Course Sub-enabling Outcomes Industrial Automation Systems

Course Sub-enabling Outcomes
• Write a ladder program and diagram and

Boolean languages
• Identify common operating modes of PLC’s
• Interface system components
• Compare sequential and combination control
processes
• Use programmable timers and counters
• Install and troubleshoot PLC’s
• Use CAD/CAM software
Industrial Automation Systems
Industrial Automation
• Industrial automation is the control of machinery and
processes used in various industries by autonomous
systems through the use of technologies like robotics and
computer software.
• Industrial production process consists of a series of simple
or complicated machines that, through the combination
of raw materials, undergo a sequential transformation
and integration in order to produce a final product.
• The term “machine” denotes every kind of
electromechanical device on the industrial floor, e.g.,
from a simple motor (such as a drilling or a cutting
machine) up to a complicated chemical machine (e.g., a
chemical combustion machine).
• The whole set of machines (namely non-homogeneous
machines), which are being integrated and combined
in an industrial production process, will be referred to
as an “integrated machine”.
• WHY! Industrial Automation
– To increase productivity
• Automation of factory or manufacturing or process plant improves
production rate through a better control of production. It helps to
produce mass production by drastically reducing assembly time per
product with a greater production quality.
– To provide optimum cost of operation
• Integration of various processes in industry with automated
machineries, minimizes cycle times and effort and hence the need of
human labor gets reduced. Thus the investment on employees has
been saved with automation.
– To improve product quality
• Since the automation reduces the human involvement, the possibility
of human errors also gets eliminated. Uniformity and product quality
with a greater conformity can be maintained with automation by
adaptively controlling and monitoring the industrial processes in all
stages right from inception of a product to an end product.
• WHY! Industrial Automation….
– To reduce routine checks
• Automation completely reduces the need for manual
checking of various process parameters. By taking advantage
of automation technologies, industrial processes
automatically adjusts process variables to set or desired
values using closed loop control techniques.
– To raise the level of safety
• Industrial automation increases the level of safety to
personnel by substituting them with automated machines in
hazardous working conditions. Traditionally, industrial robots
and robotic devices are implemented in such risky and
hazardous places.
• Disadvantages Of Industrial Automation
– Technology limits.
• Current technology is unable to automate all the desired
tasks.
– Security Threats/Vulnerability
• An automated system may have a limited level of intelligence,
and is therefore more susceptible to committing an error.
– Unpredictable development costs
• Research and development cost of automating a process may
exceed the cost saved by the automation itself
– High initial cost
• The automation of a new product or plant requires a huge
initial investment in comparison with the unit cost of the
product, although the cost of automation is spread among
many products.
Types of Industrial Automation Systems
 Fixed or Hard Automation
 This type of automation is employed to perform fixed and
repetitive operations in order to achieve high production rates.
 It uses special purpose or dedicated equipment to automate the
fixed sequence assembling or processing operations.
 Once it is employed, it is relatively hard to change or vary the
product design. Therefore, it is inflexible in providing product
variety, but increases the efficiency with higher production rate
and reduces unit cost.
 Some of these automated systems are distilled process, paint
shops, conveyors and Transfer lines.
 Programmable Automation
 In this Automation product, a specific class of product changes
assembling or processing operation can be changed with the
modification of control program in the automated equipment.
 This automation is best suited for batch production process
where product volume is medium to high.
 In this, it is hard to change and reconfigure the system for a new
product or sequence of operations requires a long setup.
 Example of this Automation system are numerically controlled
machines, paper mills, steel rolling mills, industrial robots etc.
 Flexible or Soft Automation
 This automation system provides the automatic control
equipment that offers a great flexibility for making changes in
the product design.
 These changes can be performed quickly through the
commands given in the form of codes by the human operators.
 This automation allows the manufacturers to produce multiple
products with different ranges as a combined combination
process rather than separate.
 Some of the examples of this automation system are automatic
guided vehicles, automobiles, and multipurpose CNC machines.
 Integrated Automation
 It denotes complete automation of a manufacturing plant, with all
processes functioning under computer control and under
coordination through digital information processing.
 It includes technologies such as computer-aided design and
manufacturing, computer-aided process planning, computer
numerical control machine tools, flexible machining systems,
automated storage and retrieval systems, automated material
handling systems such as robots and automated cranes and
conveyors, computerized scheduling and production control.
 It may also integrate a business system through a common database.
 In other words, it symbolizes full integration of process and
management operations using information and communication
technologies. Typical examples of such technologies are seen in
Advanced Process Automation Systems and Computer Integrated
Manufacturing (CIM)
• Industrial Automation Tools;-
– Supervisory Control and Data Acquisition (SCADA)
• Find new ways to operate faster
– Programmable Logic Controller (PLC)
• Multiple input and output arrangement
– Human Machine Interface (HMI)
• Control industrial automation equipment's
– Artificial Neural Network (ANN)
• Responsible in processing information
– Distributed Control System (DCS)
• Monitoring networks
– Robotics
• Industrial Automation Tools;-……..
– Supervisory Control and Data Acquisition (SCADA)
 This is a type of application that gets operating data about a system to
control and optimize a system. However, the application can be a
petrochemical distillation process, a water filtration system, a pipeline
compressor and so on.
– Programmable Logic Controller (PLC)
 Programmable Logic Controller (PLC) showcases a great impact on
automation.
 As the name indicates; it is a programmable logic controller. We can
control the devices and can easily switch from one process to other
process through it.
 It is possible because you can program it logically and thus it gets the
name programmable logic controller. You can program as well as you
can control using it. It is majorly designed for multiple input and
output arrangements and it can withstand extreme temperatures
with resistance to vibration and impact
– Human Machine Interface (HMI)
 The Human Machine Interface (HMI) includes the electronics
that are required to signal and control the state of industrial
automation equipment.
 However, these interface products can range from a basic
LED status indicator to a 2-inch TFT panel with touch-screen
interface.
 To use HMI, requirements include robustness, resistance to
water, dust, and moisture, a wide range of temperatures
and, in some environments. These interfaces must provide
Ingress Protection (IP) ratings up to IP65, IP67, and
IP68.Artificial Neural Network (ANN) Responsible in
processing information
– Distributed Control System (DCS)
 Distributed Control System (DCS) is one of the industrial
automation system favored by several processes in the
manufacturing industry.
 It contains one or more controller elements distributed in
the system.
 Broad categories of application of DCS includes electrical
power grids and generation plants; traffic signals, water
management systems; environmental control systems; oil
refining and chemical plants; pharmaceutical manufacturing;
bulk oil carrier ships; and sensor networks.
– Robotics
 Robotics have been used everywhere around us.
 Right from surgery robots to entertainment robots, they help
people to complete complex tasks.
 They have made our lives so much easier and improved its
quality. They can be used in performing various application
tasks such as allocating, painting welding, repairing and so
on.
 The role of industrial robotic systems play in the production
process is vital as their work range from assembly to internal
treatments to testing.
– Artificial Neural network(ANN)
Artificial Neural Network (ANN) tool is also known as
the neural network.
It is more like a mathematical model and is responsible
in processing information coming from biological
networks. Structures of ANN can be changed based on
both external and internal data fed into the learning
phase of the system. Applications of this automation
tool include financial applications and data mining.
• Boolean Languages/Algebra & Binary Logic
– Boolean algebra: Devised for dealing mathematically with
philosophical propositions which have ONLY TWO possible
values: TRUE or FALSE//ON or OFF.
SW1 Open >> Lamp is OFF

SW1 Closed >> Lamp is ON
• Boolean Languages/Algebra & Binary Logic….
– As we know, in classified Electronic systems…system can
either be:
Analog >> Continuous System
Digital >> Discrete System
– So, In Boolean algebra the TWO possible conditions of
discrete system can be represented by the binary
digits(BITS)- “0” and “1”.
Light ON = “1” = +5V = HIGH
Light OFF = “0” = 0V = LOW
– So If we define: Open = “0”, CLOSED = “1”
Then
– As we know, in classified Electronic systems…system can
either be:
Analog >> Continuous System
Digital >> Discrete System
– So, In Boolean algebra the TWO possible conditions of
discrete system can be represented by the binary
digits(BITS)- “0” and “1”.
Light ON = “1” = +5V = HIGH
Light OFF = “0” = 0V = LOW
– So If we define: Open = “0”, CLOSED = “1”
Then
– Boolean algebra deals with the rules which govern various
operations between the binary variables.
– AND operation
• Describes events which can occur IF and only IF two or more other
events are TRUE.
• Consider:
• The truth table is:
• Lamp will light ONLY when the switches A and B are CLOSED, i.e. A
and B both “1”
– AND operation……
• Boolean Equation
Notation: A.B = C
AB=C
• Symbol : AND gate
– OR operation
• Describes events which can occur IF at LEAST ONE of the other
events are TRUE.
• Consider:
• Switches Configuration are in parallel, lamp will light when A OR B

are closed, i.e. A or B = “1” or Both “1”
• Truth Table
– OR operation...
• Notation: C=A+B
• Symbol : OR gate
– NOT operation
• Changes a statement from TRUE to FALSE and vice–versa, i.e. inversion.
• Consider:
• The Truth table is:
• When A is CLOSED virtually NO CURRENT flows through L, so it is

effectively OFF.
– NOT operation…
• NOTATION: C = A
• SYMBOL: NOT gate
– NAND operation
• Situation where BOTH the inputs A and B have to be 0 for there to
be a 1 output. There is an output when input A and input B are not
1. The combination of these gates is termed a NAND gate.
• Truth Table……..????
• NOTATION: ……????
• SYMBOL: NAND gate……????
//The consequence of having the NOT gate is to invert the outputs of the
AND gate.
NOTE:
An alternative arrangement, which gives exactly the same results, is to
put a NOT gate on each input and then follow that with OR
– NOR operation
• Situation where there is an output when neither input A nor input
B is 1.
• SYMBOL: NOR gate……????
//The consequence of having the NOT gate is to invert the outputs of the
OR gate.
NOTE:
An alternative, which gives exactly the same results, is to put a NOT gate
on each input and then an AND gate for the resulting inverted inputs
– XOR operation
• Situation where if there is a need for a gate that gives an output
when either of the inputs is 1 but not when both are 1,Such a gate
is called an Exclusive OR or XOR gate
• SYMBOL: XOR gate……????
NOTE:
One way of obtaining such a gate is by using NOT, AND and OR gates
– BASIC LAWS OF BOOLEAN ALGEBRA
COMUTATIVE LAW:
A+B=B+A
A.B =B.A
ASSOCIATIVE LAW:
A + (B + C) = (A + B) + C
A(BC) = (AB)C
DISTRIBUTIVE LAW:
A(B + C) = AB + AC
– BASIC RULES OF BOOLEAN ALGEBRA
1. A + 0 = A
2. A + 1 = 1
3. A . 0 = 0
4. A . 1 = A
5. A + A = A
6. A + A = 1
7. A . A = A
8. A . A = 0
9. A = A
10. A + AB = A
11. A + AB = A + B
12. (A+B)(A+C) = A+BC
• Steps in designing a logic system
i. Define the problem
ii. Write the truth table
iii. Write the Boolean (or logic) equations
iv. Simplify equations to minimize the number of gates
v. Draw a logic diagram
vi. Implement the logic diagram using electronic circuitry
• Logic system design gates minimization techniques using
Boolean algebra laws.
– Example 1:
We have a car with 3 main control systems. we want a warning
lamp to light if any of the following conditions occur:
1. ALL SYSTEMS ARE DOWN
2. SYSTEMS A,B DOWN BUT C IS OK
3. SYSTEMS A,C DOWN BUT B IS OK
4. SYSTEM A DOWN BUT B,C ARE OK
Minimization Tech:
– There are two possible states for each system:
Assign:
system: down = “0”, ok = ”1”
light: off = “0”, on = “1”
Boolean algebra laws…..
– Example 1:….
Minimization Tech:……
ii. Truth Table
iii. logical Equation
iv. Simplify equations

– Example 1:….
v. Logic Diagram
Boolean algebra laws.
– Example 2:
– Given 4 systems : a, b, c and d a warning buzzer is to sound when the
following conditions occur.
1. a and b are down
2. a,c and d are down
3. b,c and d are down
4. b and d are down
Minimization Tech:
– There are two possible states for each system:
Assign:
system: down = “0”, ok = ”1”
light: off = “0”, on = “1”
– Example 1:….
ii. Truth Table
iii. logical Equation

– Example 1:….
iv. Simplify equations
– Example 2:….
v. Logic Diagram
• Ladder Diagram/Logic
– Ladder diagrams are specialized schematics commonly used to
document industrial control logic systems.
– They are called "ladder" diagrams because they resemble a ladder,
with two vertical rails (power rails/power supply) and as many
"rungs" (horizontal lines) as there are control circuits to represent.
– If we wanted to draw a simple ladder diagram showing a lamp that is
controlled by a hand switch, it would look like this:
– Primary programming language for PLCs.

– Other programming methods include:
• Function block diagrams (FBDs)
• Structured text (ST)
• Instruction List (IL)
• Sequential function charts (SFCs)
• Ladder Diagram/Logic……
– Ladder diagram are derived from relay logic diagrams.
– Contacts elements are arranged in rungs to provide control.
Note:
• In PLC Ladder Logic:No Real Power Flow (like in relay ladder)
• There must be continuous path through the contacts to energize the
output.
• Ladder Diagram
– Binary Input Devices
Device One/Zero Interpretation
• Limit switch Contact/no contact
• Photo detector Contact/no contact
• Pushbutton switch On/off
• Timer On/off
• Control relay Contact/no contact
• Circuit breaker Contact/no contact
• Ladder Diagram
– Binary Output Devices
Device One/Zero Interpretation
• Motor On/off
• Alarm buzzer On/off
• Lights On/off
• Control relay Contact/no contact
• Valves Closed/open
• Clutch Engaged/not engaged
• Solenoid Energised/not energised
• Anatomy of Ladder Diagram
 Input instructions are entered on the
left
 Output instructions are entered on
the right
 The power rails simulate the power
supply lines L1 and L2 for AC circuits
and +24V and ground for DC circuits
 Most PLCs allow more than one
output per rung
 The processor (or “controller”) scans
ladder rungs from top-to-bottom and
from left-to-right.
 The basic sequence is altered
whenever jump or subroutine
instructions are executed.
• The basic ladder logic contact symbols are:
– Normally open (NO):Passes power (on) if *** is on (closed).
– Normally closed (NC) contact: Passes power (on) if *** is off

(open).
The basic ladder logic coil (output) symbols are:
• The Operation Principle of Ladder Diagram
– Ladder Diagram is a type of graphic language for automatic
control systems it had been used for a long period since World
War II. Until today
– It is the oldest and most popular language for automatic control
systems. Originally there are only few basic elements available
such as A-contact (Normally ON), B contact (Normally OFF),
output Coil, Timers and Counters. Not until the appearance of
microprocessor based PLC, more elements for Ladder Diagram,
such as differential contact, retentive coil and other instructions
that a conventional system cannot provide, became available.
– The basic operation principle for both conventional and PLC
Ladder Diagram is the same.
– The main difference between the two systems is that the
appearance of the symbols for conventional Ladder Diagram are
more closer to the real devices, while for PLC system, symbols
are simplified for computer display.
• The Operation Principle of Ladder Diagram
– There are two types of logic system available for Ladder Diagram
logic, namely combination logic and sequential logic
Combination Logic
• Combination logic of the Ladder Diagram is a circuit that combines
one or more input elements in series or parallel and then send the
results to the output elements, such as Coils, Timers/Counters and ,
and other application instructions.

Combination Logic
Combination Logic
Combination Logic
• The above example illustrated the combination logic using the actual
wiring diagram, conventional Ladder Diagram, and PLC Ladder Diagram.
Circuit 1 uses a NO (Normally Open) switch that is also called "A" switch or
contact.
• Under normal condition (switch is not pressed), the switch contact is at
OFF state and the light is off. If the switch is pressed, the contact status
turns ON and the light is on. In contrast, circuit 2 uses a NC (Normally
Close) switch that is also called "B" switch or contact.
• Under normal condition, the switch contact is at ON state and the light is
on. If the switch is pressed, the contact status turns OFF and the light also
turns off.
• Circuit 3 contains more than one input element. Output Y2 light will turn
on under the condition when X2 is closed or X3 switches to ON, and X4
must switch ON too
Sequential Logic
• The sequential logic is a circuit with feedback control; that is, the output
of the circuit will be feedback as an input to the same circuit.
• The output result remains in the same state even if the input condition
changes to the original position. This process can be best explained by the
ON/OFF circuit of a latched motor driver
Sequential Logic
Sequential Logic
When we first connect this circuit to the power source, X6 switch is ON

but X5 switch is OFF, therefore the relay Y3 is OFF.
The relay output contacts 1and 2 are OFF because they belong to A
contact (ON when relay is ON). Motor does not run. If we press down the
switch X5, the relay turns ON as well as contacts 1and 2 are ON and the
Motor starts. Once the relay turns ON, if we release the X5 switch (turns
OFF), relay can retain its state with the feedback support from contact 1
and it is called Latch Circuit
Differences Between Conventional and PLC Ladder Diagram
 SCAN TIME
– Basic operation principle for both conventional and PLC Ladder Diagram are
the same, but in reality, PLC uses the CPU to emulate the conventional Ladder
Diagram operations; that is, PLC uses scanning method to monitor the statuses
of input elements and output coils, then uses the Ladder Diagram program to
emulate the results which are the same as the results produced by the
conventional Ladder Diagram logic operations.
– There is only one CPU, so the PLC has to sequentially examine and execute the
program from its first step to the last step, then returns to the first step again
and repeats the operation (cyclic execution).
– The duration of a single cycle of this operation is called the scan time.
– The scan time varies with the program size. If the scan time is too long, then
input and output delay will occur. Longer delay time may cause big problems
in controlling fast response systems. At this time, PLCs with short scan time are
required.
– Scan time is an important specification for PLCs. Due to the advance in
microcomputer nowadays the scan speed has been enhanced a great deal.
Illustration
Scanning process of a PLC Ladder Diagram
Differences Between Conventional and PLC Ladder Diagram…
 Reverse flow
• As shown below, if X0, X1, X4 and X6 are ON, and the remaining elements
are OFF.In a conventional Ladder Diagram circuit, a reverse flow route for
output Y0 can be defined by the dashed line and Y0 will be ON.
• While for PLC, Y0 is OFF because the PLC Ladder Diagram scans from left
to right, if X3 is off then CPU believes node “a” is OFF, although X4 and
node “b” are all ON, since the PLC scan reaches X3 first. In other words,
the PLC ladder can only allow left to right signal flow while conventional
ladder can flow bi-directional.
Ladder Diagram Structure and Terminology
Contact
 This an element with open or short status.
 One kind of contact is called "Input contact"(reference number prefix with X) and
its status reference from the external signals (the input signal comes from the
input terminal block/module).
 Another one is called "Relay contact" and its status reflects the status of relay
coil
 Example of contact are: A contact, B contact, up/down differential (TU/TD)
contacts and Open/Short contacts
Ladder Diagram Structure and Terminology……
 Relay
 It consists of a Coil and a Contact
 We must energize the coil of relay first (using OUT instruction) in order to turn
on the relay. After the coil is energized, its contact status will be ON too
 As shown in the diagram below, if Y0 turns ON, then the relay contact A is ON
and contact B is OFF, TU contact only turns ON for one scan duration and TD
contact is OFF.
 There are four types of PLC relays, namely :
 Y(output relay)
 M(internal relay)
 S(step relay)
 TR(temporary relay).
 The statuses of output relays will be sent to the output terminal block/module.
 Origin-line: The starting line at the left side of the Ladder Diagram.
 Element: Element is the basic unit of a Ladder Diagram. An element consists of two
parts. One is the element symbol which is called “OP Code” and another is the
reference number part which is called "Operand”.
Ladder Diagram Structure and Terminology……
 Node: The connection point between two or more elements
 Block:
 It is a circuit consists of two or more elements.
1. Serial block: Two or more elements are connected in series to form a single row
circuit
2. Parallel block: Parallel block is a type of a parallel closed circuit formed by
connecting elements or serial blocks in parallel.
 Branch: In any network, branch is obtained if the right side of a vertical line is
connected with two or more rows of circuits.
 Merge Branch/Line is defined as another vertical line at the right side of a branch
line that merges the branch circuits into a closed circuit (forming a parallel block).
This vertical line is called “Merge line”.

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Course Sub-enabling Outcomes

• Write a ladder program and diagram and

SW1 Open >> Lamp is OFF

• The truth table is:

• Switches Configuration are in parallel, lamp will light when A OR B

• The Truth table is:

• When A is CLOSED virtually NO CURRENT flows through L, so it is

iii. logical Equation

iv. Simplify equations

iii. logical Equation

– Primary programming language for PLCs.

– Normally closed (NC) contact: Passes power (on) if *** is off

and other application instructions.

When we first connect this circuit to the power source, X6 switch is ON

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