Chapter 1:

Industrial Automation
Ks. Cao Duc Loi
4.1 Boolean Logic Components

 The binary system of numbers has only two values, 0 and 1, while it is utilized for
the mathematical description of various physical systems characterized from a
binary logic of two states

 In electrical systems, the condition “in operation” (ON) is indicated with a “1” and
the condition “not in operation” (OFF) is indicated with a “0”

 In its general form, Boolean algebra is defined as the set of the elements a, b, c, ..., or
B={a, b, c, ...} in which the equality, as well as the following operations, are valid:

1. The operation of the logical OR, which is represented by the (+) operator
Circuits of the logical AND, which is represented by the ( ⋅) operator
2. The operation
Industrial Automation
3. The operation of the inversion or the complement (NOT), which is represented by
the (‫ )־‬operator
4.1 Boolean Logic Components

Figure 4.1 Switching elements and possible assignments of binary variables

a) Binary representation of NO and NC relay contacts

Industrial Automation Circuits b) Open contact as A = 0
c) Open contact as A = 1
d) Close contact as A = 0
e) Close contact as A = 1
4.1 Boolean Logic Components
 In general, a Boolean variable represents the level of voltage in a wire
of a digital electronic circuit.
 Most commonly, the state with the high energy level is denoted as
“1” or “high level” and the corresponding one with the low energy
level as “0” or as “low level

 In the typical digital electronic circuits (transistor–transistor

logic or TTL circuits), the electrical voltage can take only two
Figure 4.2 Waveform of a digital values: 0 V and +5 V, more especially, every electrical voltage
signal below 0.4 V is equivalent to a “logical 0”, while every voltage
above 2.4 V is equivalent to a “logical 1”

 In electrical circuits, the electrical components can be connected only in two ways, which is through
series or parallel connections.
Industrial Automation Circuits
 The series connection of electrical components or switching contacts corresponds to the logical
operation AND,
 while the parallel connection corresponds to the logical operation OR. These two operations, as
well as the inversion operation, are implemented with the help of the related logical gates AND,
OR, and NOT
4.1 Boolean Logic Components
 A logical function Z = f(A, B, C,...) is a function where the independent
variables A, B, C, ... As well as the dependent variable Z all belong to
the Boolean algebra

 For example, consider the pushbutton shown in Figure 4.3a, where its
contact is NO; the left connection terminal is considered to be under a
Figure 4.3 The pushbutton as a binary voltage and thus equivalent to a logical 1
variable: (a) No button and (b) NC button  If b=0 (the button is not pressed) then Z=0 (there is no voltage).
 If b=1 (the button is pressed) then Z=1 (there is voltage)

 The STOP and the START labels can be considered as binary variables
Industrial Automation Circuits of the corresponding buttons

Figure 4.4 Permanent stop or operation of

a machine
4.1 Boolean Logic Components
4.1.1 Postulates and Theorems of Boolean Algebra

Industrial Automation Circuits

Figure 4.5 Basic postulates and theorems of Boolean Algebra.

4.2 State Diagrams
4.2.1 Classical Stage Diagrams

 The methodology in design automation with the state diagram approach involves the
following steps:

1. A detailed, extended description of the desired operation of the complex machine

or the industrial automation and definition of the operating states

2. Construction of the state diagram based on the design rules that will be described
subsequently

3. Extraction of logical Boolean expressions

Industrial Automation Circuits

4. Design of the industrial automation based on the derived logical expressions

Figure 4.5 Basic postulates and theorems of Boolean Algebra.

4.2 State Diagrams
4.2.1 Classical Stage Diagrams

 The state diagram itself is a direct method of modeling industrial systems that contain a set of
logical variables, where their number defines the order of the system

 For example, the state of a complex machine can be the following set of logical values:

 “The first motor is in operation, the valve is energized, the second motor is not in operation”

 Where in most cases and for simplification purposes it can be equivalently characterized by
verbal terms like “the
Industrial Automation Circuits
machine is getting ready”. The state diagram is constructed according
to the following rules:
4.2 State Diagrams
4.2.1 Classical Stage Diagrams

1. We denote with circles the different states of the 4. For all the dual variables of the state diagram we calculate
complex machine or industrial system. In the following expression:
every circle, we define the corresponding state.

2. Every possible transition among different states is

denoted by an arrow connecting the corresponding
states. The arrow’s direction denotes the transition’s
direction. The “Present State of X variable” is used as a memory
type element that updates the current value of the variable.
3. On every directed arrow, we denote the Boolean As will be presented subsequently, this term has the same
variable or the logical expression of the Boolean role as the “self-latching contact” principle, which was
variables that cause the change of state. We denote resented in Section 3.1.1, describing the empirical
“Turn Automation
OFF” as theCircuits
logical expression of the variables methodology of circuit design.
Industrial
that cause the change of the dual variable value,
characterizing the changed state, from 1 to 0, and 5. Based on the extracted and simplified logical expressions
“Turn ON” as the logical expression of variables that from Step 4, we design the industrial automation circuit.
cause the corresponding change of the same dual
variable value from 0 to 1.
4.2 State Diagrams
4.2.1 Classical Stage Diagrams Example 4.1: START/STOP Operation of a Motor
 From the analysis in Chapters 2 and 3, it was clear that the
automation circuit will contain a power relay C, which
will control the power supply of the motor, and inherently
has two states: C=0 where the motor is not in operation
and C=1 where the motor is in operation.
 It is also defined from the desired industrial application
that the transition between these states will take place
through the utilization of two buttons b1 and b 0 for the
START and STOP operations, correspondingly
Figure 4.6 State diagram for the direct on line starting motor.
 Thus, for this example, we can define state C based on Step
3, so that:

Figure 4.7 The automation circuit extracted from the state

diagram of Figure 4.6.
4.2 State Diagrams
4.2.1 Classical Stage Diagrams Example 4.2: START/STOP Operation of a Motor with
Thermal Overload
Protection

Figure 4.8 State diagram for the direct on line starting motor
with thermal overload protection and two START-STOP
control position.

Or

Figure 4.9 The automation circuit extracted from the state

diagram of Figure 4.8.
4.2 State Diagrams
4.2.2 State Diagrams with Sensors Example 4.3: Machine Operation by Pushbuttons and Sensor

Figure 4.10 A state diagram where the states constitute de-

energizing signal (electrical latching)

Figure 4.11 Logical design of an automation circuit including

electrical latching and sensory command
4.2 State Diagrams
Example 4.4: A Three-Speed Machine Automation
4.2.2 State Diagrams with Sensors

Figure 4.12 State diagram of a machine operation with three

speeds.
4.2 State Diagrams
4.2.2 State Diagrams with Sensors

Example 4.4: A Three-Speed Machine Automation

Figure 4.13 The automation circuit of a machine with

three-speed motor as extracted from the state diagram
of Figure 4.12
4.2 State Diagrams
4.2.3 Step-by-Step Transition due to a Discrete Successive Signal

Example 4.5: Combined Operation of Two Machines

 Two machines M and N operate through the action of a

pushbutton b and two sensors S1 and S2, according to the
following specifications:

1. By pressing the push button b once, the machine M starts to

operate.
2. By pressing button b for a second time, the machine N starts
to operate, while the machine M continues to operate.
3. If both machines operate and sensor s1 is energized, then the Figure 4.14 Indirect transition from one state to another, for
machine M stops, while the machine N continues to operate. satisfaction of the “one-change each time” rule of state diagram
If instead of sensor S1, sensor S2 is energized nothing must design
happen.
4. If only the machine N operates and sensor S2 is energized,
then the machine N stops also
4.2 State Diagrams
4.2.3 Step-by-Step Transition due to a Discrete Successive Signal
Example 4.5: Combined Operation of Two Machines

Figure 4.15 Automation circuit confirming the double transition of the

state diagram, which means the auxiliary relay A and B are energized
both with only one press the button b.
4.2 State Diagrams
4.2.3 Step-by-Step Transition due to a Discrete Successive Signal
Example 4.6: Different Design of the Example 4.5 State Diagram

Figure 4.16 State diagram including the complement of a signal

As a condition for separating successive actuations.
4.2 State Diagrams
4.2.3 Step-by-Step Transition due to a Discrete Successive Signal
Example 4.6: Different Design of the Example 4.5 State Diagram

Figure 4.17 The automation circuit of the two machine Example 4.6
extracted from the state diagram of Figure 4.16
4.2 State Diagrams
4.2.3 Step-by-Step Transition due to a Discrete Successive Signal
Example 4.7: Power Factor Correction by Manual
Insertion of Capacitors.

Figure 4.18 State diagram for the power factor

correction by manual insertion of capacitors.
4.2 State Diagrams
4.2.4 State Diagrams with Time Relays Example 4.8: Starting of Two Motors with Time
Delay Between Them
 Additional design principles

1. Every time relay should be considered as a common

relay, and should represent a state of the system.

2. The output contact of the time relay that is going to be

energized with a time delay should be considered as
the signal that will cause the transition of the system
from one state into another one.
4.2 State Diagrams
Example 4.8: Starting of Two Motors with Time
4.2.4 State Diagrams with Time Relays Delay Between Them

Figure 4.19 Logic design of an automation Figure 4.20 The final automation circuit of
circuit containing timer. Figure 4.19, after simplification
4.2 State Diagrams
4.2.5 Component’s State Diagram Method

1. A pair of transitions must be introduced between S0 and each state Ci : One for Turn ON and
another for Turn OFF of the state Ci .
2. The logic of the system operation, derived from the corresponding specifications, is allocated
on the transitions as conditions for firing them.
3. It is permitted to have two or more synchronous transitions. Hence, two or more states Ci may
exist simultaneously in an energized situation.
4. The ON or OFF mode of a state Ci may be a condition of a transition.
5. If two or more components are identical from the point of view of the operation’s conditions,
then they are expressed by one common state.
6. After completion of the diagram, the logical formula (1) is applied for each state Ci. Hence,
there is no need for the introduction of auxiliary variables and further coding assignments.
 Example 4.9: Automation of a Multi-Conveyor Assembly Station
4.2 State Diagrams
4.2.5 Component’s State Diagram Method
4.2 State Diagrams
4.2.5 Component’s State Diagram Method

Figure 4.21 The automation circuit extracted

from the component state diagram (Ex: 4.9)
4.2 State Diagrams Example 4.10: A Drilling and Milling Machine Tool
4.2.6 State Diagrams and Minimum Realizations with Two Different in Duration Processes
 First solution based on the empirical
method

 Second solution based on the component state

diagram method

Figure 4.22 A metal drilling and milling machine tool with

two different processes in terms duration and type
4.2 State Diagrams
4.2.6 State Diagrams and Minimum Realizations

 Second solution based on the component state

diagram method
4.2 State Diagrams
4.2.6 State Diagrams and Minimum Realizations
 Third solution based on the system state diagram method
4.2 State Diagrams Example 4.11: Chemical Process Automation in a Reactor
4.2.7 Sequential Automation Systems 1. The valve V1 closes
2. With precondition that the valve V1 has been closed, the
refrigerator (RFG) starts to operate
and simultaneously the valve V2 opens. The valve V2 remains
open until the liquid A level
inside the reactor reaches the height L 2 and is detected by a
corresponding sensor.
3. With step 2 completed, the stirring impeller (STR) starts to
operate. The stirring impeller and the refrigerator stop to
operate at the end of the mixing cycle.
4. With the precondition that the stirring impeller operates, the
valve V 3 opens and remains open, until the liquid B level
reaches the height L 3 detected by a second corresponding
sensor.
5. With Step 4 completed, a time interval of 40 min follows for
the mixing and the chemical reaction of the two liquids.
6. At the end of this reaction period, the valve V1 opens and the
reactor starts to empty.
7. When the level of the produced liquid drops to height L1,
Figure 4.23 A chemical reactor for mixing two liquids and then the valve V1 closes and a new operation cycle begins if
compounding a new product the corresponding condition exists.
4.2 State Diagrams Example 4.11: Chemical Process Automation in a Reactor
4.2.7 Sequential Automation Systems
4.2 State Diagrams Example 4.11: Chemical Process Automation in a Reactor
4.2.7 Sequential Automation Systems
4.3 Applications
4.3.1 Bidirectional Lead Screw Movable Worktable with Two Speed

1. With the press of a button b1, the lead screw worktable (T)
should move to the right with a low speed (R LS ).
2. When the limit switch x is energized, the table should
continue to move towards the right, but with the high speed
(R HS ), until it reaches the limit switch y, where it returns to
the low speed of motion (R LS ).
3. As soon as the limit switch z is energized, the direction of the
movement should be inverted, which means that the table
should move to the left (L LS ) without a change in the speed.
4. The movement to the left should continue in a similar way
until the press of the limit switch y, where it continues at low
speed (L LS ). From the limit switch y until the limit switch x,
the movement is happening at high speed (L HS ) and from
the x until the w at low speed (L LS ), where again the motion
is reversed.
5. This palindromic movement of the table continues until a
button b 0 is pressed, only while the lead screw table moves
toward the right at low speed.
4.3 Applications
4.3.1 Bidirectional Lead Screw Movable Worktable with Two Speed
4.3 Applications
4.3.1 Bidirectional Lead Screw Movable Worktable with Two Speed
4.3 Applications 1. Initially, we define the movement of the table to the right with
“SR” and the movement to the left with “SL”. In both states, and
4.3.2 Palindromic Movement of a Worktable with Memory with the press of a button “s” (STOP), the table stops
in its current position.
2. With a pre ss of the button “m” (memory button), the table
continues moving in the same manner before it was stopped, due
to the press of the button “s”.
3. If the table is moving to the right (SR ), then either by the press of
a button “a” or when it reaches the end of its movement where the
limit switch “z” is energized, the direction of the
motion will be inverted, which means that the table should move
to the left (SL).
4. With the same approach, when the table is moving to the left (S
L), either with a press of a button “d”, or when it reaches in the
end of its movement where the limit switch “w” is energized, the
direction of the motion will be inverted, which means that the
table should move to the right (SR ).
5. If, during the movement of the table to the left (S L ), the limit
switch “w” is energized, while the limit switch “z” remains
energized, due to a fault (e.g., the limit switch has been blocked),
then the table should stop, like in the case where the button “s”
had been pressed
4.3 Applications
4.3.2 Palindromic Movement of a Worktable with Memory
4.3 Applications
4.3.2 Palindromic Movement of a Worktable with Memory
4.3 Applications
4.3.3 Operation of N Machines with Pause under Specific Conditions
4.3 Applications
4.3.3 Operation of N Machines with Pause under Specific Conditions
4.3 Applications
4.3.3 Operation of N Machines with Pause under Specific Conditions
4.3 Applications
4.3.3 Operation of N Machines with Pause under Specific Conditions
4.3 Applications
4.3.3 Operation of N Machines with Pause under Specific Conditions

Figure 4.24 The improved automation circuit adding the

possibility to save the stopping command.