Automation and Applications

8/7/2019 Automation and Applications

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AUTOMATION:Document By

SANTOSH BHARADWAJ REDDY

Email: [email protected]

More Papers and Presentations available on above site

Automation is the use of control systems such as computers to control industrial machinery andprocesses, replacing human operators. In the scope of industrialization, it is a step beyond mechanization.Whereas mechanization provided human operators with machinery to assist them with the physicalrequirements of work, automation greatly reduces the need for human sensory and mental requirements aswell.

ADVANTAGES OF AUTOMATION:

The purpose of automation has shifted from increasing productivity and reducing costs, to broaderissues, such as increasing quality and flexibility in the manufacturing process.

Automation is now often applied primarily to increase quality in the manufacturing process, whereautomation can increase quality substantially.

For example, automobile and truck pistons used to be installed into engines manually. This israpidly being transitioned to automated machine installation, because the error rate for manual installmentwas around 1-1.5%, but has been reduced to 0.00001% with automation.

Hazardous operations, such as oil refining, the manufacturing of industrial chemicals, and all formsof metal working, were always early contenders for automation.

Application of Automation

Power generation

TRANSMISSION AND DISTRIBUTION:
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Oil and gas industries

Process industries


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Building automation

HISTORY OF AUTOMATION


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MANUAL CONTROL

HARDWIRED CONTROL:Prior to PLCs, many of these control tasks were solved with contactor or relay controls. This is

often referred to as hard-wired control. Circuit diagrams had to be designed, electrical components specifiedand installed, and wiring lists created. Electricians would then wire the components necessary to perform aspecific task. If an error was made the wires had to be reconnected correctly. A change in function or systemexpansion required extensive component changes and rewiring.


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DRAWBACKS:Bulky and complex wiring.Difficult to change the logic.Unreliable.

RELAY :

RELAY LOGIC AND GATE:

ELECTRONICS CONTROL


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Logic gates and Electronic Circuits are used

Ease of programmingEase of maintenance

Drawbacks:Difficult to Troubleshoot while Change the Logic of the Process

Difficult to expandNot suitable for industrial conditions

PROGRAMMABLE LOGICAL CONTORL

What is a Programmable Logic Controller PLC?

PLC is a device, which is used to control a machine or process as per the human control sequence.A PLC monitors inputs, makes decisions based on its program, and controls outputs to automate a processor machine.

Advantages

Smaller physical size than hard-wire solutions Easier and faster to make changes PLCs have integrated diagnostics and override functions Diagnostics are centrally available

Applications can be immediately documented Applications can be duplicated faster and less expensively


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PROCESSOR MEMORY ORGANIZATION

The memory of a PLC is organized by types.

The memory space can be divided into two broad categories:


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Program and Data Memory:

Advanced ladder logic functins allow controllers to perform calculatins, make decisions and doother complex tasks. Timers and counters are examples of ladder logic functions. They are more comples than basic

inputs contacts and output coils and relay heavily upon data stored in the memory of the PLC.

PROGRAM FILES:

The user program will account for most of the memory of a PLC system.

Program files contain the logic controlling machine operation.This logic consistes of instructions that are programmed in a ladder logic format.

DATA FILES:

The data file protion of memory stores input and output status, processor status, the status of various bits andnumerical data.

INPUT TABLE FILE OPERATION:


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1. I/O scan records status data of input devices. Energizes output devices that have their associated status

bits set to ON (1)2. Program scan instruction are executed sequentially.

SCAN PROCESS:

The scan time indicates how fast the controller can react to changes in inputs. Scan times vary with computermodel and program content, and length. If a controller has to react to an input signal that changes states twice during

the scan time, it is possible that the PLC will never be able to detect this change.


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When the inputs is closed, the input module senses a voltage and an ON condition (1) is entered into the inputtable bit 0012.

During the program scan the processor sets instructins 0012 and 506 to ON(1).


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The processor turns light output 506 ON during the next I/O scan.

KEYENCE

ADDRESS:

INPUTS:0000 to 00150100 to 0115

0200 to 02150300 to 03150400 to 0415

OUTPUTS:0500 to 0515

0600 to 06150700 to 0715

0800 to 08150900 to 0915

INTERNAL MEMORY BIT:1000 to 1015

Upto

1900 to 1915

TIMERS:TMR space # (0.1sec)

TMH space # (0.01sec)TMS space # (0.001sec)

COUNTERS:

Up counter: C space #spaceUp/Dwn counter: Cspace#


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PROCEDURE FOR PROGRAMMING:


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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1. Edit command/Lable2. Edit line command

3. Show/Hide command4. Jump to specified line/step

5. Find6. Replace operand7. Usage information8. Edit list

9. compail10. Show compilation error 11. Transfer to PLC12. Read from PLC

13. Plc monitor 14. Simulator 15. Display mode16. Description of operation

1 2 3 4 5 6 7 8 9 10

1. N.O. contact OR input2. NC contact OR input

3. NO contact input4. NC contact input5. Output coil6. NC output coil

7. Input vertical connection line8. Delete vertical connection line

9. Input Horizontal connection line


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10. Delete Horizontal connection line

BASIC PROGRAMMES:

--| |-- NORMALY OPEN CONTACT

--| / |-- NORMALY CLOSED CONTACT

--( )-- COIL

EX: 1

When the switch (SW) is ON, the LOAD should ON (Rung 0001)

When the switch (SW) is OFF, the LOAD should ON (Rung 0002

Note: The all programming sequence should complete with END AND ENDH.

LADDER LOGICS FOR DIGITAL GATES:

OR :

I1 I2 L

0 0 0

0 1 1

1 0 1

1 1 1

AND:

I1 I2 L


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0 0 0

0 1 0

1 0 0

1 1 1

NOR:

I1 I2 L

0 0 1

0 1 0

1 0 0

1 1 0

NAND:

I1 I2 L

0 0 1

0 1 11 0 1

1 1 0

EX-OR: EX-NOR:

I1 I2 L

0 0 1

0 1 1

1 0 1


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1 1 0

SWITCH CONTACTS:

EX 1: SW1= 0000, SW2= 0001, LD1 = 500, LD2 = 501

SW1 SW2 LD1 LD2

1 0 1 0

1 1 0 1

EX 2:

SW1 SW2 SW3 LD1 LD2 LD3

0 1 1 1 0 0

1 0 0 0 1 0

1 1 1 0 0 1

I1 I2 L

0 0 1

0 1 1

1 0 1

1 1 0


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Document By

SANTOSH BHARADWAJ REDDY

Email: [email protected]

Engineeringpapers.blogspot.com

More Papers and Presentations available on above site
mailto:[email protected]:[email protected]

Automation and Applications

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