industrial automation sustem
TRANSCRIPT
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SIX MONTHS TRAINING REPORT ATIBMCE KVCH
ON(INDUSTRIAL AUTOMATION)
SUBMITTED BY
PARAS KUMAR
1407748
SUBMITTED TO
Mr. Satnam Singh Matharu
(HOD of EE Department)
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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.
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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.
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Industrial Automation
The use of Computerized or robotic devices to complete manufacturing tasks.
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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.
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MAIN PARTES OF AUTOMATION
AUTOMATION
SCADA
PLC
HMI
AUTOCADE
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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.
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Block diagram and their arrangement
Block diagram Simple Arrangement
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WONDERWARE - INTOCH
ALLEN BRADLEY - RSVIEW32
SEIMENS - WINCC
GE FANUC - CIMPLICITY
KPIT - ASTRA
SCADA SOFTWARES
and many more …..
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Features of SCADA system
Animation property.
Dynamics property.
Trends.
Alarms.
Security.
Scripts.
Communication with Excel.
Communication with PLCs.
Mimics (miscellaneous)
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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 )
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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 ….
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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.
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Application of Animation
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Dynamics properties
Their are three types of Dynamics properties
Location property
Percent fill property and
Object size property.
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Location property
In this property We change the location of any object either horizontally or
vertically both at a time.
Horizontally motion Vertically motion
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Application Location properties
Horizontal Application Vertical Application
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Object Size Property
To vary the size of any object either height or width or both at a time.
.
Width wise Height wise
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Percent filling property
This property is used to show the filling and infilling of tanks, pipes etc.
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Trends
Trend are used for graphical representation of any process.
Types of Trends
Real Time Trend
Historical Trends
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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.
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Historical Trend
It shows both present and
past change in value.
It updates manually.
It uses eight numbers of
pans/inputs at a time.
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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 ;
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Miscellaneous property
I. Visibility
II. Blink
III. Orientation and
IV. Disable
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“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.
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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.
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Simple working of PLC
Machine can be controlled by PLC without human efforts.
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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.
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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
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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
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Block diagram of a PLC
Outputs
LEDs
Inputs
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Programming of PLC
Ladder Logic Program for Start/Stop of Motor
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Starting of Motor
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Continuous Running of motor when Start Button is released
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To Stop The Motor
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PLC operation sequence
Self test.
Input scan
Logic solve/scan
Output scan
Over all steps depends up on the
clock frequency.
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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”.
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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
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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.
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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.
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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
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Project worked
PLC Based automatic water bottle filling system
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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.
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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
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Assembly of conveyor belt and Roller
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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
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Electrical circuit
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Working
Start
PLC
MOTOR SENSOR
PUMP/
SOLENOID BOTTLE
FILLING
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Conclusion
The automated bottle filling system
is beneficial in reducing:-
work,
time and
cost of filling.
Hence it must be used in application
specific.
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Thank You!!!