ETAS PVT. LTD. SEMINAR PRESENTED by Er . Kailash Tiwari

1. ETAS PVT. LTD. SEMINAR PRESENTED byEr. KailashTiwari

2. ET AUTOMATION SERVICES(An ISO 9001-2008) • Existing for the last 2 Years • Executes Automation projects for all types of process & manufacturing industries • Imparts automation training to Engineers / engineering professional • Imparted training to more than 5000 fresh engineers & 100 professionals

3. What is Automation ? Automation is basically the delegation of human control function to technical equipment to automate the systems that produce their goods or services in the most efficient manner possible.

4. Benefits of Industrial Automation • Increasing Productivity • Increased productivity = more units/day = more money • Products produced more consistently • increased consistency = higher quality = increased consumer satisfaction • Example - A bottled soft drink such as a Coke or a Pepsi always tastes the same no matter where or when you purchase it. Consumers count on this. • Products produced more reliably • robots can run 24 hours/day without getting tired or bored • Decreased labor expenses • Automated systems reduce the amount of people needed to produce the goods • Increasing Safety in working conditions

5. USE OF Industrial Automation Automation is encompassing virtually every walk of life. Automation solutions are required right from agricultural to space technology. Plant Automation is the necessity for the manufacturing industry to survive in today’s globally competitive market

6. Programmable Logic Controller Electronic Control using Logic Gates Hard wired logic Control Pneumatic Control Manual Control History of Automation

7. 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.

8. 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 lot of rework to implement control logic • Longer project time

9. Hard wired logic control • The contactor and Relays together with hardware timers and counters were used in achieving the desired level of automation Drawbacks • Bulky panels • Complex wiring • Longer project time • Difficult maintenance and troubleshooting

10. 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 Drawbacks • Changes in control logic not possible • More project time

11. plc[programmable logic controller] 1. PLC is a solid state/ computerized industrial computer that performs discrete or sequential logic in the factory environment. 2. These are originally developed to replace mechanical relays, timers Counters and contactors. 3. The very first plc was developed by modicon in later 1965.

12. Advantages of plc 1. Reliability in operation. 2.Flexability in control techniques 3.Flexibility in Programming and Reprogramming in the Plant 4. Large quantity of contacts 5. Online offline modifications 6. Cost effective for controlling complex system 7. Small Physical size and shorter project time 8. Speed in operation 9. Ability to communicate with computer in the plant 10. Ease of maintenance/ troubleshooting 11. Documentation 12. Security

13. Block diagram of plc

14. Basic parts of plc • Input Module • Output Module • CPU (central processing unit) • Power Supply • Communication Bus

15. Input to plc Input to the plc may be of following 1. Discrete/Digital input 2. Analog input Discrete/Digital input: • A Discrete/Digital input is an input that has either ON( means closed or1) or OFF( means open or 0) condition. for examples : Push buttons, Toggle switches, Limit switches , proximity switches. Analog input: • An Analog input is an input that has a continuous signal that may vary from 4-20 mamp. Or 0-10 volt. for examples: temperature, pressure, flow& level sensors are analog input to PLC.

16. Output of plc Output of the PLC may be of following • Discrete/Digital output • Analog output Discrete/Digital output: • A Discrete output is an output that is either in ON or OFF condition. • Solenoid coil, Indicator lamps, Alarm, Relay coils are examples of discrete outputs. Analog output: • An Analog output is a output that has a continuous signal that may vary from 4-20 mamp. Or 0-10 volt. • Control valve, servo/stepper motors are the examples of analog outputs.

17. Central Processing Unit • It is a micro-processor based circuitry. The CPU consists of following blocks : 1. Arithmetic Logic Unit (ALU), Program memory 2. Process image memory (Internal memory of CPU) 3. Internal timers and counters 4. Flags • CPU performs the task necessary to fulfill the PLC functions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device communication, special functions or data handling execution and self diagnostics.

18. Power Supply • The power supply gives the voltage required for electronics module (I/O Logic signals, CPU, memory unit and peripheral devices) of the PLC from the line supply. • The power supply provides isolation necessary to protect the solid state devices from most high voltage line spikes. • As I/O is expanded, some PLC may require additional power supplies in order to maintain proper power levels.

19. Communication Bus System • It is path for the transmission of the signal . Bu system is responsible for the signal exchange between processor and I/O modules • The bus system comprise of several single line ie wires / tracks

20. O:0/7 O:0/7 PLC Signal Flow Output Modules Input Module Processor Memory Data Input Image Table Output Image Table I:0/6 I:0/6 I:1/4 O:1/5 Input Devices Output Devices Ladder Program O:0/7 I:0/6 I:1/4 O:1/5 I:1/4 O:1/5 Programming Terminal

21. PLC Programming Standards The open, manufacturer-independent programming standard for automation is IEC 61131-3. You can thus choose what configuration interface you wish to use when writing your application : • Ladder Diagram • Instruction List • Function Block Diagram • Sequential Function Chart • Structured Text

22. Classification of plc 1.Depending upon the Physical assembly a. Compact Type b. Compact + Modular Type c. Modular Type 2. Depending upon the no. of I/Os a. small(<100) b. medium(<10000) c. large(>10000) 3. Depending upon the I/Os supported a. Digital b. Analog

23. Various brands of plc • Allen Bradley ………………………………..USA • Siemens …………………………Germany • Modicon ……………………………France • Mitshubishi ……………………………..Japan • GE Fanuc ………………………………..USA • Omron ……………………………..Japan

24. Few more examples of automation • Automation at Home Security • Automation at Bottling Plant • Automation at Coal Unloading • Robotic Arm Controlling • Brewing Batch Controlling • Conveyor_UPS Controlling

25. Industrial Automation Components Field Instruments Control Hardware Control Software

26. Automation : Typical installation . . . . SCADA Software Communication Cable Control Hardware Control Panel Field Cabling Junction Box Field Cabling Sensors Placed in the field

27. Sensors with transmitters are the field devices placed in the field who actually sense the parameter and send the analog signal to the control hardware. The analog signals used are Ohm (RTD), mV (Thermocouple), 4-20 mA, +/-10 V, etc Sensors ( Field Instruments )

28. Role of Engineers In Industrial Automation Designing of the Automation system Erection and Commissioning Maintenance and Troubleshooting of existing system Applied Engineers

29. Job Prospect for Fresher • Today management of almost all manufacturing units are going for industrial automation to survive in globally competitive market. Most of these industrial units are looking forward for trained engineers in the field of industrial automation. • Since they are thinking about more accuracy, productivity in less time & with minimum manpower , It’s a golden opportunity to prepare yourself to take on this task.

30. Job prospects for Engineers Manufacturing Industries like Reliance, Ceat, Godrej, Colgate …. Automation Solution Products manufacturer/developer like Rockwell, Siemens, Grouppe Schneider, Yokogawa, ABB System Integrators for Grouppe Schneider Rockwell, Siemens, etc Consultants for Automation

31. Current Situation Automation is a high growth sector globally hence it is essential to all professionals and students to have practical knowledge about the hardware and software used in Industrial Automation.

42. How ETAS will Help You Fortunately you have ETAS with you. Our practical and professional training courses in diversified hardware and software used in Industrial Automation are designed to fill the vacuum between your practical knowledge and industry demands. Hundreds of Individuals have benefited by our courses. They have increased their technical knowledge, thus leading to better job opportunity.

43. THANK YOU FOR LITENING ME

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