Industrial automation is the use of technology and control systems to operate, monitor, and optimize industrial processes, machinery, and equipment. It involves the use of various technologies, including programmable logic controllers (PLCs), sensors, and robotics, to automate repetitive and complex tasks, improve efficiency, and reduce costs.
The primary benefit of industrial automation is improved productivity. By automating repetitive tasks, machines can work faster and more accurately, leading to increased output and lower production costs. Automation can also lead to better quality control, reducing defects and waste. Industrial automation can also help businesses to save on labor costs, as machines can perform tasks that would otherwise require human labor.
Another significant benefit of industrial automation is increased safety. Automation can help to reduce the risk of injury to workers by performing hazardous tasks or operating in dangerous environments. It can also help to reduce the risk of human error, which can lead to accidents and injuries.
There are several types of industrial automation, including process automation, discrete automation, and hybrid automation. Process automation involves controlling the flow of materials and products through a manufacturing process. This type of automation is commonly used in chemical plants, food processing, and other industries where there is a continuous flow of materials.
Discrete automation involves controlling individual machines or components, such as robotic arms, conveyors, or assembly lines. This type of automation is commonly used in automotive manufacturing, electronics, and other industries where there is a need to perform specific tasks.
Hybrid automation involves combining process and discrete automation to optimize production. This type of automation is commonly used in industries such as aerospace, defense, and medical device manufacturing, where there is a need to balance the efficiency of the manufacturing process with the precision and accuracy required to produce complex products.
Industrial automation also offers several advantages beyond increased productivity, safety, and quality control. It can help to improve energy efficiency and reduce environmental impact by optimizing the use of resources such as water, electricity, and raw materials. Automation can also improve data collection and analysis, providing valuable insights into production processes that can help to identify areas for improvement and optimize performance.
In recent years, industrial automation has become increasingly accessible to smaller businesses, thanks to advancements in technology and the availability of off-the-shelf automation solutions. As a result, industrial automation is no longer just for large corporations with vast resources, but is becoming more widely adopted across a range of industries and business sizes.
3. Content
01 Introduction to Industrial Automation
02 SCADA (Supervisory Control And Data Acquisition )
03 Programmable Logic Controller (PLC)
04 Sensors and Transducer
Electric Drives
05
5. What is Industrial Automation?
Industrial automation is the use of
control systems, such as computers or
robots, and information technologies for
handling different processes and
machineries in an industry to replace a
human being. It is the second step beyond
mechanization in the scope of
industrialization.
6.
7.
8. In the industrial automation section, sensors play a very important
role to make the products intelligent and highly automatic.
Sensors
The main function of a signal conditioner is to pick up the signal
and convert it into a higher level of electrical signal. Signal
conversion is often used by industrial applications.
Signal Conditioning
Both pneumatics and hydraulics are applications of fluid power.
Pneumatics uses an easily compressible gas such as air or a
suitable pure gas—while hydraulics uses relatively
incompressible liquid media such as oil..
Hydraulic System
PLC's act as the physical interfaces between devices on the plant
or manufacturing floor and a SCADA or HMI system.
PLC
Electrical drives are major component in industrial applications,
driven technical developments and focus of various developments.
The core component of every electrical drive is the motor. .
Electrical Drives
Industrial
Automation
PLC
Elements of industrial Automation
9. $
Need
Prevent Products or Materials
from Being Damaged or
Destroyed
Increase Efficiency and Save
money
Collect better Data & Devise
the Right Process
Improvements
Reduce Worker Fatigue and
Effort or Labor Intensive
Operation
Why You Need To Invest In Industrial Automation?
X
11. What is SCADA?
• A SCADA system is a collection of both software and hardware components that
allow supervision and control of plants, both locally and remotely.
• Basically consists of data accessing featuring and controlling remotely.
• Conversion of data is possible i.e. Analog to Digital and vice-versa.
• Can communicate to any of the protocols available in market.
• Completely rely on windows based system.
• SCADA is not dedicated to any one type of application or industry.
13. While these systems simplify a given infrastructure, their components are quite
complex. There are five essential composing parts of a SCADA system:
•Human Machine Interface (HMI)
•supervisory system
•Remote Terminal Units (RTUs)
•Programmable Logic Controllers (PLCs)
•communication infrastructures
14. Components of SCADA System
Supervisory computers
This is the core of the SCADA system, gathering data on the process and sending
control commands to the field connected devices. It refers to the computer and
software responsible for communicating with the field connection controllers.
Remote terminal units (RTUS)
Remote terminal units, also known as (RTJS), connect to sensors and actuators in
the process, and are networked to the supervisory computer system.
Programmable logic controllers(PLCS)
These are connected to sensors and actuators in the process, and are networked
to the supervisory system and are programmed in one or more IEC 61131-3
programming languages.
15. Function of SCADA
A SCADA system performs four functions:
• Data acquisition
• Networked data communication
• Data presentation
• Control
16. Function of SCADA
1. Sensors (either digital or analog) and control relays that directly interface with the
managed system.
2. Remote telemetry units (RTUs). These are small computerized units deployed in
the field at specific sites and locations. RTUs serve as local collection points for
gathering reports from sensors and delivering commands to control relays.
3. SCADA master units. These are larger computer consoles that serve as the central
processor for the SCADA system. Master units provide a human interface to the system
and automatically regulate the managed system in response to sensor inputs.
4. The communications network that connects the SCADA master unit to the RTUs in
the field.
18. What is PLC?
• A Programmable Logic Controller (PLC), also referred to as programmable
controller, is the name given to a type of computer commonly used in commercial
and industrial control applications.
• The PLC receives information from connected sensors or input devices, processes
the data, and triggers outputs based on pre-programmed parameters.
• Depending on the inputs and outputs, a PLC can monitor and record run-time data
such as machine productivity or operating temperature, automatically start and stop
processes, generate alarms if a machine malfunctions, and more. Programmable
Logic Controllers are a flexible and robust control solution, adaptable to almost any
application.
19. A basic PLC system consists of the following sections:
Input/ Output Section
CPU or Central Processing Unit
Programming Device
Power Supply
Memory
20. Programming Languages
A program loaded into PLC systems in machine code, a sequence of binary code
numbers to represent the program instructions.
Assembly language based on the use of mnemonics can be used, and a computer
program called an assembler is used to translate the mnemonics into machine code.
High level Languages (C, BASIC, etc.) can be used.
Programming Devices
PLC can be reprogrammed through an appropriate programming device:
1. Programming Console
2.PC
3.Hand Programmer
Introduction to Ladder Logic
Ladder logic uses graphic symbols similar to relay schematic circuit diagrams.
Ladder diagram consists of two vertical lines representing the power rails. Circuits
are connected as horizontal lines between these two vertical
24. What is sensors?
• A sensor is a device that measures physical input from its
environment and converts it into data that can be
interpreted by either a human or a machine.
• A device that gives an output by detecting the changes in
quantities or events can be defined as a sensor.
25. Types of sensors used in Automation
• Temperature Sensors
• Pressure sensors
• MEMS Sensors
• Torque Sensors
• Light Sensors
• Ultrasonic Sensors
26. • A temperature sensor is an electronic device that measures the temperature
of its environment and converts the input data into electronic data to record,
monitor, or signal temperature changes.
Fig: RTD
• Resistance temperature detector sensor works on the
principle of resistance change by changing
temperature. Resistance is directly proportional to
temperature and has a wide range of temperature
measurements capabilities. These are more accurate
temperature sensor and have ranged between -270
C0 to 850 C0
Temperature Sensor
27. Application of Temperature sensor:
1. Manufacturing Industries
2. Automobile
3. Medical
4. Aerospace & Automotive
5. Household appliances
6. HVAC
Thermistor
28. Pressure Sensors
A pressure sensor is a device for pressure measurement of gases or liquids.
Application of Pressure Sensor:
• Measuring inlet, outlet or system pressure in engine test setup
• Measuring pressure drops in a line for preventive maintenance
• Measuring fluid height or level in tanks
• Measuring the pressure of slurry/slush using a flush
diaphragm pressure transducer
• Sanitary pressure transducers in the bio or pharmaceutical
industry.
29. Light Dependent Resistor (LDR) Sensors
• A Light Sensor generates an output signal indicating the intensity of light by
measuring the radiant energy that exists in a very narrow range of frequencies
basically called “light”,
• Light sensors are more commonly known as “Photoelectric
Devices” or “Photo Sensors” because the convert light energy
(photons) into electricity (electrons).
• Photoelectric devices can be grouped into two main categories, those which
generate electricity when illuminated, such as Photo-voltaics or Photo-
emissives etc, and those which change their electrical properties in some way
such as Photo-resistors or Photo-conductors.
30. Application of LDR Sensor
• Light-dependent resistors are simple and low-cost devices.
• These devices are used where there is a need to sense the
presence and absence of light is necessary.
• These resistors are used as light sensors and the applications
of LDR mainly include alarm clocks, street lights, light
intensity meters, burglar alarm circuits.
31. Role of sensor in Automation
1. Robot designs able to withstand the challenging conditions that exist
in many industrial applications.
2. High accuracy that provides the correct data and information to the
factory systems and analytics.
3. High-resolution capability that can detect the slightest changes in
any parameter being measured.
4. Long term stability where the sensors performance remains the same
over years of service. This eliminates the need for costly recalibration
cycles and periodic maintenance.
33. • An Electric Drive can be defined as, a system which is used to control the
movement of an electrical machine.
• An electric drive can be built with an electric drive motor as well as a
complicated control system to control the motor’s rotation shaft.
• At present, the controlling of this can be done simply using the software.
• Thus, the controlling turns into more accurate & this drive concept also
offers the ease of utilizing.
Electric Drives
35. AC Motors:
• AC motors do a lot of the heavy lifting in many industrial automation
applications.
• They convert AC electrical energy into mechanical
energy, which produces a mechanical rotary action that
does some form of work.
• AC motors are the most common types of motors used
in commercial and industrial applications.
• An induction motor is a type of AC motor where
power is supplied to a rotating shaft by means
of electromagnetic induction.
36. DC Motors:
• The Dc motor is widely used in the field of servo automation and robotics.
• The operating principle of an electric motor is based on
the interaction of two magnetic fields that attract and repel
each other.
• In a brushless motor, the current reversal is obtained
electronically, through a bank of power transistors (usually
IGBTs) controlled by a microcontroller.
.
• In a brushed motor, the mechanical contact of the brushes with the electrical
contacts on the rotor close the circuit between the power supply and the rotor
winding.
37. Stepper Motors:
A stepper motor, also known as step motor or stepping motor, is a brushless DC
electric motor that divides a full rotation into a number of equal steps.
Application of Stepper Motor in automation:
• Used in positioning systems.
• They are used in numeric control of machine tools.
• The Stepper Motor are in spacecrafts launched for
• scientific explorations of the planets etc.
• The stepper motor also use in X-Y plotter and robotics.
38. Servo Motors:
• A servo motor is a type of motor that can rotate with great precision. Normally
this type of motor consists of a control circuit that provides feedback on the
current position of the motor shaft, this feedback allows the servo motors to
rotate with great precision
• If you want to rotate an object at
some specific angles or distance,
then you use a servo motor.
39. Application of Servo Motors:
• The servo motor is used in robotics to activate movements, giving the arm to its
precise angle.
• The Servo motor is used to start, move and stop conveyor belts carrying the
product along with many stages. For instance, product labeling, bottling and
packaging.
.
• The Servo motor is used in Textiles to control spinning and weaving machines,
knitting machines and looms
• The Servo motor is used in automatic door openers to control the door in public
places like supermarkets, hospitals and theatres.
40. CONCLUSION
Automation is the use of machines, control systems and information technologies to optimize
productivity in the production of goods and delivery services.
The correct incentive for applying automation is to increase productivity, and/or quality
beyond that possible, with current human labor level so as to realize economies of scale,
and/or realia predictable quality even.
The incorrect application of automation, which occurs most often, is an effort to eliminate or
replace human labor.
As we all know that the branch instrumentation plays a very important role in the
management of automation in any industry or process plan. Each and every process requires
the need of certain specific instruments for their controlling.
When the word automation comes into play, instrumentation automatically involves in it.
Without the help of instrumentation it is not possible to apply automation in any industry.
