Industrial Automation

Automation is encompassing virtually every

walk of life.

Automation solutions are required right from

agricultural to space technology.

Plant Automation is the necessity for the

manufacturing industry to survive in today’s
globally competitive market
 History of Industrial
Automation
Industrial Automation, with its machine and process
control, had its origin in the 1920s with the advent
of “ Pneumatic controllers” These devices, using
compressed air were flexible, economical and safe.
They created no spark hazards in an explosive
atmosphere and could be used under wet condition
without electrical shock hazard. It was very easy to
connect one device to another with tubing , pipe or
flexible hose.
 History of Industrial
Automation

Action were controlled by a simple manipulation of

valves, which in turn were controlled by relays and
switches. The air system provided great flexibility
in motion & speed control. Because there were few
moving parts reliability and low maintenance cost
were evident. Even today, Pneumatic control is widely
used in conjunction with PLCs and industrial computer
in all sort of machine and process control application
 History of Industrial
Automation

Even though pneumatic had, still has, its advantages,

especially with the advent of digital-logic pneumatic
-control components as an actual controlling device
it began to be replaced by discrete solid state
controllers in 1960s. These new controllers,
consisting first of transistors and later of individual
low and medium scale integrated circuits provided
reliable small, low power digital logic control
 History of Industrial
Automation

The big leap into true automation and industrial

control, however took place with the arrival of the
early 1970s. Now it was the program, or software,
that modeled and emulated the modulating control
that had been previously achieved by hardwiring
discrete gates, encoders/decoders, counters, timers,
flip-flops and similar digital circuitry.
 History of Industrial
Automation

Furthermore, with the tiny microprocessor controller

“ distributive intelligence” become reality.
The controller was brought closer to the part of the
process to be controlled.
 History of Industrial
Automation

Although the microprocessor controller (often called”

micro controller”) has found its in machine and process
control, embedded as it is within the controlled device,
it is the PLC that has come to dominate industrial
automation. With its dedicated I/Os (analog and
digital), redundant hardware, Scanner processing and
ladder logic programming,the PLC today represents
the optimum way to achieve industrial control.
Industrial Automation Components …

 FieldInstruments
 Control Hardware
 Control Software
 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
 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 …..

And Many more

Leading Manufacturers in Sensors
( Field Instruments )

Fisher Rosemount
Yokogawa
Endress & Haussers
Radix
ToshBro
Forbes Marshal
 Control hardware

 Standalone PID Controllers

 Programmable logic controllers (PLC)

 Distributed Control System (DCS)

 cPCI Systems (Compact PCI Systems)

 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
 Typical Installations using PID Controllers

Controllers placed in field

RS-232

RS-485 Bus
Leading Manufacturers in PID Controllers

Yokogawa
ABB
Moore
Eurotherm
ASCON
Chino
Bells
Fuji
 Programmable Logic Controllers

PLCs were launched to replace the relay logic.

Advancement in the PLC technology made these

hardware applicable for critical process operation
also.
Now a days PLCs are the most widely used control
hardware in control applications. The applications
ranges from standalone system for CNC machines
to Hot swappable Redundant System for Critical
Process Control
 Configuration of PLC : Modicon

Built in display for I/O Programming Terminal PC Connection

(in-rack, AS-i) and Diag

8 Analog Inputs 1
Analog Output

I/O Modules
Up/Down Fast
Counter

Up Counter TSX37-22

Unitelway Port for connection PCMCIA communications port

of up to 5 Slaves
PCMCIA memory expansion port
 Configuration of PLC : Siemens

CPU

I/O Modules
External Power
Supply
 Configuration of PLC : Allen Bradley

CPU

I/O Modules
Power Supply
Programming Languages in PLCs

Ladder Logic ( LAD/LD )

Structured Text ( ST)
Instruction List ( IL )
Sequential Function Chart ( SFC )
Function Block Diagram ( FBD )
 Supervisory Control & Data
Acquisition Software

Features of typical SCADA software

 Dynamic process graphic
 Real-time and Historical trending
 Alarms
 Recipe Management
 Security
 Device connectivity
 Script for logic development
 Database connectivity
Some of the Leading SCADA Software

 Wonderware : InTouch
 Intellution : Fix DMACS
 Merz : Aspic
 Allen Bradley : Rsview
 Siemens : WinCC
 GE Fanuc : Cimplicity
 KPIT : ASTRA
 CITEC
 SCADA Software Packages

 The SCADA/HMI software are marketed using the number

of I/Os and type of package
 Number of I/Os
64/75 Tags, 128/150 Tags, 256/300 Tags
1000/1500 Tags, Unlimited (64,000 Tags)
 Type of package
Development + Runtime
Runtime
 SCADA Packages

Number of I/Os
 64 , 256, 1000, Unlimited Tags
Type of package
monitoring
 Development + Runtime + Network : Development of as well as runtime
monitoring of the application is possible.

 Runtime : No development is possible. You can monitor and control the plant.
 Factory Focus : This is a unlimited I/O run-time package where only monitoring is
possible
Automation : Typical installation . . . .
SCADA Software

Communication Cable

Control Hardware
Control Panel
Field Cabling

Junction Box

Field Cabling

Sensors Placed in the field

Automation : Advanced Technology . . . .
SCADA Software

Communication Cable

Control Hardware
Control Panel
Field Bus Network

Filed Bus Scanners

Field Cabling

Smart Transmitters Placed in the field

 Hot Redundant System Configuration

TAPS
SPLITTERS
Remote
I/O Network
FIBER OPTIC LINK
 Networking of PLCs
Supervisory HMI

Modicon : Modbus +, Uniteleway, Ethernet

Allen Bradley : DH+, DH485, Ethernet, Control Net, Devicenet
Siemens : Sinec L1/L2/H1, Profibus
 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.
 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.
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