ELECTROCUS

SOLUTION
What is Automation?

Use of control systems and

information technologies to reduce
the need for human work in the
production of goods and services.
Role of Automation
Automation is a step beyond mechanization.

Mechanization provided human operators with machinery

to assist them with the muscular requirements of work.

Automation greatly decreases the need for human sensory

and mental requirements as well.
HISTORY OF PROGRAMMED
AUTOMATION CONTROL

ELECTRONIC
CONTROL

HARD WIRED
CONTROL

MANUAL
CONTROL
Manual Control
 All actions were taken by the operators.

 Limitations

 Mass production is not possible.

 First step towards automation.
 The contactor & relays together with timers
& counters were used in achieving the desired
level of automation.

 Limitations
 Bulky & Complex Wiring

 Involves lot of rework to implement changes in

control logic

 The work can be started only when the task is fully

defined & this leads to longer project time.
ELECTRONICS CONTROL
 With the advancement in electronics ,
 Relays & auxiliary contactors were replaced
by Logic gates in the control circuits.

 The bi-metallic & motorized timers were

replaced by electronic timers…..etc.
 Advantages
 Reduced space requirements

 Energy saving

 Less maintenance & hence greater reliability

PROGRAMMED CONTROL
 With the up-coming of microprocessors, the whole
process of control & automation went a radical
change.

 Instead of achieving the desired control or

automation through physical wiring of control
devices, it is achieved through a program or say
software called Program Controllers.
 Saving man-kind to work in dangerous environment.

 Performing tasks that are beyond human capabilities

of size, weight, speed, etc.

 Economic Improvement
 Increases un-employment

 Technical Limitation

 High initial cost is required.

ANN - Artificial Neural Network

SCADA - Supervisory Control and Data Acquisition

PLC - Programmable Logic Controller

 NC- Numeric Control

What does PLC stand
for?
 PLC - Programmable Logic Controller.

 PLC implements logic control functions by

means of a program.

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History of the PLC

The first PLC, model 084, was invented by

Dick Morley in 1969.

The first commercial successful PLC, the

184, was introduced in 1973 which was
designed by Michael Greenberg.
What is a PLC?
The Basic Block

CPU

Inputs Outputs

A PROGRAMMABLE LOGIC CONTROLLER is a solid state

control system that continuously monitors the status of devices
connected as inputs. Based upon a user written program,
stored in memory, it controls the status of devices connected as
outputs.
What is a PLC with Distributed I/O?
Getting Complex

CPU

Inputs Outputs

Remote

Outputs

Inputs
What is a PLC with Distributed Control?
Getting Really Complex
CPU CPU

Inputs Outputs
Inputs Outputs

Remote

Outputs

Inputs
Major Components of a Common
PLC
POWER
SUPPLY

I M O M
N O U O
P D T D
U U PROCESSOR P U
T L U L
From E T E To
SENSORS OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE

17
Major Components of a Common PLC
 POWER SUPPLY
Provides the voltage needed to run the primary PLC components.

 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 the
sequence of operation and control of process equipment or
driven machine.
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Programming Device
Types:
 Hand held unit with LED / LCD display

 Desktop type with a CRT display

 Compatible computer terminal

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I/O Module
The I/O interface section of a PLC connects it to external field
devices.

The main purpose of the I/O interface is to condition the

various signals received from or sent to the external input and output
devices.

Input modules converts signals from discrete or analog input

devices to logic levels acceptable to PLC’s processor.

Output modules converts signal from the processor to levels

capable of driving the connected discrete or analog output devices.
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Input Module
DC INPUT MODULE
IS NEEDED TO:
USE TO Prevent voltage
DROP THE transients from
VOLTAGE damaging the
TO LOGIC processor.
LEVEL Helps reduce the
effects of
electrical noise

Current Buffer,
FROM Limiting Filter,
OPTO- TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits

21
 Contd….
Input Module
AC INPUT MODULE
IS NEEDED TO:
CONVERTS THE AC Prevent voltage
INPUT TO DC AND transients from
DROPS THE damaging the
VOLTAGE TO LOGIC processor.
LEVEL Helps reduce the
effects of
electrical noise

Rectifier, Buffer,
FROM Resistor OPTO-
Filter,
TO
INPUT Network ISOLATOR Hysteresis
PROCESSOR
DEVICE Circuits

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23
24
25
Output Module
DC / AC OUTPUT MODULE
IS NEEDED TO:
Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of
electrical noise

Amplifier
FROM OPTO-
RELAY
TTL TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE

26
27
What are the Inputs devices?
• Switches and Push buttons

• Sensing Devices
• Limit Switches
• Photoelectric Sensors
• Proximity Sensors
• Condition Sensors
• Pressure Switches
• Level Switches
• Temperature Switches
• Vacuum Switches
• Float Switches
•Encoders
What are the Output devices?
• Valves

• Motor Starters
• Solenoids
• Actuators
• Control Relays
• Horns & Alarms
• Stack Lights
• Fans
• Counter/Totalizer
• Pumps
• Printers
Different types of I/O circuits
General - Purpose Outputs
Usually low- voltage and low-current
circuits.
Used to drive indicating lights and other
non-inductive loads.
Noise suppression may or may not be
included on this types of modules.

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Different types of I/O circuits
Pilot Duty Outputs
Used to drive high-current electromagnetic loads
such as solenoids, relays, valves, and motor starters.

These loads are highly inductive and exhibit a

large inrush current.

 Capable of withstanding an inrush current of 10

times the rated load for a short period of time
without failure. 31
Different types of I/O circuits
Analog I/O
 Circuits of this type sense or drive analog signals.

 Signal voltage or current derived from the process

variable. Standard Analog Input signals: 4-20mA;
0-10V

Analog outputs can be used to drive devices such as

volt-meters, X-Y recorders, servo-motors drives, and
valves through the use of transducers. Standard Analog
Output signals: 4-20mA; 0-5V; 0-10V 32
Different types of I/O circuits
Special - Purpose I/O
Interfacing to very specific type of circuits such as
servomotors, stepper motors, PID controllers, high-speed
pulse counting, decoder circuits, multiplexed displays, and
keyboards.

 This module allows for limited access to timer and

counter presets and other PLC variables without
requiring a program loader.
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Interfacing of I/O devices with PLCs
OUTPUTS

INPUTS MOTOR

PLC CONTACTOR
LAMP

PUSHBUTTONS

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Processors
It contains the PLC’s microprocessor, its supporting circuitry, and
its memory system.

 The main functions of the microprocessor is to

 analyze data coming from field sensors.

 decisions based on the user’s defined control program.
 Returns signal back to the field devices.
 Field sensors: switches, flow, level, pressure, temp.
transmitters, etc.
 Field output devices: motors, valves, solenoids, lamps, or
audible devices.

 The memory system in the processor module has two parts:

a system memory and an application memory. 35
 Memory Map Organization
•System memory includes an area called the EXECUTIVE,
composed of permanently-stored programs that direct all
system activities, such as execution of the users control
program, communication with peripheral devices, and other
SYSTEM system activities.
•The system memory also contains the routines that
implement the PLC’s instruction set, which is composed of
specific control functions such as logic, sequencing, timing,
counting, and arithmetic.
•System memory is generally built from read-only memory
APPLICATION devices.
• The application memory is divided into the data table area and user
•Data Table program area.
•User Program •The data table stores any data associated with the user’s control
program, such as system input and output status data, and any stored
constants, variables, or preset values. The data table is where data is
monitored, manipulated, and changed for control purposes.
•The user program area is where the programmed instructions
36
entered by the user are stored as an application control program.
37
38
39
In traditional
 Wiring makes the rule.
Control,

In PLC Control,
 Program makes the rule.

Thus, It is much simpler to change program than

wiring!
40
 Programming is done through programming terminal which
converts engineering language (logic control) to machine
language (binary code).
 Programming Terminal

41
Program can be written either in the form of a
Statement list:
a set of mnemonic instructions representing a function of the
CPU.
or a
Ladder diagram:
a graphical language resembling the electrical relay diagrams.

Advantage
 One of the advantage of PLC is that it can be programmed by
non-specialists also.
42
Statement list

43
Ladder diagram

44
 Most PLC manufacturers offer software packages that allow a
standard computer to be used as a programming terminal.

45
PLC Programming Softwares:

1. Allen-Bradley – Rockwell Software RSLogix500

2. Modicon - Modsoft
3. Omron – Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Texas Instruments – Simatic
7. Telemecanique – Modicon TSX Micro
Types of Programming Software Languages

 Ladder Logic (LL)

 IEC Format
⚫ Function Block Diagram (FBD)
⚫Structured Text (ST)
⚫Instruction List (IL)
⚫Ladder Diagram (LD)
⚫Sequential Function Chart (SFC)
PLC Operation
Basic Function of a PLC is

Read all field input devices via the input interfaces.

 Execute the user program stored in application memory.

Based on control scheme, programmed by user, turn the

field output devices on or off, or perform whatever control
is necessary for the process application.

This process of sequentially reading the inputs, executing

the program in memory, and updating the outputs is known
as scanning. 48
PLC Operation
While the PLC is running, the scanning process includes the
following four phases, which are repeated continuously as individual
cycles of operation:
PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan 49
PLC Operation
PHASE 1 – Input Status scan

 A PLC scan cycle begins with the CPU reading the status of its
inputs.

PHASE 2– Logic Solve/Program Execution

 The application program is executed using the status of the inputs.

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 PHASE 3– Logic Solve/Program
 Execution
Once the program is executed, the CPU performs diagnostics and
communication tasks.

PHASE 4 - Output Status Scan

An output status scan is then performed, whereby the stored output
values are sent to actuators and other field output devices. The cycle
ends by updating the outputs.

As soon as Phase 4 is completed, the entire cycle begins again with

Phase 1 as input scan.
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 SCAN TIME :
 The time taken by PLC to implement a scan cycle is called
SCAN TIME. The scan time is composed of the program scan
time and the I/O update time.

 The program scan time generally depends on the amount of

memory taken by the control program and type of instructions
used in the program.

 The time to make a single scan can vary from 1 ms to 100 ms.
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Criteria for selecting a PLC
 Number of logical inputs and outputs.
 Memory
 Number of special I/O modules
 Scan Time
 Communications
 Software
Peripherals required while working
with PLCs:
 Programming Terminal - laptop or desktop PC.

 PLC Software. PLC manufacturers have their own specific

software and license key.

 Communication cable for connection from Laptop to PLC.

 Backup copy of the ladder program (on diskette, CDROM, hard

disk, flash memory). If none, upload it from the PLC.

 Documentation- (PLC manual, Software manual, drawings,

ladder program printout, and Seq. of Operations manual.)
Areas of Application
 Manufacturing / Machining
 Food / Beverage
 Metals
 Power
 Mining
 Petrochemical / Chemical
55
Tank Used to Mix Two Liquids
MOTOR
A
FS FLOAT SWITCH

SOLENOIDS B

SOLENOID
C
TIME
R

1 -MINUTE
56
Tank Used to Mix Two Liquids
A tank is used to mix two liquids. The control circuit operates
as follows:

1.When the start button is pressed, solenoids A and B

energize. This permits the two liquids to begin filling the tank.

2.When the tank is filled, the float switch trips. This de-
energizes solenoids A and B and starts the motor used to mix
the liquids together.

3. The motor is permitted to run for one minute. After one

minute has elapsed, the motor turns off and solenoid C
energizes to drain the tank. 57
 PLC can sense a vehicle at the entrance or exit, and open and
close the gate automatically
 The current vehicle count is easily determined by
programming a simple counter

58
 PLC can be used to start/stop latching logic for motor control
 Counters can be used for monitoring product amounts

59
Introduction to NC and CNC Machines

 Numerical control is a method of automatically operating a

manufacturing machine based on a code of letters, numbers, and
special characters.

 A CNC machine is an NC machine with the added feature of an on-

board computer. In CNC (Computer Numerical Control), the
instructions are stored as a program in a micro-computer attached to
the machine. which handles control logic of the machine, making it
more adaptable than earlier hard-wired controllers.
 ADVANTAGES of CNC
 Increases Productivity

 More accuracy with less waste of scrap

 Reduced inventory
 Machining Complex shapes

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 DRAWBACKS of CNC
 High capital cost
 High maintenance requirements
 Not cost-effective for low-level production on simple
parts

 Maintenance personnel must have both mechanical and

electronics expertise

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 NC SYSTEM ELEMENTS

2004 63
Introduction to NC programming
 Manual part programming
 Computer-assisted part programming
 Formats
 Fixed-Address
 Tab-Sequential
 Word-Address
Manual NC programming
 Absolute Programming

 Incremental Programming

 Example (on Board)

 Basic Elements of NC Program
 Blocks of Commands
 NC Words
 NC Function ~ NC word(s)
 Several Functions in one block
 When viewing, a block is same as a line of text
 Pre-defined Terminator
 Optional Blocks
OPERATIONAL FEATURES of CNC MACHINES

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CNC SYSTEM ELEMENTS
A typical CNC system consists of the following six
elements
⚫ Part program
⚫ Program input device
⚫ Machine control unit
⚫ Drive system
⚫ Machine tool
⚫ Feedback system

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PART PROGRAM
⚫ A part program is a series of coded instructions required to
produce a part. It controls the movement of the machine
tool and the on/off control of auxiliary functions such as
spindle rotation and coolant. The coded instructions are
composed of letters, numbers and symbols and are
arranged in a format of functional blocks as in the
following example
N10 G01 X5.0 Y2.5 F15.0
| | | | |
| | | | Feed rate (15 in/min)
| | | Y-coordinate (2.5")
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number
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PROGRAM INPUT DEVICE
⚫ The program input device is the mechanism for part
programs to be entered into the CNC control. The
most commonly used program input devices are
keyboards, punched tape reader, diskette drivers,
throgh RS 232 serial ports and networks.

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DRIVE SYSTEM
⚫ A drive system consists of amplifier circuits, stepping
motors or servomotors and ball lead-screws. The MCU
feeds control signals (position and speed) of each axis
to the amplifier circuits. The control signals are
augmented to actuate stepping motors which in turn
rotate the ball lead-screws to position the machine
table.

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MACHINE CONTROL UNIT
The machine control unit (MCU) is the heart of a CNC
system. It is used to perform the following functions:

⚫ Read coded instructions

⚫ Decode coded instructions
⚫ Implement interpolations (linear, circular, and helical) to
generate axis motion commands
⚫ Feed axis motion commands to the amplifier circuits for
driving the axis mechanisms
⚫ Receive the feedback signals of position and speed for each
drive axis
⚫ Implement auxiliary control functions such as coolant or
spindle on/off, and tool change
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TYPES of CNC CONTROL SYSTEMS

⚫ Open-loop control
⚫ Closed-loop control

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FEEDBACK SYSTEM
⚫ The feedback system is also referred to as the
measuring system. It uses position and speed
transducers to continuously monitor the position at
which the cutting tool is located at any particular time.
The MCU uses the difference between reference
signals and feedback signals to generate the control
signals for correcting position and speed errors.

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CNC PROGRAMMING
⚫Offline programming linked to CAD programs.
⚫Conversational programming by the operator.
⚫MDI ~ Manual Data Input.
⚫Manual Control using jog buttons or electronic
hand-wheel.
⚫Word-Address Coding using standard G-codes
and M-codes.

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1.Absolute positioning. In this mode, the desired
target position of the tool for a particular move is
given relative to the origin point of the program.

2.Incremental positioning. In this mode, the next

target position for the tool is given relative to the
current tool position.

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INFORMATION NEEDED by a CNC
1. Preparatory Information: units, incremental or absolute
positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. Miscellaneous Control: Spindle on/off, direction of
rotation, stops for part movement
This information is conveyed to the machine through a set
of instructions arranged in a desired sequence – Program.
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 Direct Numerical Control (DNC):
A system in which a central computer downloads the NC
programs block by block to many NC machine tools
simultaneously is called Direct Numerical Control (DNC)
system.
 It work with the early NC machine tools which can not
read more than a block of information at a time.
 The central computer feed the program information one
block at a time. When the machine execute the
information, the next block of information would be fed.
78
Distributed Numerical Control (DNC):

 Distributed NC is known by the same acronym as

Direct Numerical Control (DNC).

 In such a system, a host computer communicate with

many CNC machine tools via networks and
download or upload programs.

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 Computer Aided Part
Programming:
⚫NC program preparation may be tedious and
difficult if the part to be machined has a complex
geometry. The main difficulty is to find out the
cutter locations during the machining.
Computers may be used to assist the
programmers in preparing the NC codes.

80
 Advantages of applying computer-aided part
programming include the following:

⚫ 1. It reduces the manual calculations involves

in determining the geometric characteristics of
the part.
⚫It provides the cutter path simulation.
⚫It provides tool collision checking.
⚫It shortens the program preparation time.
⚫It makes the program preparation easier.

81
⚫ The Aerospace Industries Association sponsored the
work that led to the first part programming language,
developed in MIT in 1955.
⚫ This was called: Automatically Programmed Tools (APT).
⚫ APT is an English like simple programming language
which basically produce the Cutter Location (CL) data.
⚫ Using the cutter location data, the program can generate
the actual NC codes by using a postprocessor .

82
 CAD/CAM Based Part
Programming:
⚫ The output of any CAD package include the geometric
data of the part to be machined. Therefore, many
CAD/CAM package can produce cutter location (CL) data
to be used for NC code generation.
⚫ There is still to be a process planning module for a
workable NC code generation.
⚫ Some of the CAD/CAM packages that have the NC code
generation capabilities are Computervision, CATIA,
CADAM, ProEngineer, MechanicalDesktop (Auto Desk).

83
NUMERICALLY CONTROLLED MACHINE TOOLS:
An NC machine tool is functionally the same as a
conventional machine tool. The technological
capabilities NC machine tools in terms of
machining are no different from those of
conventional ones. The difference is in the way in
which the various machine functions and slide
movements are controlled. 84
The functions and motions such as;

turning the spindle on and off

setting cutting speeds
setting feed rate
turning coolant on and off
moving tool with respect to workpiece

are performed by Machine Control Unit (MCU) in

NC machine tools.
85
 SAMPLE
CNC MACHINES

87
Flow of Computer-
 CNC
Aided ProcessingDevelop or obtain the 3D

geometric model of the part,

 using CAD.
 Decide which machining operations and cutter-path
directions are required
 (computer assisted).
 Choose the tooling required (computer assisted).
 Run CAM software to generate the
CNC part program. Verify and edit
program.
 CNC Machine Axes of
The coordinate system used for the tool path must be identical to the
Motion
coordinate system used by the CNC machine. The standards for
machine axes are established according to the industry standard report
EIA RS-267A.

Right hand rule

Vertical
milling
machine
Horizont
al milling
machine

CNC machines milling machines

rform simultaneous linear motion along
the three axis and are call d t e-axes
machines.
89
CNC Machine Axes of
Motion

Coordinate system for a Lathe

90
CNC Machine Axes of
Motion
More complex CNC machines have the capability of executing additional rotary
th th
motions (4 and 5 axes).

91
CNC Machine Axes of
Motion

Five-axis machine
configurations

Mechanical Engineering Department 92

CNC Machine Tool Positioning
Within a given machine axes coordinate system, CNC can be programmed to
locate tool positions in the following modes; incremental, absolute, or

Modes
mixed.

Mechanical Engineering Department 93

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95
CNC LASER CUTTING

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CNC PRESS

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CNC RAPID PROTOTYPING

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INDUSTRIES MOST AFFECTED by
CNC
⚫ Aerospace
⚫ Machinery
⚫ Electrical
⚫ Fabrication
⚫ Automotive
⚫ Instrumentation
⚫ Mold making

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2004
SAMPLE PRODUCTS
OF
CNC MANUFACTURING

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2004