SUMMER TRAINING AT PROLIFIC SYSTEMS &

TECHNOLOGIES PVT. LTD.

SUBMITTED BY: SUBMITTED TO:

AMAN KUMAR SINGH MRS. ANURADHA

ROLL NO. 160060108005 HEAD OF DEPARTMENT
B.TECH(IV-YEAR)
EEE
COLLEGE OF ENGINEERING ROORKEE
 CONTENT

• INTRODUCTION
• DEFINATION OF AUTOMATION
• TYPES OF AUTOMATION
• HISTORY OF AUTOMATION
• SCOPE OF AUTOMATION IN INDUSTRIES
• INDUSTRIAL AUTOMATION
* PLC
* SCADA
* HMI
* DCS
 INTRODUCTION
• In the industry 4.0 factories have machines which are augmented with wireless
connectivity and sensors, connected to a system that can visualize the entire
production line and make decisions on its own.
• Industry 4.0 is the trend towards automation and data exchange in manufacturing
technologies and processes which include cyber-physical systems (CPS), the
internet of things (IoT), industrial internet of things (IIOT), cloud
computing, cognitive computing and artificial intelligence.
• The concept includes:
*Smart manufacturing
*Smart factory
*Lights out (manufacturing) also known as dark factories
*Industrial internet of things also called internet of things for manufacturing
 WHAT IS AUTOMATION ?

• Replacing manual operations with electronics and computer-controlled devices

•Automation is the technology by which a process or procedure is performed

with minimal human assistance . Automation or automatic control is the use of
various control systems for operating equipment such as machinery,
processes in factories, boilers and heat treating ovens, switching on telephone
networks, steering and stabilization of ships, aircraft and other applications
and vehicles with minimal or reduced human intervention

• The deletion of human effort to the machine equipment to increase the

efficiency , quality, productivity and to save time and money.
 TYPES OF AUTOMATION

1. Fixed automation: It is a system in which the sequence of processing (or

assembly) operations is fixed by the equipment configuration. It is the
integration and coordination of many such operations into one piece of
equipment that makes the system complex.

2. Programmable automation: In this the production equipment is designed

with the capability to change the sequence of operations to accommodate
different product configurations. The operation sequence is controlled by a
program, which is a set of instructions coded so that the system can read and
interpret them. New programs can be prepared and entered into the
equipment to produce new products

3. Flexible automation: It is an extension of programmable automation. A

flexible automated system is one that is capable of producing a variety of
products (or parts) with virtually no time lost for changeovers from one
product to the next. There is no production time lost while reprogramming the
system and altering the physical setup (tooling, fixtures, and machine setting)
 HISTORY OF AUTOMATION

• Manual control system

• Pneumatics and Hydraulics control system
• Hard wired logic control system
• Smart electrical device (electrical to electronics)
• Intelligent controllers
*PLC
*SCADA
*VFD
*HMI
*DCS
•
SCOPE OF AUTOMATION IN INDUSTRIES

• Power & Steel plant

• Chemical
• Paint
• Gas & oil
• Automobile Industries
• Mobile manufacturing industries
• Textile industry
• Medicine
 PLC

• A Programmable Logic Controller, or PLC, is a ruggedized computer used for

industrial automation. These controllers can automate a specific process,
machine function, or even an entire production line.

• Modicon created the first programmable logic controller ( PLC ) in the United
States in 1968. With a core group of engineers, Richard E. Morley founded
Bedford Associates and invented the first programmable logic controller.

• Global Companies in a Automation Industry

1. Siemens
2. Allen Bradley
3. Mitsubishi
4. Delta
5. Yokogawa
6. Omron
7. Schneider Electric
8. Honeywell
WORKING:

• The PLC receives information from

connected sensors or input devices,
processes the data, and triggers outputs
based on pre-programmed parameters.

• Depending on the inputs and outputs, a PLC

can monitor and record run-time data such as
machine productivity or operating
temperature, automatically start and stop
processes, generate alarms if a machine
malfunctions, and more. Programmable Logic
Controllers are a flexible and robust control
solution, adaptable to almost any application

TYPES:
Modular:- Input can be as per selection of input
modules.
Compact:- Input number fixed, input modules
are fitted on CPU
ALLEN BRADLEY:
• Allen Bradley is the brand-name of a line of Factory Automation Equipment
manufactured by Rockwell Automation. The connection between the controller and
the computer is either serial cable or Ethernet cable
• Hardware : Designed by Reliance Electric America
Software : Rockwell Solutions
• Types of PLC version
LANGUAGE USED IN PROGRAMMING:

1. LAD (Ladder language)

2. FBD (Functional block diagram)
3. STL (Statement list)
4. SFC (Sequential functional chart)
5. IL (Instruction list)
RULES FOR PROGRAMMING:
• I/P devices are always represented by using contact i.e. NO&NC and always
used in left side of ladder also contact can be used series or parallel.
•O//P devices are represented by coils which is always used in right side of ladder
Types of coils are:
*OTE(Output energized)
*OTL(Output latch)
*OTU(Output unlatch)

ADDRESSING PATTERN:

File name : Slot number . Word number / Bit number

EXAMPLE:
COFFEE VENDING MACHINE

Toggle Push Button to Start

Drop Cup (for 10 seconds)
Feed Hot Water (for 10 seconds)
If required, Add Milk (for 10 seconds)
If required, Add Sugar (for 10 seconds)
Procedure Complete - Illuminate Complete Light (for 10 seconds)
I have implemented everything except the OPTIONAL add Milk & OPTIONAL
add Sugar.
Options are:
To have a Coffee without either Milk or Sugar.
Or have a Coffee with Milk and Not Sugar.
Or have a Coffee with Sugar & Not Milk.
Or have a Coffee with BOTH Sugar & Milk
EXAMPLE:
SEIMENS :
• SIMATIC software is the universal configuring and programming environment for
SIMATIC controllers, human machine interface systems and process control systems.
• SIMATIC software with STEP 7 and numerous engineering tools supports all
phases of product deployment, from hardware configuration of the system and
parameterization of modules to service of the installed system.
• Addressing format:
FILE NAME BIT NUMBER . BYTE NUMBER
e.g. I0.0 ,M0.0, Q0.0
• Programming cable used : MPI(Multi point interface)
• Communication cable used : Profibus
EXAMPLE:

BLINKING CIRCUIT:
 • Similarly ,MITSUBISHI PLC addressing format is X0 , Y0

• In Omron PLC there are 12 inputs in one slot so addressing start from 0.0 to 0.11
and then 1.0 to 1.11 and so on. So if there are 18 inputs then address of input will
be from 0.0 to 0.11 and 1.0 to 1
• In Omron PLC there are 8 outputs in one slot and the addressing is as follows:-
CPM1A/CPM1A PLC :- 10.0 to 10.7 , 11.0 to 11.7 and so on .
CP1E/CP1H PLC :- 100.0 to 100.7 , 101.0 to 101.7 and so on
 SCADA

• SCADA is an acronym for supervisory control and data acquisition, a computer

system for gathering and analyzing real time data.
• SCADA systems are used to monitor and control a plant or equipment in
industries such as telecommunications, water and waste control, energy, oil and
gas refining and transportation
• SCADA systems were first used in the 1960s.
• SCADA systems are essential to a wide range of industries, and are broadly used
for the controlling and monitoring of a process. SCADA systems are prominently
used as they have the power to control, monitor, and transmit data in a smart and
seamless way.
• Mainly used SCADA software in industries are
Wonderware : InTouch , Intellution : Fix DMACS , Merz : Aspic , Allen Bradley :
Rsview , Siemens : WinCC , GE Fanuc : Cimplicity , KPIT : ASTRA
Main feature of SCADA

•GUI is designed by simple Drag and Paste concept.

•Tagging and Coding is done by considering programming bit

•On SCADA ,we can monitor Real Time operation and Historical Trend

•Alarm triggering which also used in this system , it trigger when certain task
complete or sudden brake of a system.

•Recipe management ,it provide the operator multiple choice for mixing the
variety of chemical and solution
APPLICATIONS:
• Electric Power Generation, Transmission, and Distribution
Using SCADA systems, electrical utilities detect current flow and line voltage,
monitor circuit breaker operation, and take sections of the power grid online or
offline.
Manufacturing Units
SCADA systems are used to regulate industrial automation and robots, and monitor
process and quality control
• Mass transit and Railway Traction
Transit officials use SCADA to regulate electricity for subways, trams and trolley
busses; to automate railway traffic signals; to monitor and identify trains and
busses, and to control railway crossing doors
• Water, Waste Water Utilities and Sewage
State and municipal water utilities use SCADA to monitor and control water flow,
tank concentrations, pipe pressure, and other variables
• Thermal power plants: Most operational inspections of thermal power plants are
automatic. The plant is therefore equipped with monitoring and alarm systems that
alert plant operators when certain working para counter deviate significantly from
their normal range.
EXAMPLE:
 HMI

•Human Machine Interface have some major feature of SCADA ,HMI it is basically
a control display screen were operator can monitor and control the machinery and
it is portable and can easily installed on the Machine itself HMI It was designed for
the specific task operation on the machine and SCADA is for entire Plant
operation.

• An HMI provides a visual representation of a control system and provides real

time data acquisition. An HMI can increase productivity by having a centralized
control center that is extremely user-friendly.

• An HMI is the centralized control unit for manufacturing lines, equipped

with Data Recipes, event logging, video feed, and event triggering, so that one
may access the system at any moment for any purpose.

• For a manufacturing line to be integrated with an HMI, it must first be working

with a Programmable Logic Controller (PLC). It is the PLC that takes the
information from the sensors, and transforms it to Boolean algebra, so the HMI
can decipher and make decisions
CONNECTION OF HMI:
HMI
 DCS

• A distributed control system (DCS) is a specially designed automated control

system that consists of geographically distributed control elements over the plant or
control area.
• It differs from the centralized control system wherein a single controller at central
location handles the control function, but in DCS each process element or machine
or group of machines is controlled by a dedicated controller. DCS consists of a large
number of local controllers in various sections of plant control area and are
connected via a high speed communication network.
• DCS is most suited for large-scale processing or manufacturing plants wherein a
large number of continuous control loops are to be monitored and controlled. The
main advantage of dividing control tasks for distributed controllers is that if any part
of DCS fails, the plant can continue to operate irrespective of failed section.
• The common communication protocols used in DCS include Ethernet, Profibus,
Foundation Field Bus, DeviceNet, Modbus, etc
HARDWARE STRUCTURE:
COMMUNICATIONS SYSTEM