Introduction To Automation

INDUSTRIAL AUTOMATION
 AUTOMATION
► Its actually derived form two Greek word one is called AUTO which
means “self” and another word is called MATOS which means
“moving”. So together an Auto-Matos is an object or device which
moves by itself
► AUTOMATION – “Auto” (self) + “Matos” (moving)

Process

Technology Less human

assistance
Processed
Manual System

Disadvantages
• Resource Utilization
• Comfortability
• Equipments life span
Automated System

Disdvantages

• Cost
• Complexity
• Accuracy
Manual System
Disadvantages

• Time
• Human Assistance
• Efficiency
• Production rate
• Resource Utilization
• Documentation
• Reliability
• Safety
Automated System

“Automation can be
define as the allocating
of human control
sequence to a machine
or technical equipment
to get the desired
result”.
HISTORY OF EVULOTUION OF
AUTOMATION
Phase I : Manual System
Phase II : Relay Logic OR Hard Wired System OR
Electric Controlled System
Phase III: Electronic Controlled System
Phase IV: Advanced Controlled System
 Hard Wired Controlled System
► Controller : Relay Circuit, Transistor, Mechanical Switches, Timers, and
counters.

► Advantage : Achieved Automation up to some extent.

► Disadvantage:
⮚ Requires a lot of switchboard space.
⮚ Installation is very labor intensive.
⮚ Trouble shooting is extremely difficult.
⮚ Modifications to the control functionality are
complicated and seriously tedious.
Electromagnetic Relay
Electromagnetic relays are those relay which operates on the principle of
electromagnetic attraction. It is a type of a magnetic switch which uses the magnet for
creating a magnetic field. The magnetic field then uses for opening and closing the
switch and for performing the mechanical operation.
 Operation of Transistor

Before Injecting Base Current After Injecting Base Current

Relay Logic
Electronic Controlled System
► Controller : Microcontroller, Microprocessor, Power electronic
devices, electronic timers and counters.
► Advantage :
⮚ Reduced space requirements.
⮚ Faster operation.

► Disadvantage:
⮚ Low Reliability.
⮚ Not suitable for all type of environment .
⮚ Does not work properly at high temperature.
⮚ Heat Dissipation.
⮚ Skilled Labor
ELECTRONIC CONTROL SYSTEM
Microprocessor Vs Microcontroller
ADVANCE CONTROL SYSTEM
► PLC : Programmable Logic Controller
► SCADA : Supervisory Control And Data Acquisition System
► DCS : Distributed Control System
► DDC : Direct Digital Control
► PAC : Programmable Automatic Controller
► HMI : Human Machine Interface
► RTU : Remote Telemetry Unit OR Remote Terminal unit
► Robotics
► ANN : Artificial Neural Network
► IIoT : Industrial Internet of Things
Programmable Logic Controller
It’s a solid state device which controls the field output devices
based on the condition of input field devices and user defined
instructions.
Supervisory Control and Data Acquisition
It’s a software application used to monitor and control the field
devices.
Distributed Control System
It’s a controller which integrates the all other subsystem which are
connected at the different levels to control, visualize and report whole
automated process system.
Direct Digital Control
It’s refers to the automated control of a process by computers and
microprocessors with field inputs.
Programmable Automatic Controller
It’s an industrial controller that combines the functionality of a PLC with
the processing capability of a PC to perform advanced process
control.
Human Machine Interface
It’s a platform which facilitates the interaction between human and an
automated machine.
Remote Telemetry Unit
It’s a controller which controls the field output devices based on
the condition of input field devices and user defined instructions
from the remote location.
Robotics
Robotics is an application of software, AI and ML capabilities to handle
the task which need less human assistance.
Variable Frequency Drive
It’s a technique often used to achieve the adjustable speed drive of
an AC motor to control its speed as well as torque.
Industrial Internet of Things
 RELAY
IT IS A ELECTROMECHANICAL DEVICE WHICH IS USED TO DRIVE HIGH
POWER CIRCUIT WITH THE HELP OF LOW POWER CIRCUIT AND LOW
POWER CIRCUIT WITH THE HELP OF HIGH POWER CIRCUIT.
Classification of Relay Based on Operating
Principle
ELECTROMAGNETIC RELAY.
SOLID STATE RELAY.
HYBRID RELAY.
REED RELAY.
OVERLOAD RELAY.
Electromagnetic Relay
Solid State Relay
Hybrid Relay
Reed Relay
Overload Relay
Classification of Relay based on
Number of Poles and Throws
Poles: Number of moving contact present in a relay.

Throws: Number of fixed contacts present for one

moving contact in a relay.
 RELAY
A relay is an electrical switch that controls a
High load circuit from a low-voltage source or
Low load from a High Voltage source.

Prepared By
 APPLICATION OF RELAY
►Relays are used for isolating a low-voltage circuit
from a high-voltage circuit.
►They are used for controlling Multiple circuits.
►They are used for the automatic changeover.
►The microprocessor uses Relay to control a heavy
electrical load.

Prepared By
 Classification of Relay
Based on Operation Based on Poles & Throw

• EMR (Electro-Mechanical Relay). • SPST (Single Pole Single Throw).

• SSR (Solid State Relay). • SPDT (Single Pole Double Throw).
• Hybrid Relay. • DPST (Double Pole Single Throw).
• Reed Relay. • DPDT (Double Pole Double Throw).
• Thermal Relay. • 4PDT (4 Pole Double Throw).

Prepared By
 Based On Operation
• EMR Electro-Mechanical Relay
This type of Relay has an electromagnetic coil and a mechanical movable contact

Prepared By
Applications of EMR
►Industrial Assembly Lines
►Machine Tool controlling
►Automotive Applications
Disadvantages of EMR
�Electrical Noice
�Wear out easily
�Sparking Problem
Prepared By
 SSR Solid State Relay
► SSR is made up of semiconductors instead of mechanical parts and
It works on isolating the low-voltage circuit from the high-voltage
circuit using an optocoupler.

Prepared By
Applications of SSR
►Regulator
►Inverter
►Power Transformers
►Power Converters

Disadvantages of SSR
�Over Heat
�Voltage Drop
Prepared By
 Hybrid Relay
It is Made up of both SSR & EMR

As we know, SSR wastes power in the form of Heat and EMR has contact arcing
problems.The hybrid relay uses both SSR & EMR to overcome their disadvantages
Prepared By
Applications
►Water heating Or Water Boilers
►Heating Applications

Prepared By
Reed Relay
► Reed relay is made up of a reed switch & an electromagnetic coil.

Ferromagnetic metal Blades

Applications
• Proximity sensor
• Microwave

Prepared By
 Thermal Relay
►An electrothermal relay is made up of a bimetallic strip

Applications
• Electric Motor Protection
• Overload Protection
Prepared By
Based on Poles & Throw
►Poles
The number of Switches inside a relay is called
the poles of the relay.
►Throw
The number of circuits being controlled per
the pole is called the throw of a relay.

Prepared By
SPST Single Pole Single Throw

SPDT Single Pole Double Throw

Prepared By
DPST Double Pole Single Throw

DPDT Double Pole Double Throw

Prepared By
4PDT 4 Pole Double Throw

Prepared By
 LOGIC GATES
►Logic Gates is an electrical circuit that can take one or
more inputs but the output can be one
� Types of Logic Gates
• OR Gate
• AND Gate
• NOT Gate
• NOR Gate
• NAND Gate
• XOR Gate
• XNOR Gate Prepared By
 OR Gate

► The Logic OR function output is only true if one or more of its inputs
are true, otherwise, the output is false.
► In Mathematical Functions, we call or as Addition +
► Logic Equation A+B=Y
Y=A+B A B Y
A
0 0 0
Y
0 1 1
B 1 0 1
1 1 1

Prepared By
Electrical Wiring Diagram

Prepared By
Relay Wiring Diagram

Prepared By
AND Gate
► The Logic AND Function output is only true when all of its inputs are
true, otherwise the output is false.
► In Mathematical Functions, we call or as Addition +
► Logic Equation A*B=Y
Y=A*B

A B Y
0 0 0

0 1 0
1 0 0
1 1 1

Prepared By
Electrical Wiring Diagram

Prepared By
Relay Wiring Diagram

Prepared By
NOT Gate

► A Digital logic gate that produces logic True when its input is False & generates
logic False when its input is True is known as a NOT gate.
► Logical Equation:- A = A

A A
0 1
1 0

Prepared By
Electrical Wiring Diagram

A A
0 1
1 0

Prepared By
Relay Wiring Diagram

A A
0 1
1 0

Prepared By
NOR Gate

► The digital logic gate which generates logic False when any of its input logic is
True is known as the NOR gate.
► Logical Equation:- Y= A+B / A.B
► Symbol

Prepared By
Electrical Wiring Diagram

A B Y
0 0 1

0 1 0
1 0 0
1 1 0

Prepared By
Relay Wiring Diagram

A B Y
0 0 1

0 1 0
1 0 0
1 1 0

Prepared By
NAND Gate

► The digital logic gate gives output False only when all of its inputs are True or it
gives output True when any of its inputs are low.
► Logical Equation:- Y= A.B / A+B
► Symbol

Prepared By
Electrical Wiring Diagram

A B Y
0 0 1

0 1 1
1 0 1
1 1 0

Prepared By
Relay Wiring Diagram

A B Y
0 0 1

0 1 1
1 0 1
1 1 0

Prepared By
XOR Gate

► The digital logic gate gives output True only when one input is True or it gives
output False when all of its inputs are the same.
A B Y
► Logical Equation:- Y = A+B
0 0 0
► Symbol 0 1 1
1 0 1
1 1 0

Prepared By
Electrical Wiring Diagram

A B Y
0 0 0

0 1 1
1 0 1
1 1 0

Prepared By
Prepared By
Relay Wiring Diagram

A B Y
0 0 0

0 1 1
1 0 1
1 1 0

Prepared By
XNOR Gate

► The digital logic gate gives output True only when both inputs are the same or it
gives output False when only one input is True.
A B Y
► Logical Equation:- Y = A+B
0 0 1
► Symbol 0 1 0
1 0 0
1 1 1

Prepared By
Electrical Wiring Diagram

A B Y
0 0 1

0 1 0
1 0 0
1 1 1

Prepared By
Prepared By
Relay Wiring Diagram

A B Y
0 0 1

0 1 0
1 0 0
1 1 1

Prepared By
 Motor Forward & Reverse Using Relay
► Condition 1 � Condition2
A B Y A B Y
0 0 OFF 0 0 FRW

0 1 FRW 0 1 OFF
1 0 REV 1 0 OFF
1 1 OFF 1 1 REV

Prepared By
►Condition 1

Prepared By
►Condition 2

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Relay Latching Using Push Button

NO Push Button NC Push Button

Difference Between Push Button and Switch

• Switches are used to hold a supply in a circuit whereas Push buttons are
used to send a supply or cut off the supply one time.

Prepared By
► Condition 1 � Condition 6
Start NO Start Stop
� Condition 2 NO NO

Start NC

� Condition 3
Start Stop
NO NC

� Condition 4
Start Stop
NC NO

� Condition 5
Start Stop
NC NC
Prepared By
►Condition 1
Start NO

Prepared By
Prepared By
►Condition 2
Start NC

Prepared By
►Condition 3
Start Stop
NO NC

Prepared By
►Condition 4
Start Stop
NC NO

Prepared By
►Condition 5
Start Stop
NC NC

Prepared By
►Condition 6
Start Stop
NO NO

Prepared By
►Use Relay to on AC load and latch the relay
1. Use No Push Button to on the load.
2. Use Nc push button to reset/off the load

Prepared By
Prepared By
Prepared By
Prepared By
PLC ARCHITECTURE
PLC BLock Diagram
Power Supply
 Classification of PLC based on
Power supply

► With SMPS

► Without SMPS
PLC Inputs and Outputs
Digital Inputs and Outputs
Optical Isolator
 Analog Inputs and
Outputs

► Display
► Solenoid valve
► Control Valve
► Servo Motor
► VFD
 Classification of PLC based on No. of
IO module
Fixed Modular Rack

● Fixed inputs and outputs ● Expandable ● Expandable

● Small scale industries ● Small and medium scale ● Medium and large scale
● 256 I/O industries industries
● 2046 I/O ● 8K-16K or more I/O
● 2Kb-4Kb ● Expansion modules are ● Expansion modules are
connected in series connected in rack
● 20Kb- 30Kb ● 2Mb-10Mb
Operational Sequence
► The operational sequence is as follows:

1. Input switch is pressed.

2. Input module places a “1″ in the Input Data/Memory/Image table.
3. The ladder logic program sees the “1″ and caused a “1″ to be put into the
output data table. (Based on your program)
4. The Output Data/Memory/Image table causes the output module to
energize associated point.
5. The output device energizes.
Memory
Communication ports
Serial Communication standards
Communication protocols

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industrial-communication-protocols-mapped-to-OSI-
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CFQAAAAAdAAAAABAI
Classification of PLC based on
output module type
► Transistor type
► Relay type
► TRIAC type
PLC Programming

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THE BASIC OF PLC PROGRAMMING
N0 – NC CONTACT, PUSHBUTTON, INSTRUCTION
LADDER LOGIC
• Ladder Logic Representation

Hot Power Rail Cold Power Rail

Positive Rail Ground Rail

Rung
 LADDER LOGIC PROGRAMMING LANGUAGE

• Ladder diagram language is the most commonly used PLC language and is
designed to mimic hardwired relay logic
RULES OF PROGRAMMING

1. Each Rung Should have at least one input and one output with proper logic
input on left side and output on right side.
2. Input can be connected in series as well as in parallel but output cannot be
connected in series need to be connected in parallel.
3. Input (input Address) can be repeated as input again, but Output (output
Address) cannot be repeated as output again.
4. Input (input Address) cannot be used as output (output Address), but output
(output Address) can be repeated or used as input (input Address).
5. Each input and output should have their own unique identification factor.
 INTRODUCTION TO LADDER LOGIC

• Basics about conventional ladder and PLC ladder logic

Basic Ladder Program
NO NC PUSHBUTTON/RELAY/CONTACT
• N0 – PUSHBUTTON
INPUT IMAGE/MEMORY TABLE

Not Conducting
Not Pressed
0 Conducting

Conducting
Pressed
1 Not Conducting
NO NC PUSHBUTTON/RELAY/CONTACT
• NC – Pushbutton
INPUT IMAGE/MEMORY TABLE

Conducting

1
Not Pressed
Non Conducting

Non Conducting
Pressed
0 Conducting
Latching Problem
► Condition 1 � Condition 6
Start NO Start Stop
� Condition 2 NO NO

Start NC

� Condition 3
Start Stop
NO NC

� Condition 4
Start Stop
NC NO

� Condition 5
Start Stop
NC NC
 Conveyor problem
Input output list
DI DO
NO Start RI
NC Stop Forward Indicator
NO Limit switch_1 Reverse indicator
NO Limit switch_1 Motor Forward
Motor Reverse
Operation Sequence
● if start=on then RI=on, after that if start goes to off state also RI should remain at ON condition.
● if (ri is on and limit switch_1 is on) then motor forward and forward indicator should be on. If Limit switch_1 goes off also
motor forward and forward indicator should remain at on state until and unless limit switch_2 turns on.
● if (ri is on and limit switch_2 is on) then motor reverse and reverse indicator should be on. If Limit switch_2 goes off also motor
reverse and reverse indicator should remain at on state until and unless limit switch_1 turns on.
● And the process should repeat.
 Tank Filling Problem
Input output list

DI DO
N0 Start RI
NC Stop Inlet valve
Low switch Outlet valve
High switch

Operation Sequence
● if start=on then RI=on, after that if start goes to off state also RI should remain at ON condition.
● if (ri is on and low switch is off) then inlet valve should be on. If low switch goes on also inlet valve should
remain at on state until and unless high switch turns on.
● if (ri is on and high switch is on) then outlet valve should be on. If high switch goes off also outlet valve
should remain at on state until and unless low switch turns off.
● And the process should repeat.
 Memory Problem
Problem 1 Problem 2 Problem 3

X0 Y0 X0 Y0 Y1 Y2 X0 Y0

1 1 1 0 0 0 1 1
0 0 0 1 0 1
0 1
1 0 1 0 1 0
1 0
0 0 1 1 0 0
0 0
1 1 0 0
1 1
0 1 0 1
1 1 1 0
0 1 1 1
● Repeat the Process
 PLC HARDWARE

1. Model No. Explanation

2. Types of PLC
3. Expansion (Based on PLC type)
4. Communication Ports & Protocols
5. Indicators
6. Memory
7. Program Capacity
8. Data Capacity
9. Programming Software
• TYPES OF PLC IN DELTA
1: Hot swappable mid range plc A-H series
• Provides automation solution for high level application
• Combination of modularized hardware structure, Adavanced functions and highly integrated software provides a
system solution for process control application
• Provides multi axis motion control via network such as ether CAT to perform high speed , High precession machine
control
• AH standard series CPU
• AH redundant CPU
• Motion CPU
• AH series expansion module
2: Compact modular mid range plc –AS series
• High performance multi purpose controller designed all kind of equipment
• Provides enhanced execution speed (40k steps /ms) and supports upto 32
extension odule or upto 1024 i/o
• Provides accurate positioning controller upto 8 axis via Can motion network
• A_S series controller are widely used in device automated equipment such as
packing printing labelling textile and pharma
3: DVP series
Offers high speed stable application of all kind od automation machine saddition to
fast logic operation
Cost effective PLC also supports various CAN protocol as well as connects delta AC
motor drive servo drive HMI temp controller
• DVP series standard CPU : EH3, ES3, ES2, EC3
• DVP slim CPU : SV2,SX2,SA2,SX,SV,SE,SS2
• DVP series motion CPU: 50MC, 15MC,20PM,10PM
 MODEL NO. EXPLANATION

• DVP 28 SV 11/00 R/T

Main Series
No. of I/O Transistor O/P
Relay Output
Sub Series AC Power Supply
DC Power Supply
 TYPES OF PLC
1. Fixed Type – I/0 are Fixed
2. Modular Type – I/0 Can be Expandable (Inbuilt I/O Available) – SERIES EXPANSION
3. Rack Type – I/O are Separate (No Inbuilt I/O) – PARALELL EXPANSION

Expansion Port
Modular PLC
 TYPES OF PLC

• DVP28SV11R/T
• Modular Type
1. Total No. of Expansion Module 7
2. Total No. of I/O are 512 – Input 256 & Output 256.
• Communication Port, Standard & Protocol
1. DIN 8 RS 232
2. Screw terminal RS 485
 INDICATOR
• Power Indicator
Is LIT when proper power supply is provided, Otherwise
Blinking.
• Run Indicator
Is LIT when PLC is in run mode, otherwise off in stop mode.
• Error Indicator
Is Blinking faster than normal if power supply is not proper,
is LIT on any other(Fatal & Non Fatal) error.
• Bat. Low
Is LIT when internal battery low.
• RS – 232
PLC to PC Communication.
• RS – 485
Scada, HMI, VFD, Other controller module.
 MEMORY

• Program Capacity and Data Capacity

 PROGRAMMING SOFTWARE
• WPL SOFT
• ISP SOFT
ASSIGNMENT NO. 3

• Types of PLC under delta

SET and RESET Instruction
 Timers and Counters

Timer is an instruction used to generate reqiured delay.

Two types
• Retentive Timer:
➔ ON-Delay timer
➔ OFF-Delay timer
➔ Pulse Delay timer

• Non-Retentive Timer:
➔ ON-Delay timer
➔ OFF-Delay timer
Timer Problem
Input output list

DI DO
Start RI
Stop Inlet valve_1
Low switch Outlet valve
High switch Inlet valve_2
Middle switch Agitator motor

Operation Sequence
● if start=on then RI=on, after that if start goes to off state also RI should remain at ON condition.
● if (ri is on and low switch is off) then inlet valve should be on. If low switch goes on also inlet valve_1 should
remain at on state until and unless middle switch turns on.
● if (ri is on and middle switch is on) then inlet valve_2 should be on. inlet valve_1 should remain at on state
until and unless high switch turns on.
● if (ri is on and high switch is on) then Agitator motor should be on for 5 sec.
● After 5 sec, if (ri is on and high switch is on) then outlet valve should be on. If high switch goes off also outlet
valve should remain at on state until and unless low switch turns off.
● And the process should repeat.
 Counters
Counter is an instruction which increments or decrements an integer by one when its
input bit transition happens.

1. Up counter
2. Down Counter
3. Up-Down counter
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Counter Problem
Data types in PLC
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● Boolean—-------------------------------------------------> 1bit
● Nibble—---------------------------------------------------> 4bit
● Byte—------------------------------------------------------>8bit
● Integer→Signed Unsigned
○ SINT—-------------------------------------------------------->8bit
○ INT—--------------------------------------------------------->16 bit
○ DINT—------------------------------------------------------->32bit
○ LINT—------------------------------------------------------->64bit
● Real—----------------------------------------------------->32bit
● word—---------------------------------------------------->16bit
● String—---------------------------------------------------->8bit
Arithmetic Problems
Write a PLC logic To
1. (a+b)^2 (Prove both LHS and RHS)
2. (a+b)^3 (Prove both LHS and RHS)
3. Find the area of a circle
4. Convert degree Celsius to degree Fahrenheit conversion
 1. (a+b)^2 = a^2 + b^2 + (2*a*b)
Steps to solve
LHS
1. Assign “a” value to D0
2. Assign “b” value to D1
3. (a+b) → D0+D1 → result will be stored in D2
4. (a+b)^2 → D2 * D2 → result will be stored in D3
RHS
1. a^2 → D0*D0 → result will be stored in D4
2. b^2 → D1*D1 → result will be stored in D5
3. a^2 + b^2 →D4+D5 → result will be stored in D6
4. (a*b) → D0*D1 → result will be stored in D7
5. (2*a*b) → (k2*D7) → result will be stored in D8
6. a^2 + b^2 + (2*a*b) → D6+D8 → result will be stored in D9
Increment and Decrement
Comparator

Comparator is a functional block which compares two values or

variables.
► Input Comparator (Contact Comparator)
► Output Comparator (Coil Comparator)
 CP1E-E20DR-A PLC HARDWARE

1. Model No. Explanation

2. Types of PLC
3. Expansion (Based on PLC type)
4. Communication Ports & Protocols
5. Indicators
6. Memory
7. Program Capacity
8. Data Capacity
9. Programming Software
 OMRON PLC
1. Model No. Explanation
1. Types of PLC: With SMPS, Relay type
2. Expansion (Based on PLC type): Fixed PLC
3. Communication Ports & Protocols: USB-B
4. Program Capacity: 2K step
5. Data Capacity: 2KB words
6. Programming Software: CX-programmer
Indicators
https://www.youtube.com/watch?v=Stqz_lzXiwo
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