9572992415

9572992415
INDUSTRIAL AUTOMATION
(ELECTRONICS ENGINEERING GROUP)
Theory No. of Period in One Session : 45 Credits
Subject Code No. of Periods Per Week Full Marks : 100
2021503 L T P/S ESE : 70 03
03 - - TA : 10
- - - CT : 20

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RATIONALE:

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In the present global scenario of manufacturing, industries are moving towards complete automation. Small and
medium scale industries are in the phase of switching to PLC and SCADA technology for’ the data acquisition
and control. Therefore, it is necessary for Electronics/instrumentation engineers to have knowledge of both PLC

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and SCAUA technology. This course attempts to provide basic knowledge of these technologies to develop
operational competency. Hence this course is foundation for the engineers who want to further specialize in the
Industrial automation field.

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Course Objectives:
The aim of this course is to help the student to attain the following industry identified objective through

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various teaching learning experiences:
a. Maintain Industrial Automation systems.

CONTENTS: THEORY
(9
es

Chapter Name of the Topic Hours

Unit I 11
ss

Industrial automation overview and data acquisition Architecture of

Industrial Automation Systems.
la

Measurement Systems Characteristics Data Acquisition Systems

Unit II Control Generation 14

lC

Introduction to Automatic Control P-I-D Control

Feedforward Control Ratio Control
ca

The branching operations based on conditions expression

Unit III 10
ni

Sequential control and PLC

Introduction to Sequence Control, PLC, RLL PLC
ch

Hardware Environment

Unit IV Industrial control application Hydraulic Control Systems Pneumatic Control 10

Te

Systems Energy Savings with Variable Speed Drives Introduction to CNC

Machines

TOTAL 45
References: 9572992415

S. No. Title of Book Author Publication

1. Industrial Instrumentation, Control and S. Mukhopadhyay,S. Sen Jaico Publishing House, 2013
Automation and A. K. Deb ISBN: 978-8184954098
2. Industrial Automation Balakrishnan FPH

3. Industrial Automation Rakesh Verma FPH

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4. Electric Motor Drives, Modelling, R. Krishnan Prentice Hall India, 2002
Analysis and Control ISBN: 978-0130910141

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Course Outcomes:

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The theory, practical experiences and relevant soft skills associated with this course are to be taught
and implemented, so that the student demonstrates the following industry-oriented COs associated
with the above-mentioned objective:

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CO 1: Identify different components of an automation system.
CO 2: Interface the given I/O crevice with appropriate PLC module.

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CO 3: Prepare a PLC ladder program for the given application.
CO 4: Select the suitable motor drives for the specified application.

(9
es
*******
ss
la
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ca
ni
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 9572992415

6TH Sem. electronics

live course

New
Batch

24
20/02/

₹3499
6TH Sem. Electronics Live
Course ₹1849
Valid till 19 Feb. 2024

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Helpline Number - 93347 89450 | 91555 63777

9572992415
 9572992415

Industrial Automation
By Rajiv Sir

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WELCOME
•
(9
in
• TECHNICAL CLASSES
s

• for Overview Class of

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• INDUSTRIAL AUTOMATION
as

• ..........by RAJIV SIR

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UNIT 1
hn

Industrial Automation Overview

• 1. Industrial automation overview and data acquisition
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• 2. Architecture of Industrial Automation system

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• 3. Measurement system characteristics

• 4. Data acquisition system
• Industrial automation is the use of control systems and
sophisticated equipment in production environment.
• This includes robots, various sensors and computers
performing tasks that were previously done manually.
 9572992415

UNIT 2
Control Generation
• 1. Introduction to control PID control
• 2. Feed forward control ratio control
• 3.Branching operation based on conditions
expression.

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• PLC is a device that can be programmed and controls
other devices on off and logic.

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• PID is a technology for controlling the value of a
device.

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UNIT 3

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Sequential Control (9
• 1. Sequential control and PLC
• 2. Introduction to Sequence control, PLC, RLL
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• 3. PLC hardware environment.

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• Sequence means an arrangement of two or more

things in a successive order.
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UNIT 4
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Industrial Control Application

• 1. Hydraulic control system
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• 2. Pneumatic control system

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• 3. Energy saving with variable speed drives

• 4. Introduction to CNC machines.
Industrial control is one of the four major applications of
electronics. In industrial control electronic components,
circuits and equipment are used to operate various types of
machines in manufacturing plants.
 9572992415
UNIT 1
Industrial automation overview and data
acquisition
• Industry : An industry is a group of manufacturers
or business that produces a particular kind of
goods or services.
• Workers in the textile industry design, fabricate

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and sell cloth.
• Automation : The application of technology,

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programs, robotics or process to achieve
outcomes with minimal human input.

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UNIT 1
(9
• Industrial automation : Industrial automation is the use of
robotics, machines and control systems to perform tasks
which were traditionally carried out by human workers.
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• Robotics : It is a branch of engineering and computer

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science which involves the conception, design,

manufacturer and operation of robots.
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• The aim of the robotics field is to create intelligent

machines which can assist humans in a variety of ways.
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UNIT 1
hn

Purpose of Industrial Automation

• Purpose of industrial automation :
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• 1. Reduced cost : The introduction of technological innovations

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in industrial automation helps in reducing production cost.

• 2. High productivity : Because of industrial automation plants
and factories can run 24×7 with minimal downtime. This
reduce assembly time and improve productivity.
• 3. Greater safety : The minimisation of human errors leads to
reduction of accidents and injuries with the use of robots and
machines to handle tasks in dangerous and hazardous
conditions allows to avoid risks and long term health effects.
 9572992415

UNIT 1
• 4. Better quality and consistency : Elimination of
human error and greater consistency leads to better
quality of products.
• 5. Improved flexibility : Automation solutions make

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the industrial processes and machinery more flexible.
• 6. Real time monitoring and predictive maintenance :

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Industrial automation enables continuous monitoring

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of all the processes in real time mode.

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Types of Industrial Automation system
• General way to classify industrial automation systems is
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based on how they are applied :
• 1. Fixed or hard automation
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• 2. Programmable automation
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• 3. Flexible or soft automation

• 4. Integrated automation
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• 1. Fixed automation : These are typically designed to carry

out a single process, tasks. These can’t be easily adapted
for other applications
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Types of Industrial Automation system

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• Once a fixed automation solution is implemented, it would

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be challenging to modify the way it handle the processes.

This is why fixed industrial automation systems are used in
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mass production and continuous flow system to automate

repetitive non variation processes of all kinds. Some
examples of fixed automation solution are :
• i. Automated conveyor belts ii. Machining transfer lines
• Iii. Paint and coating stations iv. Material handling
conveyor systems.
 9572992415

Example of Fixed Automation

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Example of Fixed Automation
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Advantages and Disadvantages of Fixed

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Automation System
• Advantages : i. High production rate
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• ii. Low unit cost

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• Disadvantages : i. High initial investment

• ii. Obsolescence
• iii. Relative inflexible
 9572992415

Programmable Automation
• It can perform multiple functions.
• Programmable automaton is controllable via commands
delivered by means of entering computer code in the
systems.
• These are designed to be more adjustable fixed

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automation.
• These are widely used across the industries.

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• Today most commonly can be found in manufacturing

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operations focussed on producing goods in batches.

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Programmable Automation
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Advantages and Disadvantages

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Examples of programmable automation are :

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i. Industrial robots
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ii. PLC programmable logic controller

iii. CNC computer numerical controlled machine tools.
Advantages : i. Suitable for batch production
ii. Flexible and able to deal with design variations
Disadvantages : i. High investment in general purpose
equipment
ii. Lower production rate than fixed automation
 9572992415

Flexible or Soft Automation

• Flexible automation includes computer controlled
industrial automation systems and software solutions
designed to interconnect . It
adjusts control and measure the sequence of

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operations of various machines and equipment as well
as human workers.

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Examples of Flexible automation
• Some examples of flexible automation are :
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• i. Movable painting, coating and welding stations.
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• ii. Robot arms can be programmed to assume

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multiple tasks
• iii. Configurable material handling systems.
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Flexible Automation
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 9572992415

Advantages and Disadvantages

Advantage : i. Continuous production of variable mixtures
of products
ii. Offers medium production rate
iii. Flexible to deal with product design variations

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Disadvantage : i. High unit cost relative to fixed

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automation
ii. Requires a high amount of investment

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Integrated Automation
• Integrated automation describes what is viewed as the
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next step in the evolution of industrial automation systems
.
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• It includes solutions designed to centralise and automate

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the utilisation of tools and management.

• Some examples of integrated automation systems are : i.
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Manufacturing execution systems MES

• ii. Automatic storage systems
• iii. IT and software environment integration solutions
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Advantages and Disadvantages

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• Advantages :
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• i. Higher productivity
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• ii. Shorter time to market

• Iii. Greater security of investment
• iv. Reduced complexity
 9572992415

Examples of Industrial Automation

• Some examples of industrial automation solutions may be given as
follows :
• 1. Packaging machines
• 2. Industrial robots
• 3. Food and beverage processing machines

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• 4. Conveyor systems
• 5. Metal fabrication, machining, welding and cutting

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• 6. Paint and coating automation processes
• 7. Quality control and inspection
• 8. PLC of all kinds.

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Advantages of Industrial Automation
• 1. The tasks which are difficult for a human operator can
(9
be easily done. These tasks include lifting heavy and large
loads.
• 2. Human operators can avoid working in dangerous and
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hazardous conditions with extreme temperature,

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pollution, intoxicating elements or radio active substances.

These can be done by industrial automation.
• 3. Several quality control inspection can integrated into the
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production process to provide consistency and uniformity.

• 4. Production is always faster and product cost will be less.
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• 5. The economy of the industry can be improved.

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Disadvantages of Industrial Automation

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• 1. Loss of job
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• 2. The initial cost of implementing industrial

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automation is very high.

• 3. Skilled persons will always be required for
maintenance and servicing.
• 4. It is feasible to use automation for certain process
 9572992415

Sensors
• A sensor is a device which detects the change in
environment and responds to some output on the
other system.
• A sensor converts a physical phenomenon into a

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measurable analog or digital voltage converted into a
human readable display or transmitted for reading or

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further processing.

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Types of sensor
• There
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• 1. Temperature sensor
• 2. Humidity sensor
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• 3. Pressure sensor
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• 4. Accelerometer
• 5. Proximity sensor
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• 6. Level sensor
• 7. Gas sensor
• 8. Infrared sensor
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Types of Actuators
hn

• Two forms of motion can be created by actuators, so these are

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mainly of two types :

• 1. Linear actuators
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• 2. Rotary actuators
• 1. Linear actuators : These are devices which move in a straight
line. These are typically found in hydraulic and pneumatic
equipment. These can be of electrical or mechanical type.
• 2. Rotary actuators : These produce a rotary motion. Electric
fans, windshield wipers and manufacturing machinery use
rotary actuators.
 9572992415

Proximity sensor and IR sensor

• Some of the applications of proximity sensors are in mobile
phones, car parking sensor, industrial object ailment,
aircrafts.
Infra red sensors are light based sensors. In this, the
transmitter and the detector are positioned adjacent to each

7)
other facing the object. When an object comes in front of
the sensor, the IR light from the transmitter is reflected from
the object and is detected by the IR receiver and thus the

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sensor detects the object.
IR sensors are used in street light sensos.

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Proximity sensor
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 9572992415

Infrared sensor

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Gas sensor
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Ultrasonic sensor
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 9572992415

Ultrasonic sensor and Gas ( smoke ) sensor

• Ultrasonic sensor is used to measure distance as well
as velocity of an object.
• Gas sensor : Gas sensors are common in laboratories,
large scale kitchen and industries. They can detect

7)
different gases like LPG, propane , butane, methane
etc.

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Programmable Logic Controller
• A PLC is an industrial computer control system
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which continuously monitors the state of input
devices and make decisions to control the state
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of output devices.
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• PLCs are made up of input points, output points

and a CPU. Inputs accept a wide range of analog
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and digital signals from different sensors.

• These work to convert them into logic signals
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which are CPU compatible .

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Actuator
hn

• An actuator is a device which produces a motion by

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converting energy and signals going into the system.

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• The motion it produces can be either rotary or linear.

• Actuator is a part of a device or machine which helps
it to achieve physical movements by converting
energy, often electrical, air or hydraulic into
mechanical force
 9572992415

Programmable Logic Controller

• An input device is a piece of computer hardware equipment
used to provide data and control signals to an information
process system.
• PLCs have following advantages over relay based traditional
relay based control systems :
• i. Reliability

7)
• ii. Flexibility
• Iii. Ease of maintenance

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iv. Improved
v. Improved safely

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Disadvantages of PLC
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• Disadvantages of PLC :
• 1. Its programming can be complex occasionally.
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• 2. With the help of PLC , not all functions are easier to

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perform. It provides limited processing power.

• 3. The connectivity in PLC is not always smooth.
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Advantages of SCADA
hn

• 1. Increase life of equipment being used by through immediate

knowledge of system performance.
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• 2. Reduce labour costs required for troubleshooting or service.

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• 3. No requirement of large capital investment.

• 4. Many automation companies are using SCADA to provide
access to real time data display, alarming, reporting , trending
from remote equipment.
• 5. Continuous monitoring of process.
• 6. Real time period
• 7. Automation and protection.
 9572992415

Applications of SCADA
• 1. In electric power generation, transmission and distribution.
Electric utilities make use of SCADA systems to observe the
flow of current and line voltage, to control the operation of CBs
and to switch on or off different sections of the power grid.
• 2. Gas utilities: SCADA tools are required to monitor the flow of
gas through the circulation chain. It also maintain the

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supporting telecom infrastructure online.
• 3. Building facilities and environment for monitoring heating,

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ventilation and air conditioning system, cooling units with
refrigerators and lighting system.
• 4. Manufacturing etc

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SCADA
• Supervisory Control And Data Acquisition ( SCADA ) :
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• It is a type of software application program for process con.
• It is a central control system which consists of Controllers
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network interfaces, input output, communication equipments

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and software.
• SCADA systems are used to monitor and control the
equipments in the development and fabrication.
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• The SCADA system takes the reading of the meters and checks
the status of sensors in regular interval so that it requires
minimal human interference.
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SCADA
hn

• The infrastructural processes include gas and gas distribution, electrical

power, water distribution.
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• Public utilities include bus traffic system and airport etc.

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• The larger number of processes occur in large industrial establishment .

• The SCADA systems are used to gather the data from sensors and instruments
located at remote area.
• The computer then processes this data and presents in a timely manner.
• The SCADA system gathers the information and transfers the information back
to the system while giving me alerts that leakage has occurred and displays
the information in a logical and organised fashion.
 9572992415

Measurement Systems Characteristics

• The performance characteristics of electrical measuring instruments
may be divided into two parts : 1. Static characteristics
• 2. Dynamic characteristics
• 1. Static characteristics : Some applications involve the measurement
of quantities that are either constant or vary slowly with time.
• Under these circumstances, it is possible to define a set of criteria

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that gives a meaningful description of the quality of measurement
without interfering with dynamic descriptions that involve the use of

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differential equations. These criteria are called static characteristics.

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Dynamic characteristics
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• Dynamic characteristics of electrical measuring
instruments : Measurement systems having inputs
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dynamic in nature, the input varies from instant to
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instant, so does the output. The behaviour of the

system under such conditions is dealt with the
dynamic response of the system and its dynamic
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characteristics of electrical measuring instruments.

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Main static characteristics

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• 1. Accuracy : Accuracy of a measurement means

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conformity to truth.
• It is the closeness with which an instrument reading
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approaches the true value of the quantity being measured.

• 2. Stability : The ability of a measuring system to maintain
standard of performance over a long period of time.
3. Resolution : The resolution is defined as the smallest
incremental of the input quantity to which the measuring
system responds. This is one of the most important
characteristics of electrical measuring instruments.
 9572992415

• 4. Precision : The term precise means sharply defined.

• Suppose that we have an ammeter which possesses high
degree of precision by virtue of finely divided, distinct scale
and a knife edge pointer with mirror arrangement to remove
parallax.
• 5. Repeatability : It describes the closeness of output reading

7)
when the same input is applied repetitively over a short period
of time, with the same measurement conditions, same

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instrument and observer, same location and same conditions
of use maintained throughout.
• It is affected by internal noise and drift.

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• 6. Drift : It is a slow variation in the output of a
(9
transducer or measuring system which is not due to
any change in the input quantity. It is primarily due to
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changes in operating conditions of the components

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inside the measuring system.

• Transducer : It is an electronic device which converts
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energy from one form to another. Fr example ;

loudspeakers, microphone, position and pressure
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sensor s.
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• 7. Linearity : It defines the proportionality between input

quantity and output signal.
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• 8. Tolerance : It is the term which is closely related to accuracy

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and defines the maximum error which is to be expected in

some value.
• 9. Range or span : Span and range are the terms which gives
information about the lower and upper calibration points.
• Range of indicating instruments is normally from zero to full
scale value.
• Span is simply the difference between the full scale and lower
scale value.
 9572992415

Dynamic Characteristics of Electrical

Measuring Instruments
• 1. Dynamic error : It is the difference of true value of the quantity
changing with time the value indicated by the instrument provided
static error is zero.
• Total dynamic error is the phase difference between input and output
of the measurement system.
• 2. Bandwidth : It is the range of frequencies for which its dynamic

7)
sensitivity is satisfactory. For measuring system, the dynamic
sensitivity is required to be within 2% of its static sensitivity.
• 3. Reliability : It is the ability of the system to reproduce the output in

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the same form as the input. In this case any time lag or phase
difference is not included.

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• 4. Speed of response : It refers to its ability to respond
to sudden changes of amplitude of input signal.
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• 5. Settling time : It is the time required by the

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instrument to settle down to its final steady state

position after the application of the input.
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DATA ACQUISITION SYSTEM

hn

• A data acquisition system is a system that comparises

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sensors, measurement devices and a computer.

• This system is used for processing acquired data, which
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involves collecting the information required to understand

electrical or physical phenomenon.
• The microprocessor based personal computers are used to
implement direct digital control.
• For such PCs special PCBs are used, called as data
acquisition system in process control.
 9572992415

Data Acquisition System

• Acquisition means to acquire or collect
• DAS is an information system which collects , stores and
distributes informations.
• It is used in industrial, commercial, electronics,

7)
environmental and scientific equipments to capture
electrical signals of environmental conditions on a
computer device.

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• It includes different tools and technologies that are
designed to accumulate data.

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DAQ
• It consists of : (i) sensor (ii) signal conditioning
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• (iii) data conversion (iv) data processing
• (v) multiplexing (vi) data handling (vii) associated
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transmission storage (viii) display devices

• 1. Transducers or sensors : These are used to convert
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the physical quantities coming from the field into

electrical signals
• It is used to measure directly the electrical quantities.
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DAQ
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• 2. Signal conditioners : Output signals of transducers

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are using weak signals which cannot be used for

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further processing.
• To make the signals strong, various signal conditioners
are used, such as amplifiers, filters and modifiers.
 9572992415

DAQ
• 3. Multiplexer : It accepts multiple analog inputs and
provide a single output signal according to the
requirements.
• 4. Analog to digital converter: It converts analog data

7)
into digital data.
• It helps in easy processing, easy transmission, digital

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display and storage.

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DAQ
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5. Recording and display devices : Data is displayed in
suitable form in order to monitor the input signals.
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Examples are : oscilloscope, numerical displays etc.

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Data can be either permanently or temporarily stored

or recorder.
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BLOCK DIAGRAM of D.A.S

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 9572992415

Benefits of D.A.S
• 1. High efficiency : The information which is collected by
DAS is used for enhancing efficiency, ensuring reliability. It
also assures that the machinery is safely operating.
• 2. Accuracy : DAS maximize the accuracy of measurements.
• 3. Decrease in update errors : DAS allows the automation

7)
of data entry processes which were previously done
manually. Automation reduces mistakes by eliminating

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human error. It also provides additional time for staff to
perform other duties.

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(9
• 4. Flexibility : DAS makes it possible to build mixed
measurement systems which are made for specific
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needs.
• 5. Faster analysis : DAS displays measurements
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without delay.
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• 6. Improved access : DAS makes it possible for users

to access the database. It also recovers information
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for processing and analysis.

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• 7. Supervision of process without human interaction :

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With DAS, there can be tracking and monitoring of a

company’s various procedures in order to identify
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problems and resolve issues and resolve issues quickly.

• 8. Quality control : DAS are capable of confirming that
system is meeting the design specifications so that a
product meets the needs of the user. It also provides
testing capabilities to see whether a product has the
required quality before the production. It also provides a
means to analyse those products which are defective.
 9572992415

• 9. High versatility : DAS are available as multi purpose

devices. The have an all in one configuration with
multiple measuring modes.
• 10. Improved data security : Since data capturing

7)
process is automated and human factor is eliminated.
Therefore security risks which are associated with

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data storage, analysis and management are reduced.

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Architecture of Industrial Automation
• Architecture of Industrial automation provides a methodology
(9
and standardisation so that thousands of elements that make
up a plant or system can work together.
• It is based on IACS architecture reference model. The basic
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model consists of 5 levels. Those are :

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• 1. Level 0 Sensors and actuators

• 2. Level 1 Automation control
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• 3. Level 2 Supervisory control

• 4. Level 3 Production control
• 5. Level 4 Enterprise system
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Architecture of Industrial Automation

hn

• 1. Level 0 : It is in field, so it is also called field level.

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• This level is fastest one.

• This level consists of mainly sensors and actuators.
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• The first control system is the sensor system.

• The sensor converts physical parameters into electrical
forms of information.
• But in order to make the control action we need to convert
it back to physical form.
• To do this we use actuator system.
 9572992415

• Actuators apply decisions.

• 2. Level 1 : This level is known as automatic control layer.
• It consists of automatic control and monitoring system.
• It drives the actuators using process information given by

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sensors.

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• Controller is an industrial automatic control system of level
1 which provides direct and feedback connection between
levels 0 and 1.

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• 3. Level 2 Supervisory controls : It drives automatic
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control system by setting target point.
• This control usually takes on the following functions :
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• It performs monitoring . Checks sensors, actuators

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and process parameters.

• It sets control points for important process variables.
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• Reconfiguration or monitoring is performed in

response to operator commands.
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• 4. Level 3 Production control : It solves the decision

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problem such as targets, resource, allocation, task

allocation to machines, maintenance management.
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• It is generally offline. It is done by humans and computer

programs ( mixed ).
• 5. Level 4 Enterprise control layer : This deals mostly the
commercial activities like supply, demand, cash flow,
product marketing etc.
• It is generally offline. It is done by humans or managers at
top level.
 9572992415

UNIT 2
CONTROL GENERATION
• In an electric power system, automatic generation
control ( AGC ) is a system to adjust the power output
of multiple generators at different power plants, in
response to changes in the load.
• AGC : It is a generator control system that adjusts the

7)
real power output of generators in response to control
signals from the system operator’s energy

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management system ( EMS ) within a time frame that
is 2 to 5 seconds.

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CONTROL GENERATION
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• EMS : It monitors system frequency and send signals
to generators to adjust supply as needed to maintain
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the system frequency.
• Control signals are transmitted via telemetry to
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remote terminal units ( RTU ) at the generator.

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• Telemetry : It automatically collects, transmits and

measures data from remote sources using sensors and
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other devices to collect data.

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CONTROL GENERATION
hn

• RTU : It converts the lower MW into higher MW

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power and gives instructions to the generator which

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results in the generator output power.

• AGC is used to maintain acceptable frequencies due to
fluctuations in load.
 9572992415

Automatic Control Systems

• A control system can be described as a system that can
control the output quantity.
• Basically it is a set of devices which can manage, command
and regulate the operation of the other device or a system
that uses control loop.

7)
• The major components of a control system are actuators,
sensors, reference input and the system.

77
• Sensor : It will measure the system output
• Reference input : It will represent the required output.

63
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15
(9
s
se
as
Cl
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ic

ACS
hn

• Automatic control is a modern day science which is

c

very useful to make a system to perform its function

Te

accurately and effectively.

• Automatic control makes the system to work faster,
get high production rate, increase accuracy, reduce
tolerance limits. It also reduces the labour
requirement.
• ACS is also called self activated system
 9572992415

Types of Automatic Control System

• It is divided into two parts :
• 1. Open loop system 2. Closed loop system
• 1. Open loop system : In this ACS , input power and output power are
independent of each other, then the control system is known as open
loop system. Most of the measuring instruments and equipment are
based on the open loop system mechanism.

7)
• 2. Closed loop system : When the output of the system is connected
with the input such that output is compared with the input which

77
makes the output dependable to the input of the system. Then this
type of control system is called closed loop system. A feedback system
is incorporated which measures the output continuously and provide
the signal back to the input system.

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15
Technical terms related with ACS
• Response : As the command is given, the result acquired as
(9
per the command, is called response.
• Process control : In the system, there are some variable at
s

which whole system works are controlled automatically,

se

this is called process control. For example variables like

temperature and pressure can be changed as per the
requirement.
as

• Feedback : This is the output value of the system which is

compared with the input given to the system.
Cl
al
ic

Technical terms
hn

• Regulator : When there is a need of keeping the value of

c

variables at a at a constant value, there is a device named

regulator.
Te

• Error detector : This is a device which uses differential

method to detect any error in the system. It compares the
output value with the actual desired value of the system.
• Lag in response : When there is a delay to obtain the
response from the command due to some causes, is
delayed, is called lag in response. This delay causes the
difficulty in the measurement of the input and output at
same time.
 9572992415

Transfer Function
• It is a method or expression to show the relation
between input and output function.
• It is defined as the ratio of output function to input
function.

7)
• Transfer function = Output of the control system/

77
Input of the control system.
• = Ro / Ri

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15
Functions of Control System
(9
Requirements of a control system :
1. The control system should be accurate.
s

2. It must be stable.
se

3. It must be sensitive.
4. It should not be sensitive to external noise.
as

5. It must be sensitive to the input commands.

Cl

6. It must operate very quickly.

al
ic

Functions
hn

• Purpose of an automatic control system :

c

• 1. Productivity can be increased.

Te

• 2. Quality can be increased.

• 3. Comfortable operation
• 4. Input can be controlled.
• 5. Remote control can be done.
 9572992415

Advantages and disadvantages of Open loop

control system
• Advantages : 1. Its construction is simple.
• 2. It is economical
• 3. It is easier to maintain.
• 4. It is stable

7)
• Disadvantages : 1. It is not accurate.
• 2. It is not reliable.

77
• 3. Any change in the output cannot be corrected
automatically.

63
55
Advantages and disadvantages of closed loop

15
system
• Advantages : 1. It is accurate.
(9
• 2. Its stability is increased by decreasing the sensitivity.
• 3. It is not affected by noise.
s

• 4. It has high bandwidth range.

se

• Disadvantages : 1. It is costlier.
• 2. It is less stable.
as

• 3. Its design is complicated.

• 4. It needs more maintenance.
• 5. Due to feedback, its gain is reduced.
Cl
al
ic

Advantages and Disadvantages of Closed loop

hn

system
1. It is accurate. 2. It is not affected by noise.
c

3. It has bandwidth range 4. By decreasing sensitivity, its

Te

stability is increased.
Disadvantages : 1. It is costlier. 2. It is less stable.
3. Due to feedback, its gain is reduced.
4. Its design is complicated.
5. It requires more maintenance.
 9572992415

Feedback and Feed forward systems

•Feedback system : The feedback control takes the system output to the
controller . The controller will compare this output with the required
value.
•Feed forward system : The feed forward control will detect the

7)
disturbances directly. It will take proper action to remove the effect of
this disturbance from the output.

77
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Advantages and Disadvantages of feedback
control
15
(9
Advantages : 1. It measures the controlled variable.
2. It will take proper action being unaffected by the
s

disturbance source.
se

3. It will decrease the sensitivity of the controlled variable.

Disadvantages : 1. Corrective action will take place after
as

the disturbance.
2. Its response is not stable.
Cl
al
ic

Advantages and Disadvantages of a Feed forward

hn

control
• Advantages :
c

1. Variable disturbance
Te

2. Before any change in the process, it would correct the

disturbance.
• Disadvantages :
1. There will not be any corrective action for the unmeasured
disturbances
2. It is not really sensitive so it cannot measure the
disturbance.
 9572992415

Advantages of Automatic Control System

1. It reduces the consumption of energy.
2. No human error is expected.
3. It is profitable.

7)
4. Smooth plant operation

77
5. Equipment will be protected.

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15
Applications of Automatic Control System (9
1. In refrigeration
2. In air conditioning
s

3. In automobile
se

4. In transportation
as

5. In industries
Cl
al
ic
hn

P.I.D CONTROLLER
• PID stands for proportional integral derivative .
c

• PID controller is a device used to control different process variables like

Te

temperature, pressure, speed, flow in industrial applications. Approximately 95 %

of the closed loop operations of the industrial automation sector uses PID
controllers.
• In PID controller, a control loop feedback device is used to regulate all the
process variables.
• Before microprocessors were invented, PID controller was implemented by the
analog electronic components. But today all PID controllers are processed by
microprocessors.
• PLCs also have inbuilt PID controllers.
 9572992415

P CONTROLLER
•P control is a type of feedback control in which the desired control, also
known as the set point, is compared with the actual output.
•In P control system the actuating signal is proportional to the error
signal. The error signal being difference between the input signal and
the feedback signal delivered from the output of the system.

7)
77
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Proportional Controller (9
Controllers are the devices that are used to control the steady
state error or transient response of the system.
Proportional Controller is a device that produces output signal
s

which is proportional to the input signal.

se

It improves steady state error.

It also improves the stability of the system.
as

It decreases sensitivity with the parameter variations.

Its disadvantage is that it produces constant steady state error.
Cl
al
ic
hn

Proportional Controller
c
Te
 9572992415

Stability analysis of control system

When we talk about the steady state error and
transient response, stability analysis of control system
is very important.
A control system is said to be stable, if its output is

7)
under control, otherwise unstable.

77
If the output of the system is bounded for bounded
input, the control system is stable.

63
55
Integral Controller

15
(9
s
se
as
Cl
al
ic

Integral Controller
hn
c
Te
 9572992415

Derivative Controller
• In derivative controller , the actuating signal is proportional to
the derivative of the error signal.
• Its main advantage is that stability is increased by using D
controller .
• Therefore it is reliable to use.

7)
• But the steady state error is increased which is its main
disadvantage.

77
63
55
PI Controller

15
• In PI controller the actuating signal is proportional to the error
(9
signal added with the integral of the error signal.
• It is used to decrease steady state error without affecting
s

stability of the system.

se

• The transient response is good in case of PI controller.

as
Cl
al
ic

PD Controller
hn

• In PD controller the actuating signal is proportional to the error

signal added with the derivative of the error signal.
c

• It is used to improve stability by controlling steady state error.

Te
 9572992415

P I D Controller

• PID controller produces an output which is the combination of

the outputs of PC, IC and DC.
• P controller is used to improve rise time.
• I controller is used to reduce sse.
• D controller is used to reduce overshoot.

7)
• In case of D controller we are having steady state problem.

77
• In case of I controller we are having stability problem.

63
55
PID Controller

15
• These two errors are overcome by the use of PID controller.
(9
• It is used in process control and automation of industries.
s
se
as
Cl
al
ic

Process Control System Configuration

hn

• There are there types of process control system configuration:

c

1. Feedback control configuration

Te

2. Feedforward control configuration

3. Ratio control configuration
 9572992415

Feedback control configuration

• In this configuration output is continuously compared with

input.
• Advantages : 1. No requirement of identification and
measurement of any disturbance.
• 2. Insensitive to modelling errors.

7)
• 3. Insensitive to parameter changes.

77
63
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15
(9
s
se
as
Cl
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Feedback Control System

hn

Disadvantage
1. It waits until the effect of the disturbances has been felt by
the system before control action is taken.
c

2. Not recommended for slow processes.

Te

3. May create instability in the closed loop response.

 9572992415

Feedforward Control Configuration.

1. Load is measured directly.

2. Control action is taken before reaching the process.
Advantage : Acts before the effect of a disturbance has been
felt by the system. 2. Good for slow
systems. 3. Doesn’t introduce instability

7)
in the closed loop.

77
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15
(9
s
se
as
Cl
al
ic
hn

Feedforward Control Configuration

• Disadvantages : 1. Requires identification of all possible
disturbances before direct measurements.
c

• 2. Sensitive to process parameter variation.

Te

• 3. Requires good knowledge of the process model.

 9572992415

Ratio Control Configuration

• Maintains a relationship between two variables.

• Control the third variable.
• Application : Boiler
• Case 1 : Sufficient air is not there .

7)
• Case 2 : If sufficient heat is not there.

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Branching Operations based on condition

15
expression
• Control Statement :
(9
• The statement which can be controlled, is said to be control
statement.
s

• Control may be done by two methods: 1. Branching

se

• 2. Looping
1. Branching : What action will be taken. It uses three
as

statements. a. If statement b. If else statement c. Ladder or

nested if else statement
Cl
al
ic

Control Statement
hn

• 2. Looping control statement : How many times action will be

taken.
c

• It uses two types control statement :

Te

a. Entry control loop

b. Exit loop control
• Entry control loop : It starts from entry level.
• Exit control loop : It starts at last step.
• Entry control loop : i. For loop ii. While loop
• Exit loop : Do while loop
 9572992415

UNIT 3
Sequence Control
• The sequence determines the order in which the cable wires will
be connected to the modular sockets and plugs. Wiring
manufacturers use colours to label the sequence.
• In washing machine, the first event in the wash cycle is to fill the
tub with water. The next tasks wash, spin and drain each are

7)
done for a fixed period of time.

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Advantages

15
• Thus the sequence control refers of making the device to
(9
operate in accordance with predetermined rules and conditions.
• Advantages of sequence control : 1. Cutting
s

• 2. Bottling liquids
se

• 3. Retooling
• 4. Monitoring
as

• 5. Part change
• 6. Sorting
Cl
al
ic

Basic Sequence Control

hn

• Basic sequence control is the assembly of the following controls.

These are :
c

1. Sequence control
Te

2. Condition control
3. Time control
• 1. Sequence control : It controls the device in a pre determined
order. Car wash is an example of sequence control.
 9572992415

Basic sequence control

• 2. Condition control : It is based on controlling the equipment

based on pre determined conditions based on conditions,
because the conditions are determined so that the machine
works when it is necessary.
• 3. Time control : It is a type of control in which commands are

7)
sent to the controlled machine based on the time. It requires a
time relay or a numerical counter.

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55
Architecture of Programmable Logic

15
Controller
• Programmable Logic Controller consists of following main parts :
(9
1. Power supply
• 2. Central Processing Unit
s

• 3. Input module s
se

• 4. Output modules
• 5. Programming device
as
Cl
al
ic

Block diagram
hn
c
Te
 9572992415

Architecture of PLC

1. Power supply : It generally works on a power supply of about

24 V, 110 V ac or 220 V ac used to power input and output
devices.
• This module supplies power to the CPU, input and output
modules.

7)
• It can be built into the PLC or be an external unit

77
63
55
Architecture of PLC

15
• 2. CPU is considered as the brain of the PLC system.
(9
• It contains an special program that tells the PLC how to :
• Execute the control instructions.
s

• Communicate with other devices.

se

• User’s program
• Other programming devices, input and output devices.
as

• This program is stored in non volatile memory.

Cl
al
ic

Architecture of PLC
hn

• 3. Input modules : The input module connects the input

terminals to the rest of the system. Each terminal is usually
c

electrically isolated by the opto isolators. This is a way of passing

Te

on the status of the input by use of a LED and phototransistor.

 9572992415

Architecture of PLC

• The input module has several functions including :

• Detects when a signal is received from the sensor.
• Convert the input signal into a voltage level that can be received
by the processor.
• Sending a signal to the PLC input indicator so that it can know

7)
when input is receiving the signal.

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55
Architecture of PLC

15
• 4. Output module : Output to actuators allow a PLC to cause
(9
something to happen in a process. A list of popular actuators is
given below :
s

• Lights : Logical outputs can be powered directly from PLC output

se

boards.
• Solenoid valves : Logical outputs that can switch a hydraulic or
pneumatic flow.
as

• Motor starters : These are also large relays.

Cl
al
ic

Architecture of PLC
hn

• The output module has several functions including : The output

unit in the PLC also functions as an interface to external
c

equipment.
Te

• The PLC output acts as a switch to the power supply to operate

the output equipment.
• Components commonly used by PLC as output units are relays.
 9572992415

Architecture of PLC

• 5. Programming device : This is the platform where the program

or the control logic is written. It can be a handheld device or a
laptop or a computer.

7)
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55
Working of PLC

15
• PLC are used to control actuators, motors, valves, sequence
(9
machines and other devices in an industrial process.
• PLC operate by receiving input from sensors and then using that
s

information to control various processes.

se

• The input module receives input signals from switches, sensors

or other devices.
as
Cl
al
ic
hn

• Output module sends control signals to actuators.

c

• The processor executes them to control the process.

• PLC read all field input devices via the input interfaces, execute
Te

the user program stored in application memory, then based on

control scheme programmed by the user, turn the field output
device on or off or perform necessary control for the process
application.
 9572992415

• This process of sequentially reading the inputs, executing the

program in memory and updating the output is known as
scanning.
• While the PLC is running, the scanning process includes 4 phases
which are repeated continuously as individual cycle of operation.

7)
• Phase 1 : A PLC scan cycle begins with the CPU reading the
status of its inputs.

77
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15
• Phase 2 : The application program is executed using the status of
(9
the inputs.
• Phase 3 : Once the program is executed, CPU performs
s

diagnostics and communication tasks.

se

• Phase 4 : An output status scan is then performed. The stored

output values are sent to actuators and other field output
devices the cycle ends by updating the outputs.
as
Cl
al
ic
hn

• As soon as phase 4 is completed the entire cycle begins again

with phase 1 input scan.
c
Te
 9572992415

7)
77
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15
(9
s
se
as
Cl
al
ic

Programming in PLC
hn

• The basic function of PLC depends on control logic or

programming technique used. Programming can be done using :
c

i. Ladder logic ii. Flow chart iii. Statement logic iv.

Te

Mnemonics
• Writing a program in PLC :
• Compute the flow chart.
• A flow chart is the symbolic representation of the instructions.
 9572992415

• Flow chart is the simplest and most basic form of control logic.
• It only involves logic decisions.
• In this we use different symbols which are given below

7)
77
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15
(9
s
se
as
Cl
al
ic
hn

• Write the Boolean expression for the different logic.

c

• Boolean algebra involves logic gates like OR, AND, NOT etc. The
different symbols.
Te

• + : OR gate
• . : AND gate
• ! : NOT gate
 9572992415

• Instructions :
• If Input : 1
• AND Input : 2
• Then Set Out put 1

7)
• Else Set Output

77
63
55
• Ladder logic program : 15
(9
• It is the most important part of PLC programming.
• Rung : One step in the ladder is called a rung .
s

• In other words, the basic statement or one control logic is called

se

rung.
• Normal output signal : Y, Timer : T
as

• Counter : C, Motor symbol : M

Cl
al
ic
hn
c
Te
 9572992415

Basic Logic Functions using Ladder logic

7)
77
63
55
15
• Writing mnemonics : Mnemonics are instructions written in
(9
symbolic form. Different symbols used are given below :
• Load : Ld , AND : AND logic, OR : OR logic
s

• Load inverse : Ldi, ANI : NAND logic,

se

• OUT : Output, ORI : NOR logic

as
Cl
al
ic

Problem: Design a simple line follower

hn

robotic system to start a motor when a

• A switch is on and simultaneously switch on the LED. The sensor
on the motor detects any obstacle and another switch is on to
c

indicate the presence of the obstacle and the motor is

Te

simultaneously switched off and the buzzer is switched on and

LED is off.
 9572992415

• Let us first assign symbols to the inputs and outputs:

• A : Input switch 1 , B : Input switch 2
• M : motor, L : LED, Buz : Buzzer

7)
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63
55
Flow chart for the given problem

15
(9
s
se
as
Cl
al
ic

Relay Ladder Logic

hn

• It is the primary programming language for PLCs. Ladder logic

programming is s graphical representation of the program
c

designed to look like relay logic.

Te

• It is the most common programming language used to

communicate with PLCs developed to relay logic.
• It uses graphical representation of contacts, coils and special
interaction blocks.
 9572992415

• Relay logic : is a method of implementing combinational logic in

electrical control circuits by using several electrical relays wired
in particular configuration.
• The circuit consists of relays along with other components such
as switches, motors, timers, actuators, contactors etc.

7)
• It works efficiently to perform basic ON OFF operations by
opening or closing the relay contacts.

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55
Working of a Relay

15
• The schematic diagrams for relay logic circuits are called line
(9
diagram.
• It is an electrical network consisting of lines or rungs.
s

• Working of a relay : Relay acts as a switch which is operated by a

se

small amount of current. The relay has two contacts NO and NC.
as
Cl
al
ic

Limitations of ICS
hn

1. Many factors such as uncertainties, disturbances, process

dynamics and actuator saturation need consideration.
c

2. The result may be complicated by using computational tools

Te

for designing a control system.

3. Coming up error may be hazardous which may damage the
entire system.
 9572992415

• In the figure, there are two sides of a relay. One is primary coil
which acts as an electromagnet on passing current through itand
other one is secondary side having NO and NC contacts.
• When the contact position is normally open, the switch is open
and the circuit is open and no current flows through the circuit.

7)
When the contact position is NC, the switch is closed and the
circuit is completed and current flows through the circuit.

77
63
55
15
• This change of state in the contacts occur whenever a small
(9
electrical signal is applied. It means when a small amount of
current flows through the relay, the contact charges.
s
se
as
Cl
al
ic
hn
c
Te
 9572992415

• Previous figure shows the switch is in NO position. Here the

primary coil circuit is not completed and therefore no current
flows through the electromagnetic coil in the circuit. Hence the
connected bulb remains OFF as the relay contact is open.

7)
77
63
55
15
(9
s
se
as
Cl
al
ic
hn

• The above figure shows the switch in NC position. In this figure

the primary coil circuit is closed, so a current flows through the
c

coil connected in that circuit. Due to the current flowing in the

Te

electromagnetic coil, a magnetic field is created. Due to this

magnetic field, the relay is energized and contact is closed.
Consequently the connected bulb turns ON.
 9572992415

Example and working Relay Logic Circuit

• The figure shows a basic relay logic circuit.
• Rung1 contains one PB initially OFF and one control relay.
• Rung 2 contains one PB initially ON and one pilot lamp.
• Rung 3 : Contains one NO and one pilot lamp.

7)
• Rung 4 : Contains one NC and one pilot lamp
• Rung 5 : Contains one NO contact, one pilot lamp and a subrung

77
with one NC contact.

63
55
Relay Logic Circuit

15
(9
s
se
as
Cl
al
ic

Realisation of LOGiC GATES using Relay

hn

Logic Circuit
c
Te
 9572992415

AND gate

7)
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63
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NOT gate

15
(9
s
se
as
Cl
al
ic

NAND gate
hn
c
Te
 9572992415

NOR gate

7)
77
63
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NOR gate

15
(9
s
se
as
Cl
al
ic

PLC Hardware Environment

hn

• A PLC consists of following components: CPU, Input module,

output module, memory and power supply.
c

• The programming terminal in the diagram is not a part of the

Te

PLC, but it is essential to have a terminal for programming or

monitoring a PLC. The arrows between blocks indicate the
information and power flowing directions.
 9572992415

PLC hardware equipment

7)
77
63
55
PLC hardware

15
• PLC hardware can be classified into two types :
(9
1. Open architecture
2. Close architectur Most of the PLC
s

controllers are proprietary. It means procurement of

se

hardware should be very compatible with each other.

For example, Siemens make PLC CPU hardware should
compatible with only Siemens IO module.
as
Cl
al
ic
hn

• If the controller is open type architecture means , we may mix or

use different vendors structure.
c

• CPU : The function of CPU is to execute the logic downloaded

Te

into it.
• PLCs also monitor and check the software status, hardware
modules healthiness status and process plant status. It also
updates these data to the users.
 9572992415

Input Output modules

• IO modules are common to all PLC types which are used to make
communication between CPU and field devices.
• To run a motor using switches with the help of relays, we need
to do wiring directly between the switches and motor using the
required relays. In PLC we are not going to make a direct

7)
connection between switches and motor.

77
63
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15
• Power supply : The power supply of PLC depend on the type of
(9
PLC model.
• Programming terminal : A plc requires a programming terminal
s

and programming software for operation.

se

• It may also download a ladder logic program.

• Memory : It is the componentthat stores information and
as

programs of data in a PLC .

Cl
al
ic

UNIT 4
hn

Industrial Control Application

• Industrial System : An industrial system consists of : 1. Inputs 2.
Processes 3. Outputs
c

1. Input : The inputs are the raw materials, labour and cost of
Te

land, transport, power etc.

2. Processes : The processes include a wide range of activities
that convert raw material into finished products
3. Output : The outputs are the end product and the income
earned from it.
 9572992415

Industrial Control Application

• Industrial Control System is a collective term used to describe

different types of control systems, associated instrumentation
and controls used to operate industrial processes.
• There are several types of ICS in which SCADA ( supervisory
control and data acquisition ) and DCS ( distributed control

7)
system ) and PLC are most common.

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Benefits of ICS

15
1. Improved efficiency
(9
2. Reduced costs
3. Reduced errors and waste
s

4. Higher product quality

se

5. More efficient data management

as
Cl
al
ic

Purpose of ICS
hn

• It manages, commands, directs and regulates the behaviour of

other devices or systems using control loops.
c

• It can range from a single home heating controller using a

Te

thermostat controlling a domestic boiler to large ICS which are

used for controlling machines
 9572992415

Hydraulic Control System

• HCS include any controls that use fluid based operation rather
than electronic power.
• When control units within these systems are shifted, the internal
fluid moves throughout the machine inner workings. As it
moves, this non compressible fluid transfers force throughout

7)
the system to shift gears or influence motion.
• Hydraulic control system rely on Pascal’s law.

77
63
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15
• It states that liquid pressure will remain equally distributed
(9
within a sealed system. Many modern machines rely on either
hydraulic controls or a hybrid electric hydraulic system.
s

• The controlled movement of parts or a controlled application of

se

force is a common requirement in the industries. These

operations are performed mainly by using electric machines as
diesel, petrol and steam engines as prime mover.
as
Cl
al
ic
hn

• These prime movers can provide various movements to the

objects by using some mechanical attachment like screw jack,
c

lever etc. The enclosed fluids can also be used as prime movers
Te

to provide controlled motion and force to the objects.

• This system consists of a number of components. It mainly
consists of :
 9572992415

1. Fluid tank
2. Filter
3. Hydraulic pump
4. Pressure regulator

7)
5. Control valve
6. Electric pump

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Hydraulic Control System

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• Fluid tank is used to hold the hydraulic liquid, usually hydraulic

oil.
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• Filters are used to remove any foreign particles so as to keep the

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fluid system clean and efficient, as well as avoid damage to the

actuator and valves.
• Hydraulic pump is used to force the fluid from the reservoir to
rest of the hydraulic circuit by converting mechanical energy into
hydraulic energy.
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• Pressure regulator regulates or maintains the required level of

pressure in the hydraulic fluid and redirect the excess fluid back
to the storage tank.
• Control valve is used to control the direction, pressure and flow
rate of a fluid flowing through the circuit.

7)
• Hydraulic actuator is a device used to convert the fluid power
into mechanical power to do useful work.

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• Motor is required to drive the the pump. 15
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• Piping system carries the hydraulic oil from one place to another.
• Fluid used is generally high density incomprehensible oil.
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Components of Pneumatic System

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1. Compressor : Compressed air is generated by using air

compressor.
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2. Motor : It transforms electrical energy into mechanical

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energy. It is used to drive the compressor.

3. Filters : These are used to filter out the foreign particles or
contaminants from the air.
4. Reservoir or air tank : The compresed air coming from the
compressor is stored in it.
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• 5. Air cooler : During compression, air temperature increases.

Therefore coolers are used to reduce the temperature of the
compressed air.
• 6. Filter regulator Lubricator : Before the air can be used, it
needs to be cleaned and lubricated properly. These are done by

7)
FRL.
• 7. Air actuator : Cylinders and motors are used to obtain the

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required movements of mechanical

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• Elements of pneumatic system. 15
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• 8. Control Valves : These are used to regulate, control and
monitor for control of direction of flow, flow rate and pressure.
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Comparison between Hydraulic and

Pneumatic Control System
• Both hydraulic and pneumatic control system use pressure but
another medium to perform their operations. Both are economic
and safe.
• HCS and PCS work as an actuator using a pump which are

7)
controlled by valves used to convert pressure into mechanical
motion.
• The type of medium used in a HCS is incompressible.

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Comparison

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• PCSs are powered by air . Since air is the main medium, they
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operate cleaner than HCS. PCS can be proposed for tasks where
food is present or in antiseptic environments. They are easy to
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store and take up less room.
• PCSs have the capability of expelling air from their operation
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into the environment. PCS operate faster.

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Choice between HCS and PCS

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• When making the decision to use a HCS or PCS, it is better to

examine the advantages of each form.
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• Advantages of HCS : 1. Easy control

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• 2. Safe and easy to maintain

• 3. Liquid oil doesn’t absorb supplied energy
• 4. Responsive and supplies more power.
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Advantages

• Advantages of PCS : 1. Use air

• 2. Air is compressible
• 3. Simple in construction
• 4. Easy to handle

7)
• 5. Low maintenance
• 6. Explosion and fire proof

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• 7. Low cost
• 8. Ability to control pressure and force

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Comparison

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• The volume of it remains the same regardless of the amount of
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pressure applied. HCS tends to be large and complex. They need
room to store their reservoir of fluid, components of the system
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are large and bulky to create the necessary pressure. These
make HCS more expensive than PCS. HCS have the advantage of
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being able to takeon larger loads than PCS.

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• Disadvantages of HCS : 1. The structural weight and size of the

system is more which makes it unsuitable for the smaller
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instruments.
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• 2. The material of storage tank, cylinder, piping and piston may

be corroded with hydraulic fluid.
• 3. The hydraulic fluid, if not properly disposed, may be harmful
to the environment.
• 4. The small impurities in the hydraulic oil can
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• Permanently damage the complete system.

• 5. The leakage of hydraulic oil is also a critical issue .
• Suitable prevention method and seals must be adopted.
• Disadvantages of PCS : 1. These have low power handling

7)
ratings.
• 2. These are slower in performance.

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• 3. In sophisticated control these are inferior to electric control.

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Introduction to CNC machines

• CNC stands for computer numerical control.15

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• The machine which is operated with the help of computer is
called CNC machine.
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• The use of computers to control machine tools like lathe, mills,

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shapers etc. is called CNC machines. In CNC machining,

programs are designed first and then it is fed to the CNC
machine. According to the program, the CNC controls the
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rotation and speed of the machine tool.

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Parts of CNC machine

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1. Input devices : These are the devices which are used to input
the part program in the CNC machine. There are three
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commonly used input devices. These are punch tape reader,

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magnetic tape reader and computer via communication.

2. Machine Control Unit : It is the heart of the CNC machine. It
programs all the controlling action of the CNC machine.
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• 3. Machine tool : A CNC machine tool always has a slide table

and a spindle to control of the position and speed. The machine
table is controlled in X and Y axis direction and the spindle is
controlled in the Z axis direction.
• 4. Driving system : The driving system of CNC machine consists

7)
of amplifier circuits, drive motors and ball lead screw.

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• 5. Feedback system : This system consists of transducers that
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acts like sensors. It is also called as measuring system. It contains
position and speed transducers that continuously monitor the
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position and speed of the cutting tool located at any instant.
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7)
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Working of CNC machine

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• Programming is done in Input device according as the drawing or
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requirement. It is now sent to MCU.
• All data processing is done in MCU. Now motion data command
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is sent to Driving system.

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• Driving system controls the speed of Machine tool.

• Processing system records the position and speed of the
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machine tool. Now it sends signal to MCU through the feedback.

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• In MCU, the feedback signal is compared with previous one. If

there is error, it is tried to be removed. And if not removed it is
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again sent to machine tool.

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• And the process is repeated uptil the removal of error.

• For observing every command, program and other important
data, a Display unit is utilised.
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Classification of CNC machine

1. Based on application: i. Turning ii. Milling iii. Lathe iv.

Cutting v. Drilling vi. Special purpose CNC machine
i. CNC turning type : It is used to generate a cylindrical or
conical surface or work piece.
• In this type tool is fixed whether work piece is movable.

7)
• It works on two axis.

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• It utilizes single point cutting tool ( SPCT )
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• It can produce continuous and discontinuous chips.
• ii. Milling type : It is used to work on flat surface.
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• In this type tool is movable whereas work piece is fixed.

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• It works on more than two axes.

• It utilizes a multi point cutting tool ( MPCT ).
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• It produces only discontinuous chips.a

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• 2. Based on feedback system :

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i. Open loop
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ii. Closed loop

• 3. Based on control machine tools :
i. Hybrid controller CNC machine : Here hard wired logic
circuits are used.
ii. Stage controller CNC system : Powerful computer is used.
 9572992415

• 4. Based on machining centre :

i. Horizontal
ii. Vertical
iii. Universal

7)
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Different CNC machines

15
1.
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Lathe CNC machines : A lathe cuts pieces in a circular
direction. This process is done with indexed tools. They carry
all cuts out with precision and high velocity.
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• Lathe CNC machines are used to produce designs too complex

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for manually run machines. A two axis system is most common.

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• 2. CNC drilling machine : These use multi point drill bits to

create circular holes in the work piece. Usually drill bits are fed
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perpendicular to the work piece surface to create vertical holes.

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• 3. Plasma cutter : Most often plasma cutting CNC machines with

metal materials are used. A very high speed and heat are
necessary when making precision cuts in metal. For this
compressed air gas
 9572992415

• is combined with electrical arcs .

• 4. Wire electric discharge machine : These machines use
electrical sparks to mould pieces into specific shapes. Spark
erosion is used to remove positions from natural electronically
conductive materials.

7)
• 5. Water jet cutters : These machines are used to cut hard
materials with high pressurised water.

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• Water jet cutter CNC machines with granite and metal.
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• Advantages of CNC machines : i. Short production time ii. High
accuracy in manufacturing
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• iii. Simple fixturing

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• iv. Reduced human errors

• v. Greater manufacturing flexibility
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Applications of CNC machines

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1. In Robotics : In lathes and mills

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2. 3D printing
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3. At home CNC : It makes product development easier, faster

and cheaper.
 9572992415

Variable Speed Drive

• A VSD controls the speed and torque of an ac motor by

converting fixed frequency and voltage input to a variable
frequency and voltage output.
• System performance can be greatly improved by controlling
speed to precisely match the load.

7)
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V. S. D

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• A variable speed drive is a type of motor controller which drives
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an electric motor by varying the frequency and voltage supplied
to the electric motor.
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• It is also known as VFD, adjustable speed drive, adjustable

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frequency drive or an ac drive.

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7)
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Working of V S D

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• The VSD works on a simple principle. The rotational speed of an
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ac induction motor depends on the number of poles in the
stator and the frequency of the applied ac power.
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• The number of poles in an IM cannot be changed easily, variable
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speed can be achieved through a variation in frequency. The VSD

rectifies standard 50 hz ac power to dc, then convert the dc to a
variable frequency ac output.
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• Motors connected to VSD provide variable speed mechanical

output with high efficiency.
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• These devices are capable of up to a 9:1 speed reduction ratio

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and a 3:1 speed increase.

• In recent years, the technology of VSD has evolved into high
sophisticated digital microprocessor, along with high switching
frequency Insulated gate bipolar transistors IGBT power devices.
 9572992415

7)
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Energy Saving with V.S.D.

15
• VSDs provide effective speed control of ac motors by
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manipulating voltage and frequency. Controlling the speed of a
motor provides users with improved process control, reduced
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wear and tear on machine, increased pf and large energy savings
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• VSDs are not suitable for all applications. They can save energy
and reduce costs of industrial plant and commercial building
c

operations. Some of the methods are :

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1. By motor speed adjustment

2. By motor sizing
3. By sensor and feedback Loops : These can control several
motors together.
 9572992415

• 4. By using constant torque motors.

• 5.By motor replacement
• Advantages of VSD :
1. Controlled stopping

7)
2. Conservation of energy
3. Ability to control the starting current

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4. Reduced power usage on start up
5. Fewer power line issues

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• Disadvantages of VSD : 15
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1. High initial investment
2. Complex installation and maintenance
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3. Harmonic distortion
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4. Motor heating
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• Most applications can be grouped into following torque category

:
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• 1. Constant torque load applications such as conveyors often

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require a starting torque close to the rated torque of the motor.

• 2. Linear torque load applications such as screw compressors
have a more linear torque requirements that increases
proportionally with speed.
 9572992415

• 3. Variable torque load applications like fans and pumps have

torque requirement that increase in proportion to the square of
the speed and reach 100% torque just below rated speed.
• The most energy savings can be achieved by using a variable
torque load

7)
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Applications of VSD

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1. Crane and hoist machines
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2. Air conditioners
3. Thermal Power Station
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4. Oil industry
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5. Irrigation
6. Treadmill
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 9572992415

6TH Sem. electronics

live course

New
Batch

24
20/02/

₹3499
6TH Sem. Electronics Live
Course ₹1849
Valid till 19 Feb. 2024

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9572992415