Industrial automation sustem

SIX MONTHS TRAINING REPORT ATIBMCE KVCH

ON(INDUSTRIAL AUTOMATION)

SUBMITTED BY

PARAS KUMAR

1407748

SUBMITTED TO

Mr. Satnam Singh Matharu

(HOD of EE Department)

TRAINING CENTER

IBMCE-KVCH partner is a 26 years old company having expertise on multiple training domain.

It provide training for 4 weeks, 6weeks, 2months and 6 months summer internship and industrial training along with technical and professional manner.

IBMCE-KVCH :-

Corporate Training.

Campus Training.

Individual Training.

What is Industrial Automation?

The term automation, inspired by the earlier word automatic .

It is the use of various control systems for operating equipment with

minimal or reduced human intervention.

Automation has been achieved by

various system:-

Mechanical

Hydraulic

Pneumatic

Electrical

Electronic and computers.

Complicated systems, such as modern

factories, airplanes and ships typically

use all these combined techniques.

Industrial Automation

The use of Computerized or robotic devices to complete manufacturing tasks.

History of industrial Automation

NIKOLA TESLA is the father of Automation system.

It was not widely used before 1947.

Before the used of automation system FEEDBACK CONTROLLERS was used,

which was introduced in 1930s and applied on general motors.

A DCS and PLC was developed in the 1970's and Several innovative start-ups developed

HMI software and sensor for PLCs and industrial I/O.

The real race to automate manufacturing can be said to have begun in the 1980s, when US

car manufacturers came up with the vision of “lights-out” manufacturing.

Industrial engineers have envisioned fully automated factories since at least the middle of

the 20th century.

MAIN PARTES OF AUTOMATION

AUTOMATION

SCADA

PLC

HMI

AUTOCADE

Supervise Control And Data Acquisition

(SCADA)

Meaning of “Supervise Control”

To supervise the controls.

It is similar to the work of a

Supervise.

Which monitors and controls all

the activities.

Meaning of “Data Acquisition”

Collection or grouping of data.

The data are gathered from like

sensors & instrument.

These data are collected in

SCADA software.

Block diagram and their arrangement

Block diagram Simple Arrangement

WONDERWARE - INTOCH

ALLEN BRADLEY - RSVIEW32

SEIMENS - WINCC

GE FANUC - CIMPLICITY

KPIT - ASTRA

SCADA SOFTWARES

and many more …..

Features of SCADA system

Animation property.

Dynamics property.

Trends.

Alarms.

Security.

Scripts.

Communication with Excel.

Communication with PLCs.

Mimics (miscellaneous)

Tag name

It is a tool to communicate different objects and operators in SCADA.

Object types

Analog (-32768 to +32768 )

Digital (0 , 1 )

String (to pass text )

Tag in SCADA

Types of Tag Saved in

Analog Tag Memory Real

Digital Tag Memory descript

String Tag Memory message

For communicating with excel I/O Real, I/O Descript ….

Animation properties

In this property we will design an industrial plant layout for industrial process .

Tools for Animation

Drawing Tools

Line

Poly line

Circle

Rectangle

Round rectangle etc.

Industrial Tools

Ball

Valve

Pump

Motor

Tank etc.

Application of Animation

Dynamics properties

Their are three types of Dynamics properties

Location property

Percent fill property and

Object size property.

Location property

In this property We change the location of any object either horizontally or

vertically both at a time.

Horizontally motion Vertically motion

Application Location properties

Horizontal Application Vertical Application

Object Size Property

To vary the size of any object either height or width or both at a time.

.

Width wise Height wise

Percent filling property

This property is used to show the filling and infilling of tanks, pipes etc.

Trends

Trend are used for graphical representation of any process.

Types of Trends

Real Time Trend

Historical Trends

Real Time Trend

It show only present

change in value.

It updates automatically

with time.

It uses four numbers of

pans / inputs at a time.

Historical Trend

It shows both present and

past change in value.

It updates manually.

It uses eight numbers of

pans/inputs at a time.

Scripts

This languages support in SCADA systems significantly enhanced their

capabilities to efficiently perform diverse industry automation operations

with flexibility and simplicity.

Simple problem Scripts

If Slider <= 100 and button == 0 then

slider = slider +1 ;

Endif ;

If slider >= 100 then

Button == 1;

Endif ;

If Slider >= 100 and button == 1then

slider = slider – 1;

Endif ;

If slider <= 0 then

Button = 0 ;

Endif ;

Miscellaneous property

I. Visibility

II. Blink

III. Orientation and

IV. Disable

“PLC”(Programmable Logic Controller)

Definition

It is an industrial computer that monitors

inputs, makes decisions based on its

program and controls outputs to automate

a process or machine.

The automation of many different

processes, such as controlling machines

or factory assembly lines, is done through

the use of small computers called a

programmable logic controllers (PLCs).

Collection of some plc.

History of PLC

PLC was introduced in late 1960’s.

First commercial & successful Programmable Logic Controllers was

designed and developed by “Modicon” as a relay replacer for General

Motors.

Earlier, it was a machine with thousands of electronic parts.

Later ,in late 1970’s,the microprocessor became reality & greatly

enhanced the role of PLC permitting it to evolve form simply relay to the

sophisticated system as it is today.

Simple working of PLC

Machine can be controlled by PLC without human efforts.

Size of PLC

SMALL

It covers units with up to128 I/O’s and memories up to 2 Kbytes.

These PLC’s are capable of providing simple to advance levels or

machine controls.

MEDIUM

Have up to 2048 I/O’s and memories up to 32 Kbytes.

LARGE

They have up to 8192 I/O’s and memories up to 750 Kbytes.

It Can control individual production processes or entire plant.

Major Components of a Common PLC

PROCESSOR

POWER

SUPPLY

I M

N O

P D

U U

T L

E

O M

U O

T D

P U

U L

T E

PROGRAMMING

DEVICE

From

SENSORS

Pushbuttons,

contacts,

limit switches,

etc.

To

OUTPUT

Programming Languages of PLC

Most common languages encountered in PLC programming are:

1) Ladder Logic

2) Functional Block Diagram

3) Sequential Function Chart

4) Boolean mnemonics

Block diagram of a PLC

Outputs

LEDs

Inputs

Programming of PLC

Ladder Logic Program for Start/Stop of Motor

Starting of Motor

Continuous Running of motor when Start Button is released

To Stop The Motor

PLC operation sequence

Self test.

Input scan

Logic solve/scan

Output scan

Over all steps depends up on the

clock frequency.

Communication between SCADA and PLC

The is a process in which both ( PLC &SCADA ) work together at a time .

Software's

For Allen - Bradley : Abkf2 and

For all PLC : KEP serverex

The software in which facilities are

present for communication is

“Allen-Bradley Logixpit”.

Human Machine Interface

( HMI )

A human machine interface

(HMI) is an interface which

permits interaction between a

human being and a machine.

Human machine interfaces

vary widely, from control

panels for nuclear power plants

to the screen and input buttons

on a cell phone

Sensor

A sensor is a device that detects andresponds to some type of input fromthe physical environment.

Types

Analog

a) RTD

b) LVDT

c) Thermocouple etc.

Digital (proximity)

a) Capacitive – For all objects

b) Inductive - For all metals

c) IR Sensor – For all's.

Automatic Computer Aided Design

(AutoCAD)

For controls designers, purpose-

built to create and modify

electrical control systems.

It includes all the functionality of

AutoCAD plus comprehensive

symbol libraries.

Common Commands

CO - Copy an object

Z - Zoom in display

E - Erase selection

EX - Extend a selection

J - Joins 2 objects to form single

object

TR - Trim a selection

O - Offset an object by distance

EXTRUDE - Converts 3D to 2D

FLATTEN - Converts 3D to 2D

Project worked

PLC Based automatic water bottle filling system

Software Work

We have solved the problem and

configure the Allen Bradly micro

logic 1000 series plc. with pc, with

the help of Rs-2-32 cable and the

software RS LOGIX micro.

We have developed normal basic

program with timer and counter

based control.

Hardware Implementation

Design of conveyor belt

A simple conveyor belt will be stretched between two rollers, one

roller which pushes it and other roller which pulls belts as the belt moves

Dimension of conveyor belt

Roller

Quantity : Two rollers

Dimension of Roller

Material used Length in inch Width in inch Thickness in mm

PVC 24 3 2

Material used Diameter in inch Length in inch

PVC 1.53 4

Assembly of conveyor belt and Roller

Electrical components

Component name Quantity specifications

Voltage regulator

( L7812)

3 12v

IR proximity

sensor

1 pnp , No types

range – 400 mm

Pump/ solenoid 1 12v DC

Relay 4 24 v

Gear motor 1 10 rpm

12v DC

SMPS 1 24 DC

2.5 A

Electrical circuit

Working

Start

PLC

MOTOR SENSOR

PUMP/

SOLENOID BOTTLE

FILLING

Conclusion

The automated bottle filling system

is beneficial in reducing:-

work,

time and

cost of filling.

Hence it must be used in application

specific.

Thank You!!!