Introduction to automation ,plc, programing language

PLC Automation

1. B. B. Kadam Assistant Professor E-mail : kadambhushan [email protected],in Contact No: 7020447673 Subject- PLC & SCADA [Electrive II (317 C)] Unit 1 - Introduction to Automation and PLC ‹#›

2. Contents ‹#› Need & Role of Automation, Types of Industrial Automation System Definition & History of PLC, Basic structure & Components of PLC Principle of Operation, Selection of PLC, PLC I/O Modules, Memory, PLC advantages & Disadvantages, What is Logic? Overview of Logic functions Number systems & Codes Hardwired Logic vs Programmed logic. ‹#›

3. Need & Role of Automation, DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› Increased Reliability More Flexibility Lower Cost Communication Capability Faster Response Time Easier Troubleshooting Easy to Test Field Devices ‹#›

4. 2. Types Of Industrial Automation System DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› Fixed Automation System Programmable Automation System Flexible Automation System Integrated Automation System ‹#›

5. 3 . Definition & History of PLC, DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› A modern controller device used extensively for sequence control today in transfer lines, robotics, process control, and many other automated systems is the Programmable Logic Controller (PLC). In essence, a PLC is a special purpose industrial microprocessor based real time computing system, which performs the following functions in the context of industrial operations ‹#›

6. ‹#› An original Modicon PLC. Image used courtesy of Schneider Electric

7. 4. Basic Structure & Components of PLC DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› ‹#›

8. 5. Principle of Operation, Selection of PLC, PLC I/O Modules, Memory DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› Operational Sequence Scan Cycle:- checks on the hardware and software for faults , also called a self-test Input Scan : A simple way of looking at this is the PLC takes a snapshot of the inputs and solves the logic. The PLC looks at each input card to determine if it is ON or OFF an d saves this information in a data table for use in the next step. This makes the process faster and avoids cases where an input changes from the start to the end of the program. Execute Program (or Logic Execution) : The PLC executes a program one instruction at a time using only the memory copy of the inputs to the ladder logic program. For example, the program has the first input as ON. Since the PLC knows which inputs are ON/OFF from the previous step, it will be able to decide whether the first output should be turned ON. Output Scan : When the ladder scan completes, the outputs are updated using the temporary values in memory. The PLC updates the status of the outputs based on which inputs were ON during the first step and the results of executing a program during the second step. The PLC now restarts the process by starting a self-check for faults. ‹#›

9. 5. Selection of PLC, PLC I/O Modules, Memory DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› Power Supply Number of Inputs and Outputs Communication Protocol Environment Specifications Motion Requirement / Speed of CPU Application Requirements of PLC Operator Interface ‹#›

10. 6 . PLC advantages & Disadvantages, DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› A dvantages Reliability Flexibility Ease of use Cost-effectiveness Safety Disa dvantages Complexity: Limited processing power: PLCs are not as powerful as some other types of systems like DCS, and they may not be able to handle complex tasks or large amounts of data. Limited expandability: Dependence on programming: ‹#›

11. 7 . What is Logic? Overview of Logic functions , DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› Ladder logic is a fast and simple way of creating logic expressions for a PLC in order to automate repetitive machine tasks and sequences. It is used in a multitude of industrial automation applications. Some industrial automation application examples where PLC ladder logic is used include…. Material Handling Conveyor System. Pallet Packing and Strapping. Ball Mill Lubrication System. Logistics Package Conveying and Sorting. Cement Batching. Beverage Bottling and Labeling. Hopper and Tank Level Control. Air and Liquid Flow and Pressure Control. https://learn.automationcommunity.com/courses/siemens-plc-tia-portal-training-course ‹#›

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14. ‹#› Functional Block Diagram

15. 7. What is Logic? Overview of Logic functions , DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› https://learn.automationcommunity.com/courses/siemens-plc-tia-portal-training-course ‹#›

16. 8 . Number systems & Codes , DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› Decimal number system (Base- 10 Binary number system (Base- 2) Octal number system (Base-8) Hexadecimal number system (Base- 16) ‹#›

17. 9 . Hardwired Logic vs Programmed logic. , DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› ‹#› STATE-I (NO) STATE-II (NC) RELAY OPERATION

18. 9. Hardwired Logic vs Programmed logic. , DEPARTMENT OF ELECTRICAL ENGINEERING, Sanjivani COE, Kopargaon ‹#› Relay Logic Vs Ladder Logic - Ladder Logic World ‹#›

19. ‹#› Hardwired Logic vs Programmed logic. Hardwired Logic Programmed logic.

20. ‹#› HARDWIRE LOGIC P ROGRAMMABLE LOGIC Difficult to develop complex logical expressions with relay logic. Easier to develop complex logical expressions with ladder logic software. The life of relay based system is less as compared to PLC Increased reliability with PLC life easily reaching +10 years, Expansion of the system is difficult as well as costly Easier and cheaper to modify or expand the control system at a later date. More time is required for design, installation and component Reduced design, installation and component costs Relays required continuous maintenance. Virtually maintenance free compared to relays Superior monitoring and reporting functionality are not available with hardwire logic Superior monitoring and reporting functionality making process troubleshooting and optimization easier. Auxiliary devices are required such as timer or counters No need to Add auxiliary timer or counters

21. DEPARTMENT OF Electrical ENGINEERING, Sanjivani COE, Kopargaon ‹#› ‹#›