WELCOME

INDUSTRIAL AUTOMATION

INTRODUCTION
This is an embedded system based industrial automation system Embedded system-software+ hardware+ additional mechanical parts This is SCADA system The project is done using MICROCHIPS MICROCONTROLLER PIC16F877A

EMBEDDED SYSTEM OVERVIEW

ADVANTAGES

Higher performance Low power consumption Slimmer and more compact Reduced design and development system Low cost

WHY PIC IS USED

SPEED HIGH PERFORMANCE RISC CPU INSTRUCTION SET SIMPLICITY INTEGRATION OF OPERATION FEATURES PROGRAMMABLE TIMER OPTIONS INTERRUPT CONTROL EPROM/OTP/ROM OPTIONS INBUILT MODULES LOW POWER CONSUMPTION WIDE OPERATING VOLTAGE RANGE:2.5 to 6.0 volt. PROGRAMMABLE CODE PROTECTION MODE POWER SAVING SLEEPMODE

MAIN AIM OF OUR PROJECT

The project SUPERVISORY CONTROL & DATA ACQUISITION SYSTEM, (SCADA) is based on embedded technology that uses MICROCHIPS micro controller PIC16F73 IC The project is concerned with the process of automating and monitoring a caustic soda production plant. The automation of plant is done in a two-stage process
1.

The first is concerned with level maintenance of two tanks and temperature controlling of the cell 2. The second stage deals with ratio controlling of Mercury and Brine solution..

REACTION PLANT
CAUSTIC SODA PRODUCTION Fig:

FEATURES

High accuracy of parameters displayed. LCD to display temperature and chemical level. Automatic controlling of chemical levels and temperature. Total process control to maintain normal operations. The system works on low voltage of 12 Volts. Highly reliable, cost effective and compact in size. Simple to install and easy to maintain.

COMPONENTS LIST

PIC (PERIPHERAL INTERFACE CONTROLLER) PIC16F73 THEMISTOR (TEMPERATURE SENSORE) FLOAT (FUAL SENSOR) LIQUID CRYSTAL DISPLAY- CYSTALONICS 16x1 REGULATOR IC [LM 7805] CRYSTAL OSCILLATOR-4MHz ZENER DIODE CAPACITORS - 10F - 1F - 22pF RESISTORS 10K DC SOURCE

BLOCK DIAGRAM

BLOCK DIAGRAM DESCRIPTION

Data acquistion unit

Transducer Signal

conditioning equipment

ADC

SENSORS
Fuel Level Sensor (Float) Temperature Sensor Thermistors

FUEL LEVEL SENSOR

Displacement transducer are used Converts sensed output to corresponding voltage Simple in construction and high resistance stability

TEMPERATURE SENSOR

Converts temp to corresponding variation in resistance

Temp sensor used here is THERMISTOR

THERMISTOR
1M

NTC thermistor

100K 10K PTC Thermistor 1K

PTC thermistor

100 10

NTC Thermistor

1 50 0 20 10 0 0 Temp in c 30 0 40 0

SIGNAL CONDITIONING EQUIPMENT

2 PARTS

1. Conditioning sensor output

2. Amplification

CONDITIONING SENSOR OUTPUT

The output from the sensors is analog in nature. There may be chances for noise and should be removed. In this part the output from sensor is filtered by coupling capacitor

AMPLIFICATION OF THE SIGNAL

The differential amplifier is the basic building block of operational amplifier. In the differential amplifier we can provide two input signals. Then at the output we will get the amplified form of the difference between the input signals. The figure of a differential amplifier is shown below

RF

R1

+Vcc _

V Vx

~
Vy

+ R2 -VE

ADC

The analog to digital (A/D) converter module has up to 8 analog inputs. The A/D allows conversion of an analog input signal to a corresponding 8 bit digital number.

The A/D module has 3 registers. These registers are: A/D Result register (ADRES) A/D Control register 0 (ADCONO) A/D control register1 (ADCON1)

LCD (Liquid Crystal Display)

LCD is a module used for monitoring various functions of the system. It consists of LCD controller IC and LCD unit The LCD drivers are of two types, the common driver and the segment driver The PIC cannot directly interface the LCD driver. So the LCD controller is placed between the MCU and the LCD drivers to handle the interface between them. The LCD controller receives the display information from the MCU, converts it into the display timing signals and display data required for the LCD drivers

The BASIC PIN DIAGRAM of a basic 16x1 LCD is shown below:

PROCESS DIAGRAM

MODIFICATIONS

Can read five more datas without changing the same PIC By adding some more components like relays switches etc we can control the furl and temperature level The serial port communication can be achieved by configuring the USART and the display and control can be done through the PC

FUTURE EXPANSIONS

By using existing system we can only read or monitor only two data or values. But in future if we want more datas to be read we can do that without any change in the PIC or program used in existing system

ADVANTAGES

VERY LOW HARDWARE COMPLEXITY

EXTERNAL PERIPHERALS REDUCED

REDUCED COST
COMPATIBILITY

LIMITATIONS

we can read more number of datas we can only monitor the values and the controlling must be done manually. By adding some more components only we can automatically control the system. working or the expansions of the system depends on the programmer capability. That is if we want to make any extensions the programs must be changed for a particular level In this existing system we can read only 5 datas. For more datas to be read the IC must be changed. For this purpose we usually use ICs having 2 inbuilt ADCS like 877 ICSby using this type we can read more number of datas

CONCLUSION

This project will surely give an overall view of vast features of the PIC micro controller The evolution in the embedded intelligence is driven by these Micro controllers. We will find microcontrollers through out homes, offices, industries and automobiles. We have made a humble effort to implement the PIC Microcontroller based factory automation and monitoring system to an instrumentation field However the larger revolution happens beneath the surface- thye embedded information processin revolution, where the social significant and investment opportunities are perhaps much greater

RESULT

An embedded system was developed for monitoring the operations in a Caustic soda manufacturing factory based on the PIC microcontroller

BIBLIOGRAPHY

Design with PIC microcontrollers : John.B. peatman. The Illustrated Electronic Dictionary : Haward.M.Berlin. Op-amps and Linear Integrated circuits : Ramakant. A. Gayakward. Semiconductor Devices Physics and Technology S.M. sze Electronic Devices And circuits : Allan Mottershead Electronic Instramentation Rangan, Mani, Sharma www.microchip.com www.picbook.com www.electronicforyou.com Power electronics; Muhammad H.Rashid.

THANK YOU!!!!