSTRIAL AUTOMATION The use of Computerized or robotic devices to
complete manufacturing tasks.
PLANT FIELDINSTRUMENT
CONTROL SYSTEM
HARDWARE CONTROL
SOFTWARE CONTROL
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DEVELOPMENT OF CONTROL SYSTEM
Manual control
Pneumatic control
Hard wired logic control
Electronics control
PLC control.
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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).
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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.
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UNDERSTANDING OF PLC (Example )
Machine can be controlled by PLC without human efforts
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MAJOR COMPONENTS OF A PLC
PROCESSOR
POWERSUPPLY
I MN O P D U UT L E
O M U OT DP UU LT E
PROGRAMMING DEVICE
From SENSORS
Pushbuttons,contacts,
limit switches,etc.
ToOUTPUT
Solenoids, contactors,
alarmsetc.
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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)
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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).
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5. POWER SUPPLY Provides the voltage needed to run the primary PLC components.
POWERSUPPLY
6. PROGRAMMING DEVICEThe programming terminal is used for programming the PLC and monitoring/sequencing PLCs operation.
PROGRAMMING DEVICE
COMPONENTS (POWER SUPPLY, PROGRAMMING DEVICE)
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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 programone 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
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Ladder logic is a programming language used to develop software for PLC used in industrial control applications.
RUNGES
RAIL RAIL
PLC PROGRAMMING
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ELEMENTS OF LADDER LOGIC
NORMALLY OPEN NORMALLY CLOSED
(CONTACT) (CONTACT)
COILS
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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).
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Manufacturing / Machining Food / BeverageTextile Industry Travel Industry Aerospace Printing Industry
AREAS OF APPLICATION
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Replacing Human Operators Dangerous Environments Beyond Human Capabilities
Fast
Easily programmed and have an easily understood programming language.
Improves Productivity
Improves Quality
ADVANTAGES
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PLC Devices Are Proprietary
Initial Costs Are High
There's Too Much Work Required In Connecting Wires
Unemployment Rate Increases
DISADVANTAGES
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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
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