Introduction Industrial Automation

 Automation is required in every walk

of life.
 Automation solutions are required
right from agricultural sector to high
technology sector like space.
 Plant Automation is the necessity for
the manufacturing industry to survive
in today’s globally competitive market
 What is industrial Automation ?
Automation is basically the delegation of human
control
function to technical equipment for
i. Increasing Productivity
ii. Increasing Quality
iii. Reducing Cost
iv. Increasing Safety in working conditions
Advantages of the Industrial
Automation
 History of Automation

 Programmable Logic Controller

 Electronic control using logic gates
 Hard wired logic control
 Pneumatic control
 Manual control
 History of industrial
automation
Manual Control
All the actions related to process control are taken
by the operators
Drawbacks
 Likely human errors and consequently its effect
on quality of final product
 The production, safety, energy consumption and
usage of raw material are all subject to the
correctness and accuracy of human action.
 Pneumatic Control
Industrial automation, with its machine and
process control, had its origin in the 1920s with
the advent of "Pneumatic Controllers".
Actions were controlled by a simple manipulation
of pneumatic valves, which in turn were controlled
by relays and switches.
Drawbacks
 Bulky and Complex System
 Involves a lot of rework to implement control
logic
 Hard wired logic
control
The contactor and Relays together with hardware
timers and
counters were used in achieving the desired level
of automation
Drawbacks
i. Bulky panels
ii. Complex wiring
iii. Longer project time
iv. Difficult maintenance and troubleshooting
Electronic Control using
Logic Gates
In 1960s with the advent of electronics, the logic gates
started replacing the relays and auxiliary contactors in
the control circuits.
The hardware timers & counters were replaced by
electronic timers
Advantages
Reduced space requirements
Energy saving
Less maintenance & greater reliability
Disadvantages
Changes in control logic not possible
More project time
 Programmable Logic
Controllers
In 1970s with the coming of microprocessors and
associated peripheral chips, the whole process of
control and automation underwent a radical change.
Instead of achieving the desired control or automation
through physical wiring of control devices, in PLC it
is achieved through a program or say software.
It can be effectively used in applications ranging from
simple control like replacing small number of relays to
complex automation problems
 Advantages of PLCs
 Reduced space
 Energy saving
 Ease of maintenance
 Economical
 Greater life & reliability
 Tremendous flexibility
 Shorten the project execution time
 Easier storage, archiving and documentation
 Industrial Automation Components

Input Junctio Controll Junctio

Output
n box er n box
Inputs Junction box Controller Junction box
Switches PLC Output
Optocoupler Relay
Toggle ADC Microcontroller
Contactor
i. Alarm
Push button -HMI ii. Horns
-SCADA ADC
Sensors DAC iii. Led
-Temperature Inverter iv. Motor
sensors VFD v. Buzzer
-Proximity sensor
-Reed switch
-Metal detector
-Pressure sensor
 SENSORS AND TRANSDUCERS
• Displacement Sensors,
• Position and Proximity Sensors
• Velocity and Motion Sensors
• Force and Fluid pressure Sensors
• Liquid flow and Liquid level Sensors
• Temperature and light sensors
• Selection of sensors.
 Conventional
Relays switch that has a coil and a set of
A relay is an electromagnetic
associated contacts.
This electromagnetic field generates a force that pulls the contacts
of the relay, causing them to make or break the controlled
external circuit connection
It is more practical to have a low power electrical relay
circuit control the high-power relay contacts than to wire a
high-power electric switch directly from the control area
to the motor and its independent power supply.
Relay with
two contacts
normally
open (NO)
and normally
closed(NC)
Simple relay circuit for controlling a bell using a single pole,
single-through (SPST) switch

A relay is typically used to control a device that requires

high voltage or draws large current.
The relay allows full power to the device without needing a
mechanical switch that can carry the high current.
A switch is normally used to control the low-power side, the
relay-coil side.

Simple relay circuit

Notice that there are two separate circuits:
The bottom uses the direct-current (dc) low power, whereas
the top uses the alternating current (ac) high power.
The two circuits are only connected through electromagnetic field
coupling.

Simple relay circuit

 Relay Logic
Relay logic systemsSystem
are control structures appropriate for both
industrial and
Hardwired is the operations/processes that will be controlled
municipal applications.
by relay logic systems.

These systems are

Inflexible and can be
Difficult to modify after
deployment.
Because the operation of relay
logic controllers is built directly
into the device, it is not easy
to troubleshoot the system
when problems arise.
It was a large complicated electrical electronics
circuit full of many small and big devices.
The logic was designed through wires with the
help of electrical
and electronic devices such as
a) Relay,
b) Contactor,
c) Hardware timer/ counter,
d) Diode
e) Resistor,
f) Capacitor etc.
Shows two relay circuits for implementing two inputs:
The implementation of AND and OR logic functions by using coil
relay
Relay has two magnetic coils and an associated normally
closed (NC) set of contacts.
Two inputs are connected to one side of each of the two coils
The other end of the coil is connected to the ground
Schematic diagrams for relay logic circuits are often called logic
diagrams.
A relay logic circuit is an electrical diagram consisting of
lines/networks/rungs
in which each must have continuity to enable the intended
A typical circuit
output device consists of a number
of networks, with
each controlling an
output

Relay logic line diagrams

Each output is controlled through a combination of input or
output conditions (e.g., switches and control relays)
connected in series, parallel, or series-parallel to
obtain the desired logic to drive the output.
Relay logic diagrams represent the physical interconnection
ofIndevices
ladder-logic diagrams,
an electromechanical relay coil is shown as a circle
and the contacts actuated by the coil as two parallel
lines.
Given this notation, the relay logic line diagrams for the AND
and OR logic functions are
The L1 and L2 designations in this logic diagram refer to the two
poles of a 120-Vac supply.
L1 is the hot side of the supply, and L2 is the ground/neutral
side.
Output devices are always connected to L2.
Any device overloads that are to be included must be shown
between the output device and L2;
the output device must be the last component before L2.
Input devices are always shown between L1 and the output
device.
Relay contact control devices may be connected either in
series, parallel, or a combination of both called series-parallel.
Control Relay Application
Figure shows the line diagram for a common application of
electromechanical relay dc motor-control circuitry
A momentary NO push-button switch starts the motor, and
another NC push-button switch stops the motor.
The control relay contact is used to latch the Start push button
after it is released. Another contact associated with the same
relay is used to start the motor.
Pressing the Stop push button at any time will interrupt the
flow of electricity to the motor and cause it to stop

Dc motor controls
The line diagram illustrates how a hardwired relay is used to
control two pilot lights. The desired control is accomplished
using two push-button switches; PB1 starts the operation, and PB2
terminates it at any time.
With no power applied to the control
relay, the contacts are in a normal state.
The NO contacts are open, and
The NC contacts are closed.
The green pilot light receives power
and turns on as indicated by the
green fill light.
The red pilot light is off as shown.

Relay controlling two pilot lights.

Rung 1:
Once the START PB1 is pressed, coil CR1 becomes energize;
this, in turn,
makes contacts CR1-1 close and maintains power to CR1
through the NC STOP push button PB2.
When CR1 energizes the switch state of the contacts,
The NO contacts close, and
The NC contacts open.
This will turn off the green light on rung 2 and
Turn on the red light on rung 3.
When the STOP push button is pressed,
The control relay loses power, and
The contacts switch to the normal state.
This results in turning the green light on and the red
light off
 Motor Magnetic Starters
A magnetic starter is used to control the high power to the
motor.
Three of the motor magnetic starter contacts are used to connect the
three phases of the high-voltage supply.
In addition, overload relays are physically attached for the motor
overload protection
Figure shows the low power motor starter circuit. START and STOP
push-button switches start and stop the motor through the control of its
magnetic starter. Magnetic starter contact M-4 is used to latch the
motor start action.

Figure High-power motor circuit Figure Low-power motor starter circuit

Figure presents a line diagram of a magnetic reversing starter
controlled by forward and reverse push buttons.
Pressing the forward push button completes the forward coil circuit
from L1 to L2.
Energizing coil F, in turn,
energizes two auxiliary
contacts F-1 and F-2. F-1
provides a latch around
the forward push button
maintaining coil F
energized.
The NC contact F-2 will
prevent the motor from
running in the

Figure Control of reversing motor

PLC programming
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.
A Programmable Logic Controller (PLC) is a type of
computer-based industrial control system that uses a
programmable memory to store instructions and
execute specific functions in response to input from
sensors or other devices.
They can be programmed to perform a wide range of
tasks, such as monitoring inputs, controlling outputs,
and making decisions based on input conditions.
PLCs are typically used in environments where
reliability and durability are important, such as
factories and other industrial settings.

A Programmable Logic Controller (PLC) is a type of computer that

is used to control and automate industrial machines and processes.
It uses a programmable memory to store instructions and make
decisions based on input from sensors or other devices.
This allows it to control and monitor different parts of a manufacturing
line or other industrial system.
 What is the programmable logic controller (PLC)?
A programmable logic controller (PLC) is an industrial grade
computer that is capable of being programmed to perform control
functions
PLC is a digitally operating system designed for use in an industrial environment which
uses a programmable memory for its internal operation of user –oriented instructions for
implementing specific functions such as
a. logic,
b. sequencing,
c. timing,
d. counting and
e. arithmetic
PLC control through digital or analog inputs and outputs in the various types of machines
or processes.
A programmable logic controller (PLC) is an industrial computer that
receives inputs from input devices and then evaluates those inputs
in relation to stored program logic and generates outputs to control
peripheral output devices
 Major Components of a Common PLC
Power supply:
a)To work on any electronic
device we need to power it on.
b)PLC provides terminals to
connect power cables to it.
c)The power supply is either AC
or DC power to PLC.
d) AC power supply is directly L,
N and earth terminals of PLC
will be connected to the socket.
e)DC power supply needed then it
will be 24 V DC. An SMPS
(Switch Mode Power Supply)
will be the power source and
Low voltage:
This low voltage is for PLC’s internal use and it is
converted by PLC itself from its power supply.
This low voltage is 5 or 3.3 V DC in old and new PLC
respectively.
As PLC is a digital device, its internal work takes place
on 0/ 1.
PLC also converts power supply into 24V DC as low
voltage for its I/O wiring purpose.
CPU: Central Processing Unit is the brain of PLC.
It is a microprocessor which monitors and
controls the logic and communication execution.
I/ O:
input/ output in block diagram refer to input output
terminals not the physical I/Os like push button, sensors,
motor, relay etc.
There is two types I/Os
a) Relay and
b) Transistor.
Memory location:
PLC has two memory locations, program and data memory
location.
The memory location where program is saved is program
memory.
Memory location where all addresses (addresses that we
use in our program) are pre located is data memory.
Communication port:
It is used to communicate PLC with other devices such
as laptop/ computer, HMI/ SCADA PC/ Drives etc.
On branded PLC you can find RS 232, RS 422, RS 485
etc.
In summary main parts PLC

POWER SUPPLY
Provides the voltage needed to run the primary PLC
components
I/O MODULES
Provides signal conversion and isolation between the
internal logic level signals inside the PLC and the field’s
high-level signal.
PROCESSOR
Provides intelligence to command and govern the
activities of the entire PLC systems.
PROGRAMMING DEVICE
used to enter the desired program that will determine
 I/O interfaces

 PLC input/output terminals are not directly connected to

PLC CPU.
 Signal is sent through light from terminal to CPU and from
CPU to terminals through Opto couplers that is why PLC
CPU last long.
 When wrong connection is made from field device then the
PLC CPU will be isolated optically
PLCs provide many other
benefits including:
a. Increased Reliability.
b. More Flexibility.
c. Lower Cost.
d. Communications Capability Relay fixed Modular
e. Faster Response Time PLC PLC
f. Easier to Troubleshoot

PLC
High-speed communicationRelay based PLC-based
Relationships between the inputs and outputs re determined by the user
program.

All the logic is contained in the

PLC’s memory
There are two ways in which I/Os (Inputs/Outputs) are
incorporated into the PLC:
Fixed and
Modular.
 Fixed I/O
PLC’s with fixed I/O typically come in a complete unit that
contains the processor, I/O section, and power supply
Disadvantage of
fixed I/O
lack of flexibility;
you are limited in
what you can get in
the quantities and
types dictated by
Fixed I/O the packaging
is typical of small PLCs that come in one package with no separate,
removable units.
The processor and I/O are packaged together, and the I/O terminals
Modular I/O
is divided by compartments into which separate modules can be
plugged.
This feature greatly increases your options and the unit’s flexibility.
is modular in nature, more flexible than fixed I/O units. The I/O rack or
chassis is a framework or housing into which modules are inserted.
 Voltage Signal
The purpose of this interface is to condition the various signals received from or
sent to external field devices.
To electrically isolate the internal components from the input and output
terminals, PLCs commonly employ an optical isolator, which uses light to couple
the circuits together .

Input/ output Interface types

Input interface
DC voltage digital input circuit
A.C voltage digital input circuit
Pulse counter circuit
ADC interface
DC voltage digital input circuit
This interface uses DC source which is normally 24V
It can be connected into forms
With the sink input interface when the input device turned on connect the circuit
to 0V line of the DC supply.
With the current sourcing interface when the input device turned on connects the
Circuit to the positive polarity of the supply
AC voltage digital input circuit
This interface uses AC source which is normally 12/24/120/220V.
It comprises rectifier and filter circuit
Analogue to digital converter circuit
it uses to accepts an analogue input signal and converts into output binary
value that corresponds to the level of the analogue input.

Output interface Relay output circuit

a) Relay output circuit
b) Transistor output
circuit
c) Triac output circuit
d) DAC interface
Transistor output circuit

Triac output circuit

 Current Signal
In the field of industrial instrumentation and
control, 4-20mA is a commonly used standard for
current loop signaling.
a) To immune to electrical noise and can be
transmitted over long distances using
twisted pair cables, which are inexpensive
and widely available.
b) 4-20mA signals can be easily converted to
other forms of measurement, such as
voltage or resistance.
c) It is very easy to identify if the cable is
broken.
 Programming Methodology
a) Ladder logic diagram
b) Block diagram function
c) Statement list
a) Ladder logic diagram
Ladder diagrams are specialized schematics commonly used to document industrial control
logic systems.
They are called “ladder” diagrams because they resemble a ladder, consist
i) two vertical rails (supply power) and
ii) many “rungs” (horizontal lines) as there are control circuits to represent.

a simple ladder diagram showing a

lamp that is controlled by a hand
switch
Fig. simple ladder diagram showing a lamp
Ladder Logic
•Parallel contacts are equivalent to an OR gate.
•Series contacts are equivalent to an AND gate.
•Normally-closed contacts are equivalent to a NOT gate
(inverter).
Things to note
•Parallel contacts are logically equivalent to an
OR gate.
•Series contacts are logically equivalent to an
AND gate.
•Normally closed (N.C.) contacts are logically
equivalent to a NOT gate.
•A relay must be used to invert the output of a
logic gate function, while simple normally-closed
switch contacts are sufficient to represent inverted
gate inputs
Permissive and Interlock Circuits
•Switch contacts installed in a rung of ladder logic designed to interrupt a circuit
if certain physical conditions are not met are called permissive contacts,
because the system requires permission from these inputs to activate the output.
•Example of Permissive circuits
A practical application of switch and relay logic is in control systems where
several process conditions have to be met before a piece of equipment is allowed
to start.
A good example of this is burner control for large combustion furnaces.
The burners in a large furnace to be started safely,
the control system requests “permission” from several process switches,
including
 High and low fuel pressure,
 Air fan flow check,
 Exhaust stack damper position,
 Access door position, etc.
Each process condition is called
a permissive, and each
permissive switch contact is
wired in series, so that if any one
of them detects an unsafe
condition, the circuit will be
opened:
If all permissive conditions are met, CR 1 will energize, and the green
lamp will be lit.
In real life, more than just a green lamp would be energized:
Usually, a control relay or fuel valve solenoid would be placed in that
rung of the circuit to be energized when all the permissive contacts were
“good:” that is, all closed.

If any one of the permissive conditions are not met, the series string of
switch contacts will be broken, CR2 will de-energize, and the red lamp
will light.

Note that the high fuel pressure contact is normally-closed.

This is because we want the switch contact to open if the fuel pressure
gets too high.

Since the “normal” condition of any pressure switch is when zero (low)
pressure is being applied to it, and we want this switch to open with
excessive (high) pressure, we must choose a switch that is closed in its
normal state.
Interlocks
witch contacts designed to prevent a control system from taking two incompatible
actions at once (such as powering an electric motor forward and backward
simultaneously) are called interlocks

A practical application of relay logic is in

control systems where we want to ensure
two incompatible events cannot occur at
the same time.
An example of this is in reversible motor
control, where two motor contactors are
wired to switch polarity (or phase sequence)
to an electric motor.
The forward and reverse contactors should
not be energized simultaneously:
When contactor M1 is energized, the 3 phases (A, B, and C) are connected directly to
terminals 1, 2, and 3 of the motor, respectively.
However, when contactor M2 is energized, phases A and B are reversed, A going to
motor terminal 2 and B going to motor terminal 1.
This reversal of phase wires results in the motor spinning the opposite direction.
 Motor Control Circuits for forward and Reverse

These parallel auxiliary contacts are sometimes referred to

as seal-in contacts, the word “seal” meaning essentially the
same thing as the word latch.
To prevent this occurrence from happening, the circuit can be designed so that the
energization of one contactor prevents the energization of the other.
This is called interlocking, and it is accomplished using auxiliary contacts on each
contactor, as such:
 Application examples
1. Develop a simple ladder logic program that will turn on switch if inputs A and B ,
or input C is on.
Solution
Let input A , B and C stand for I1, I2 and I3 respectively
2. Develop a simple ladder logic program that will operate the machine in auto and manual m
Solution
The ladder diagram for a given problem will have two switches (I1 for auto mode while I2 for
Manual mode)
Also interlock contact is needed to avoid both mode to operate at the same time

Auto mode

Manual mode
3. Develop a ladder logic program that will operate two motors M1 and M2 which are required to
to turn ON one after another .First motor M1 start by pressing switch I2 and then by pressing
switch I2, M2 should start. But condition is like that when M2 starts M1 remains OFF. .
Solution
4. Develop a ladder logic program that will be used to find and check bottle cap from a
bottling plant

5. Write a ladder diagram for forward movement of motor by pushing the forward push
button. On pushing the reverse push button motor should start in reverse direction. Motor
should stop before changing the direction of motion. Insert a stop the motor at any time
PHYSICAL WIRING
L
220-230V AC
N

L N N I1 I2 I3 I4 I5 I6 I7 I8

412-AC-RC
PORT

Q1 Q2 Q3 Q4

M CONTACTOR LAMP BUZZER

SOLENOID

L N +
- L N + -