SOLUTION: discrete control of manufacturing | My Assignment Tutor

Industrial systems!Lecture 2Dr Ahmed Chebboa.chebbo@lcuck.ac.ukPROGRAMMABLE!LOGIC CONTROLLERS-  Review brief history of PLCs and manufacturingcontrol systems.-  Introduce the concepts of discrete control ofmanufacturing-  Review the various kinds of instrumentation usedfor control.-  Overview ladder logic programmingThink of some common examples of PLCapplications !!Industrial Applications of PLC1. Transportation System likes Conveyor Belt System.2. Packing and Labeling System in Food & Beverage.3. Automatic Bottle or Liquid Filling System.4. Packaging and Labelling System in Pharma Industries.5. Transportation System like Escalator and Elevator.6. Industrial Crane Control System for Operation ofOverhead Traveling Crane.7. Glass Industries for glass production and recording data.8. Paper Industries for the production of Pages, Books orNewspapers, etc.9. Cement Industries for manufacturing or mixing the rightquality and quantities of raw materials, and accuracy ofdata regarding.Industrial Applications of PLC (cont.)10. Automatic Drainage Water Pump Monitoring and ControllingSystem.11.  Time and Count-based Control System for an IndustrialMachine.12. Temperature Controller or Humidity by using the SensorsInput to the PLC system.13. Fault Detection and Protection of Industrial Machines like anInduction Motor.14. Wind Turbine System for Maximum Efficiency, RecordingData, and Safety Purposes.15. Energy Management System like Boiler, Ball Milling, CoalKiln, Shaft Kiln, etc.16. Oil and Gas Industries for controlling the Purging Procedure.Power Station Applications of PLC1. PLC uses for the Smart Grid System to Monitor and Detectfault conditions.2. It is used in the Power Generation, Transmission, andDistribution System.3. In the Power Substation, PLC can use the Auto AssemblyLine System.4. Some Electrical Equipment (like Circuit Breaker Tripping,Capacitor Switching) can be automatically operated withPLC.5. A Single-Phase or Three-Phase Sequence Detect by usingthe PLC.6. In Oil, and Gas an Automation Power Plant, PLC needs forValve Switching for Changeover of Fuels, Pilot Light ON orOFF, Flame Safety Checking, Oil Filtering procedure, andmore things.Commercial Applications of PLC1.  Smart Traffic Control Signal System.2.  Smart Elevator Control System.3.  Fire Detection and Alarm System.4.  Automatic Machine Handling System.5.  Automatic Vehicle Washer System6.  Automated Guided Vehicle System.7.  In the Roller Coasters Machine.8.  Automation System for Well Drainage System.9.  Luggage Handling System. For example, at the Airport.10. Pressure Controller in Multi-Motor Pump Applications.11.  Sequence or Numerical Counting and Packing System.12. Mining Equipment Line Detection and Remote ControlSystem.13. For Wind Turbine Operation, PLCs convert signals from theWind Speed and Direction Sensors to better control theDomestic Applications of PLC1.  Water Tank Level Control System2.  Car Washing and Parking System.3.  Flashing Light Controlling System.4.  Automatic Door Opening/Closing System.5.  Remote Monitoring Application like Air compressor (AC),Fan.6.  ON/OFF Switching Application like Light, Motor, and Moredaily life applications of PLC.Domestic Applications of PLC1.  Water Tank Level Control System2.  Car Washing and Parking System.3.  Flashing Light Controlling System.4.  Automatic Door Opening/Closing System.5.  Remote Monitoring Application like Air compressor (AC),Fan.6.  ON/OFF Switching Application like Light, Motor, and Moredaily life applications of PLC.Types of control-  Temporal Ø control based in time-  State Ø control based in state level-  Hybrid Ø both temporal and stateMain Idea of Programmable LogicControllers (PLCs)•  Initially designed to replace relay logic boards–  Sequence device actuation–  Coordinate activities•  Accepts input from a series of switches•  Sends output to devices or relaysFunctions of PLCs1) on-off control,2) sequential control,3) feedback control, and4) motion control.Control Devices1) Mechanical control – cam, governor, etc.,2) Pneumatic control – compressed air, valves, etc.3) Electromechanical control – switches, relays, atimer, counters, etc,4) Electronics control – similar to electromechanicalcontrol, except uses electronic switches.5) Computer control.Definition of Programmable Logic!ControllerInvented in 1968 as a substitute for hardwired relay panels.“A digitally operating electronic apparatus which uses a programmablememory for the internal storage of instructions by implementingspecific functions such as logic sequencing, timing, counting, andarithmetic to control, through digital or analog input/output modules,various types of machines or processes. The digital computer which isused to perform the functions of a programmable controller isconsidered to be within this scope. Excluded are drum and other similarmechanical sequencing controllers.”National Electrical Manufacturing Association (NEMA)Top PLC Manufacturers1)  Siemens2)  Rockwell Automation /Allen Bradley3)  Mitsubishi Electric4)  Schneider Electric5)  ABB6)  Honeywell Process7)  Omron8)  Hitachi IndustrialEquipment Systems9)  IDEC10)  B&R Industrial Automation11)  Bosch Rexroth12)  Koyo Electronics Industries13)  Delta14)  Eaton15)  Keyence16)  LS Electric17)  PanasonicPLCCPUSystemUser LadderDiagramWorkingmemoryregisters InputFlagOutputInputModuleOutputModule PLC ConfigurationWhat devices does a PLC interact with?•  INPUT RELAYS-(contacts) They physically exist andreceive signals from switches, sensors, etc. Typicallythey are not relays but rather they are transistors.•  INTERNAL UTILITY RELAYS-(contacts) These do notreceive signals from the outside world nor do theyphysically exist. They are simulated relays and arewhat enables a PLC to eliminate external relays. Thereare also some special relays that are dedicated toperforming only one task. Some are always on whilesome are always off. Some are on only once duringpower-on and are typically used for initializing datathat was stored.What devices does a PLC interact with?(cont.)•  COUNTERS-These again do not physically exist. Theyare simulated counters and they can be programmed tocount pulses. Typically these counters can count up,down or both up and down. Since they are simulatedthey are limited in their counting speed. Somemanufacturers also include high-speed counters that arehardware based. We can think of these as physicallyexisting. Most times these counters can count up, downor up and down.What devices does a PLC interact with?(cont.)•  TIMERS-These also do not physically exist. Theycome in many varieties and increments. The mostcommon type is an on-delay type. Others include offdelay and both retentive and non-retentive types.Increments vary from 1ms through 1s.•  OUTPUT RELAYS-(coils)These are connected to theoutside world. They physically exist and send on/offsignals to solenoids, lights, etc. They can be transistors,relays, or triacs depending upon the model chosen.What devices does a PLC interact with?(cont.)•  DATA STORAGE-Typically there are registersassigned to simply store data. They are usually used astemporary storage for math or data manipulation. Theycan also typically be used to store data when power isremoved from the PLC. Upon power-up they will stillhave the same contents as before power was removed.Very convenient and necessary!!SwitchesSPDT DPSTNon-locking LockingNormally Open Normally ClosedMultiple ThrowP1P2Multiple PoleBreak-before-make Make-before-breakA Single Pole DoubleThrow (SPDT) switch isa switch that only has asingle input and canconnect toand switch between the2 outputs. This means ithas one input terminaland two output terminalsDouble Pole SingleThrow (DPST) Switch?A Double Pole SingleThrow (DPST) switch isa switch that has 2inputs and 2 outputs;each input has 1corresponding outputTypes of Switches1. Basic switch, operated by a mechanical level,2. Push-button switch,3. Slide switch,4. Thumbwheel switch,5. Limit switch,6. Proximity switch, and7. Photoelectric switch.RATING: voltage, currentRELAYSA switch whose operation is activated by an electromagnet iscalled a “relay” contactcoil inputRelay coil Output contactCounterDigital counters output in the form of a relay contact when a preassignedcount value is reached.RegisterAccumulatorcontact inputreset outputInputResetOutputCount 0 1 2 3 4 5 0 1 5TimerA timer consists of an internal clock, a count value register, andan accumulator. It is used for or some timing purpose. ClockAccumulator contactresetoutputRegisterContactTime 5 seconds.ClockResetOutputCount 0 1 2 3 4 5 An Example of Relay LogicL1LS1 PB1 LS2 R1R1R1TIMERR2PR=5For process control, it is desired to have the process start (by turning on amotor) five seconds after a part touches a limit switch. The process isterminated automatically when the finished part touches a second limitswitch. An emergency switch will stop the process any time when it ispushed.LS1PB1LS2R1TIMER5MotorR2PLC ArchitectureProgrammable controllers replace most of the relaypanel wiring by software programming. ProcessorI/OModulesMemoryPowerSupply ProgramLoaderPrinterCassetteLoaderEPROMLoaderSwitches Machines Peripherals External DevicesPCA typical PLCPLC Components1. Processor Microprocessor based, may allow arithmetic operations, logicoperators, block memory moves, computer interface, local areanetwork, functions, etc.2. Memory Measured in words.ROM (Read Only Memory),RAM (Random Access Memory),PROM (Programmable Read Only Memory),EEPROM (Electronically Erasable ProgrammableROM),EPROM (Erasable Programmable Read Only Memory),EAPROM (Electronically Alterable Programmable Read Only Memory), andBubble Memory.3. I/O Modular plug-in peripheryAC voltage input and output,DC voltage input and output,Low level analog input,High level analog input and output,Special purpose modules, e.g.., high speed timers,Stepping motor controllers, etc. PID, MotionPLC Components4. Power supply AC power5. Peripheral Hand held programmer (loader),Operator console,Printer,Simulator,EPROM loader,Graphics processor, andNetwork communication interface. MAP, LANPLC ComponentsLadder DiagramA ladder diagram (also called contact symbology) is a meansof graphically representing the logic required in a relay logicsystem.AR1PB1 PB2R1R1start emergency stopRailRungLadder RepresentationPLC Wiring Diagram 01 02 202020 110111020312 AInput PLC OutputExternalswitchesStored programSCANA PLC resolves the logic of a ladderdiagram (program) rung by rung, fromthe top to the bottom. Usually, all theoutputs are updated based on the statusof the internal registers. Then the inputstates are checked and the correspondinginput registers are updated. Only afterthe I/Os have been resolved, is theprogram then executed. This process isrun in a endless cycle. The time it takesto finish one cycle is called the scantime.PLC Instructions1) Relay,2) Timer and counter,3) Program control,4) Arithmetic,5) Data manipulation,6) Data transfer, and7) Others, such as sequencers.Logic StatesON : TRUE, contact closure, energize, etc.OFF: FALSE, contact open , de-energize, etc.AND and OR LOGICPB1 PB2 R1R2R1 = PB1.AND.PB2R2 = PB2.AND.~PB4PB3 PB4PB1 R1PB2R1 = PB1 .OR. PB2ANDORCOMBINED AND & ORR1 = PB1 .OR. (PB2 .AND. PB3)PB1 R1PB2 PB3 RELAYA Relay consists of two parts, the coil and the contact(s).Contacts:a. Normally open -| |-b. Normally closed -|/|-c. Off-on transitional -|↑|-d. On-off transitional -|↓ |-Coil:a. Energize Coil -( )-b. De-energize -(/)-c. Latch -(L)-d. Unlatch -(U)-( )Advantages of PLC•  They are re-programmable•  Solid state switches last much longer than relays•  Complex logics can be easily represented•  Multiple devices can be embedded in one unit•  Can easily be scaled up or modified.•  Smaller physical size than hard-wire solutions.•  Easier and faster to make changes.•  PLCs have integrated diagnostics and override functions.•  Diagnostics are centrally available.•  Applications can be immediately documented.•  Applications can be duplicated faster and less expensively.Advantages of PLC•  Connection between switches/output can be modified throughsoftware easily.•  Troubleshooting is Easier and Faster.•  Ease of Maintenance – less downtime.•  Easy to develop Programs by offline simulation•  Less amount of Space Needed•  Changes are easier and faster to implement,•  Integrated diagnosticsAdvantages of PLC•  Inputs and Outputs are easier to monitor by HMI devices….andfrom PC’s•  Can withstand severe environmental conditions.•  Cost effective for controlling complex systems.•  Computational abilities make possible more sophisticatedcontrols•  Reliable components make for long uptime before failure.Disadvantages of the PLC•  Most PLCs manufacturers offer only closed architectures fortheir products .•  PLC devices are proprietary, proprietary, which means thatparts and from one manufacturer can’t easily be used incombination with parts of another manufacturer, which limitsthe design and cost options.•  Subject to the limitations imposed by semiconductor basedsystems.•  Setup and training costs could be highProgramming a PLCOil is consumed randomly. The tank needs to be refilled by turning on apump. Two hydrostatic switches are used to detect a high and low level.Ladder Logic for TankLogic for Ladder SolutionHow does it work?Example: Traffic Lights Cycle timeStreet Red Yellow GreenMain 3 1 4Jefferson 5 1 2 Main streetJefferson street WIRING DIAGRAM 64ProgrammableController6566677071 input outputJefferson RedJefferson YellowJefferson GreenMain GreenMain YellowMain RedPROGRAM (1)RUNG1RUNG2RUNG3RUNG4RUNG5RUNG6RUNG7RUNG8RUNG9RUNG10RUNG11RUNG12 20903809023040 6766901 902901 903902 904904 905901 90471901 903901 902901 901 RTORTO901RTO67 M. Red66 J. Green71 M. Green70 M. YellowRSTRSTRTO904RSTRST ProgramRUNG13 649026590370 RTO907 501010 RTO906RTO90590665 J. Yellow64907J. Red901 907 RSTRST901 906RUNG14 901 905 RSTRUNG15RUNG16RUNG17RUNG18RUNG19RUNG 20https://www.youtube.com/watch?v=fn3KWM1kuAw!How Boston Dynamics TaughtIts Robots to DanceActivityhttps://www.youtube.com/watch?v=zsajTNtxfAEhttps://www.youtube.com/watch?v=CM6DntkoYyQWatch the following Video and Create you own PLCprogram for an application of your choice (try simpleapplication)Thank YouA. Chebbo