AUTOMATION WITH

PLC AND SCADA

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Programmable Logic Controllers
( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic

apparatus which uses a programming
memory for the internal storage of
instructions for implementing specific
functions such as logic, sequencing,
timing, counting and arithmetic to
control through digital or analog
modules, various types of machines or
process.
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Is it beneficial for a mechanical engineering
student to learn PLC and SCADA?
Mechanical engineers can go for this field as
its totally industrial core field. You have to deal
with Robots, Automatic Machines, Controllers
and Process Flow.

Now industry are being replaced by

Automation and robotics. All process and work
are carried out by machines and robotics
process automation. Every industrial sector
like manufacturing, process industries,
chemical, food & beverages, Oil Gas ,
Transport, machine tools every where
“Innovate,
Industrial Automate,is
automation Integrate”
used. -
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What is PLC programming for mechanical engineers?

PLC is programmable logic controller which can control

the electromechanical system automatically with its
logic as per programme.

So mechanical engineers also can work in this

automation field , but you must have basic knowledge for
Micro controller, Digital logic Design, Electrical machine
for getting in automation.

Right now many mechanical engineers are working in

field of Mechatronics & Robotics Automation . So PLC
SCADA would be beneficial for the mech engineers in
future also as day by day automation sector is growing. -
Dharmesh Kavaiya, Industrial Automation Engineer in
SIEMENS

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Programmable Logic Controller

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 S.P.A PRINCIPLE

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 SENSORS

SWITCHES, PUSH BUTTONS

ELECTRONIC SENSORS PROXIMITY
SENSORS

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 PROCESSORS

SMART RELAY
PLC ARDUINO

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 ACTUATORS

LINEAR CYLINDER ACTUATOR

HYDRAULIC SOLENOID

CONTROL VALVE

PNEUMATIC
SOLENOID

RELAY

MAGNETIC CONTACTOR
MOTORS
ROTARY ACTUATOR

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 SENSORS

PROCESSORS

ACTUATORS

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 I.P.O PRINCIPLE

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 INPUTS

PROCESSORS

OUTPUTS
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Programmable Logic Controller
SENSORS PROCESSORS ACTUATORS

INPUTS PROCESSORS OUTPUTS

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Programmable Logic Controller
PLC

PUMPS
FANS AND BLOWERS
VALVES

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Programmable Logic Controller
PLC

SHIP
BOILER

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Programmable Logic Controller
PLC

BUILDING

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 Programmable Logic Controller

= VIRTUAL RELAYS , “Bit”

= VIRTUAL TIMERS

= VIRTUAL COUNTERS
PLC

= VIRTUAL PID CONTROLLER

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 ADVANTAGES OF PLC

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 ADVANTAGES OF PLC
Less wiring.

PLC CONTROL PANEL

CONVENTIONAL RELAY PANEL

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ADVANTAGES OF PLC

•Wiring between devices and relay

contacts are done in the PLC
program.

I0.0 I0.1 Q0.0

Q0.0

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 ADVANTAGES OF PLC

Easier and
faster to make
changes.

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ADVANTAGES OF PLC

Trouble shooting aids make

programming easier and reduce
downtime
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PROGRAMMING LANGUAGES

FBD- FUNCTION BLOCK DIAGRAM

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LADDER PROGRAMMING

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PROGRAMMING LANGUAGES

STRUCTURED TEXT PROGRAMMING

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 PROGRAMMING LANGUAGES

SFC – SEQUENTIAL FUNCTION CHART

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IL- INSTRUCTION LIST PROGRAMMING

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Discrete Input

A discrete input also referred as

digital input is an input that is either
ON or OFF are connected to the PLC
digital input. In the ON condition it is
referred to as logic 1 or a logic high
and in the OFF condition maybe
referred to as logic o or logic low.

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 Discrete Input
24VDC
S1 S2 S3 K14 K15 S6
0VDC

COM I0.0 I0.1 I0.2 I0.3 I0.4 I0.5

PLC INPUT MODULE

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 Discrete Input
24VDC

0VDC LOGIC 0

COM I0.0 I0.1 I0.2 I0.3 I0.4 I0.5

PLC INPUT MODULE

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 Discrete Input
24VDC

0VDC LOGIC 1

COM I0.0 I0.1 I0.2 I0.3 I0.4 I0.5

PLC INPUT MODULE

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32

Digital Input (Discrete Input)

A discrete input is either in an ON or OFF
condition. Push button switches, toggle
switches, proximity sensors, limit
switches, relay contacts are example of
devices connected to the Discrete or
digital inputs. Below, the push button
switches can be turned ON or OFF
momentarily to execute a logical function.

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 24vdc power supply

Start- stop push buttons

PUMP
PLC

Magnetic Contactor

Relay

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34

Analog Input
An analog input is an input signal that has a continuous
signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA
or 0 to10V. Below, a level transmitter monitors the level of
liquid in the tank. Depending on the level ,the signal to the
PLC can either increase or decrease as the level increases
or decreases.
Level Transmitter
IN
PLC
Analog
Input
Module

Tank

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 Discrete Output

PLC OUTPUT MODULE

COM Q0.0 Q01. Q0.2 Q0.3 Q0.4 Q0.5

24VDC K1 K2 K3 K4 K5 K6

0VDC

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36

Digital Output (Discrete Output)

A discrete output is either in an ON or OFF condition.
Solenoids, contactors coils, lamps are example of
devices connected to the Discrete or digital outputs.
Below, the relay can be turned ON or OFF by the PLC
output it is connected to.
PLC OUT
DIGITAL
OUTPUT
MODULE
Relay
Magnetic
contactor

PUMP

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37

Analog Output
An analog output is an output signal that has a continuous
signal. Typical outputs may vary from 0 to 20mA, 4 to
20mA or 0 to10V.

PLC
OUT

Analog
Output
Module Modulating Valve

EP Positioner

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38

Analog Output
An analog output is an output signal that has a continuous
signal. Typical outputs may vary from 0 to 20mA, 4 to
20mA or 0 to10V.

OUT Modulating Valve

PLC

Analog
Output
Module

Pump

VFD

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BASIC PLC COMMANDS
LADDER SYMBOLS
Normally Open Input

Normally Close Input

Output

Function Block

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BASIC LADDER LOGIC
RUNG OR NETWORK
I0.0 Q0.0

TRUTH TABLE
I0.0 Q0.0
0 0
1 1

“Yes or Identity” LOGIC

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BASIC LADDER LOGIC
RUNG OR NETWORK
I0.0 Q0.0

TRUTH TABLE
I0.0 Q0.0
0 1
1 0

“NOT or Inverter Logic

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BASIC LADDER LOGIC
RUNG OR NETWORK
I0.0 I0.1 Q0.0

TRUTH TABLE
I0.0 I0.1 Q0.0
0 0 0
“AND” LOGIC 1 0 0
0 1 1
1 1 1

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BASIC LADDER LOGIC
RUNG OR NETWORK
I0.0 Q0.0

I0.1
TRUTH TABLE
I0.0 I0.1 Q0.0
0 0 0
“OR” LOGIC 1 0 1
0 1 1
1 1 1

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SCADA
►Supervisory Control and
Data Acquisition

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SCADA
► Supervisory control and data acquisition
(SCADA) is a control system
architecture that uses computers,
networked data communications and
graphical user interfaces for high-level
process supervisory management, but
uses other peripheral devices such as
programmable logic controller(PLC) and
discrete PID controllers to interface with
the process plant or machinery.

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► WONDERWARE INTOUCH SCADA
(SCHNEIDER)

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NETWORK ARCHITECTURE

SCADA SERVER1 SCADA SERVER2

VFD
ETHERNET HUB

PLC1 PLC2 PLC3

FIELD DEVICES (I/O)

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InTouch SCADA Advantages
►Ease of Use
 Intuitive creation and deployment process
 No programming skills required
 SmartSymbols – object oriented graphics
►Enhances engineering productivity
 Agile, extensible applications
 Expansive communication
• More I/O servers than anybody
►Maintains engineering investment
 Flexible Architectures
 Migration for older versions

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 Quickly create graphic object
► Custom
drawing tools
► Wizards
► Over 800
Industrial
Symbols
► SmartSymbols

► Tools that enable you to quickly add

graphics to your application
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 ArchestrA Graphics
► What Are ArchestrA Graphics?
 A new generation of graphical
visualization capabilities
 Defined and Managed in the IDE
using new Symbol Editor
 Used in InTouch 10.0 Applications
 Used in Application Server Objects
 Intelligent and Scalable
 Customer investment in existing
SmartSymbols can be migrated
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► ArchestrA Graphics are different:
 Resolution Neutral
• Vector based – numerous benefits
 Advanced Visualization Features
• Smoothing
• Transparency
• Fills – Gradients, Patterns, Textures
• Group Editing
• Rotation anchors
 More Animations
• Better, more sophisticated animation
 Scriptable
• Custom Properties
 Object-based
• Encapsulate engineering
• High reusability
• Highly efficient for maintenance
► Supports .NET Control embedding
 Permit windows into other systems
 Robust, Powerful and Versatile
SmartSymbols
► Object oriented graphics
► Easy to Build and Maintain
 Standardized libraries of objects
 Use existing InTouch graphics
 Libraries of SmartSymbols can be exported to
other applications
► Super-Fast Change Propagation!
 Only modify the template, all instances update
throughout the application
► Productivity Improvements

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 Visualization

► Vibrant, graphical windows

► Empower your operator
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►Enhance Engineering
Productivity

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Flexible Architecture
► Design the application once
 SmartSymbol Library
 Standard windows
► Deploy it anywhere
 Standalone, Terminal Services, InTouch View
 Mobile, Internet
 TabletPCs and Industrial Touch Panel
Computers
NAD (Network App Dev)
 Automatically send changes to applications
 Enables user control for updates

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 The Vision

Any Device
Any Network
Any Data
An open-standard based
architecture, designed from the
ground up with security in
mind.
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 Platform Independence

Portability

Mobility

Interoperability

Productivity Reliability Security

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Standard InTouch
►Full featured,
versatile, powerful,
easy to use
►Standalone and
Client/Server
architecture
►Migration of
application to any other
InTouch version
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InTouch for Terminal Services
►Central deployment Terminal Server Clients
►Thin Client utilization
►Re-use of existing hardware
►Simplified software management
►Lower overall cost,
higher ROI

RDP & ICA

Terminal Server Protocols
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►Extensibility Options

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Add more Functionality
►Built in powerful
script editor
 Advanced
programming
capabilities
 Easy to develop
 Self Checking
 Non programmers
can quickly develop
simple scripts

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 InSQL Support
►Browse InSQL tags right
from InTouch
►Use built in ActiveX
controls to easily analyze
InSQL information
►Monitor the status of your
InSQL server

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Secure
►Supports 4 security models
 NT authentication
 InTouch security
 No security
 Archestra security

 Administration of security is simplified by enabling the

customer to use whichever authentication method best fits
their application.
 Enables easier compliance with government
regulations.

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Alarm Display Features
►3 Different Display Objects
 Distributed Alarm Display
• Historical Alarms
 Alarm Database View Control
• Current Alarms
 Alarm Viewer Control
• ActiveX based
• Current and Historical Alarms
Easily scriptable, sortable and
configurable. View the information you want
to see in the way you need to see it

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Distributed Application Tools
►Alarming
►History
►NAD(Network Application Dev)
►Remote Tag Referencing
►Dynamic Resolution Conversion
►Distributed Time Zones

Leverage all the benefits of a distributed

architecture with tools built into InTouch!
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 InTouch Add-ons
►Recipe Manager
•Manage Recipes through InTouch
►SPC Pro
•Quality analysis of data
►SQL Access
•Access, modify, create and delete tables
in a database
►16 Pen Trend
•Real time trend tool
►Symbol Factory
Symbol Factory Graphic Wizard
•Over 800 graphics in over 21 industries

Included with InTouch to help increase your productivity

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Toolkits
►Extensibility Toolkit
• Wizard Development Kit
• Script Development Kit
• InTouch Database Extension API’s
►I/O Server Toolkit
• Connect every device you use

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InTouch Today
► Well-known Robust Technology
 Reliable
 Migrateable
• Products are upwards compatible -- protecting your investment in
time, energy and money

► Installed Base Global Leader

 Over 200,000 installations
 Install base represents every industry

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Wonderware Software integration
► Integrates with all other Wonderware
software
• Industrial Application Server
• IndustrialSQL Server – Real Time plant Historian
• SuiteVoyager – Internet Information Portal
• SCADAlarm – Voice, Email and Paging system for Alarms
• InTrack – Resource Tracking
• InControl – Logic Control Engine
• InBatch – Batch Processing
• Avantis – Asset Utilization
• DT Analyst – Downtime Tracking Analysis
• QI Analyst – Quality information about your process
• ActiveFactory – IndustrialSQL Server Client Tools
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 Powering intelligent plant
decisions in real time.

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INDUSTRIAL INTERNET OF THINGS
► IIoT
► IoT

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INTERNET OF THINGS (IoT)
► The Internet of Things (IoT) is the network
of physical devices, vehicles, home
appliances, and other items embedded with
electronics, software, sensors, actuators, and
connectivity which enables these things to
connect and exchange data creating
opportunities for more direct integration of
the physical world into computer-based
systems, resulting in efficiency
improvements, economic benefits, and
reduced human exertions-WIKIPEDIA
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► Discover the power of the Industrial Internet
of Things (IIoT).mp4

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► Internet of Things explained simply.mp4

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► How It Works Internet of Things.mp4

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1. OPERATOR TO MACHINE COMMUNICATION
ANYWHERE

HMI/SCADA- HUMAN MACHINE

INTERFACE
GRAPHIC USER INTERFACE (GUI)

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►M TO M TECH

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►2. MACHINE TO
MACHINE
COMMUNICATION

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 MACHINE TO MACHINE
TECHNOLOGY
Data Collection Data Transmission Data Analysis

Satellite Comm

M to M gateway

Cellular Comm

Powerline Comm

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►SMART MACHINES
►SMART FACTORY
►SMART TV
►SMART PHONE
►SMART
TRANSPORATION
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