Automation & Control

The Process
Any process consist of :-
(1) Application
(2) Control System

feedback
Application Control System
(Operative Part) (Action Coordinator)

control command
 Automation Objectives

Reducing cost
Directly Improving quality

Improving working
Indirectly condition
 Automatic Control

Control System is divided into

Input processing Output

Processing section has the task to produce

predetermined responses (in the form of outputs) as a
result of information by the input signal measurements
 Inputs
Input signals are provided by transducers / detectors that
convert physical quantities into electrical signals. Depending on
transducer used, the information detected can discontinues (binary)
or continuous (analog) representation of the input quantity
Transducers Measured Quantity Output Quantity
Switch Movement / Position Binary Voltage
Limit Switch Movement / Position Binary Voltage
Thermostat Temperature Varying Voltage
Thermocouple Temperature Varying Voltage
Thermistor Temperature Varying Resistance
Strain Gauge Pressure / Movement Varying Resistance
Photo Cell Light Varying Voltage
Proximity Cell Presence of Objects Varying Resistance
 Outputs
Output devices (like relays, pumps, motors..) are tools used by a
control system to alter certain key element or quantities within the
process.they are also transducers but contrary signals from the control
system into other necessary. There are also discontinuous (binary) or
continuous (analog) devices
Output device Quantity Produced Input
Motor Rational motion Electrical
Pump Rational motion + product Electrical
displacement
Piston Linear motion / pressure Hydraulic / pneumatic
Solenoid Linear motion / pressure Electrical
Heater Heat Electrical
Valve Orifice variation Electrical/Hydraulic/pneumatic
Relay Elec. Switching / limited Electrical
physical movement
 Processing Section
This corresponds to the operations required to keep process
“in control” in conjunction obtained from input readings, producing
resultant output action.input causes output action due to a control
plan which can either hardwired or programmable

System Type Hard program

Relay Digital
Electrical logic Digital
Pneumatic logic Digital
Analog logic Digital
Computers Digital/analog
plcs
PLCs Digital
 Digital Systems
Discontinuous or on / off control is most common system, since
many machines and processes consist of units controlled by a larger
number of simple operation or sequence steps

Switched input valve open

Binary control
Switched output
system
valve closed

Many devices produce or respond to digital signals,where there

are only one of tow conditions
 Analog Systems

Continuous or analog control is related to the varying

quantities such as temperature, speed, … change gradually and
continuously across an infinite of values.

Sensed signal elec. signal Analog elec. signal controlled device

Control
System
 Control Strategies
Open Loop Requirements
Control
Action
Plant
Outcome
plan system

Disturbance

Feedforward Requirements Action Outcome

Control Plant
plan system
Modification to plan taking
account of disturbance Disturbance
Measurements
of disturbances
Closed Loop
Feedback
Measured
value Deviation
Requirements (error signal) Control Action Plant Measurement
Compare plan system
(set point) outcome

Disturbance
 PID Controller Structure
Comparator
Set error Proportional
point term
Summing
junction
Integral PID
Measured
term output
value

Derivative
MV term
MV=SP MV=SP
SP

Disturbance causes changes in MV

 Industrial Processes
Continuous Batch Discrete

I/P is introduced and A batch process uses in this type of process

runs continuously a set quantity of I/P an individual item
producing an O/P material & performs under goes various
process may run for process operations on operations before
long period of time this material being produced in a
typically minutes .producing a specific final form alternatively,
hours or event weeks. quantity of finished several components
(e.g steel sheet O/P product that will may be combined
Production) undergo further stages Within the process. to
of processing. (e.g emerge as one unit
food&beverage
production )
 Relay Control
☺Group of relays with large number of contacts .
☺space required .
☺Fixed application,
☺Simple control tasks.
☺Difficult expansion and/ or modification.
☺ Slow action.

Relays continue to be used as output device

another types of control systems, being ideal for the
But! conversion of small signals to higher current /
voltage driving signal
 Electronic Control
Linear integrated circuits
Handie analog signals.
Important component”op-amp”.
Involve complex math (differentiation,integration,…).
Bases of loop controls.
Limited fine tuning of feedback systems.

Digital integrated circuits

Deal exclusively with binary signals.
Process information through logic gates.
Various logic families (CMOS, TTL, …).
Logic symbols & Boolean algebra…design&analysis.
Large ICs with enormous number of gates.
Heard of microprocessors.
 Sequential Control
basis of computer operation.
digital systems that have outputs dependent on previous system
state

Combinational Logic

Storage Device
Programmable Computing Control
Systems

Data memory

Input Data Firmware Output Data

Program
Programmable logic
control
PLC a Process Control Computer
System

Key Board Monitor

Data Processing
Light Pen Printer
Computer System
Mouse Plotter

Motion Sensor Motor

Sound Sensor Process Control Solenoid
Heat Sensor Computer System Heater
Light Sensor Light
Definition & Advantages
A PLC is user-friendly, microprocessor-based, specialized
computer that carries out control schemes of many types and levels of
complexity. It can be programmed, controlled and operated by person
unskilled in computers

•rugged-noise
•rugged-noiseimmune
immuneequipment
equipment
•modular-easy
•modular-easyinstallation/replacement
installation/replacement
•standard
•standardI/O
I/Oconnections
connections&&signal
signallevels
levels
•simple
•simpleprogramming.
programming.
•compact
•compactsizes.
sizes.
•cost
•costcompetitive
competitive
Comparison with Other Control Systems
C\Cs Relay systems Computers PLC systems
Price Per Function Fairly Low High Low

Physical Size Bulky Fairly Compact Very Compact

Operating Speed Slow Fairly Fast Fast

Noise Immunity Excellent Fairly Good Good

Installation Time Consuming in Time Consuming Easy in All
All Phases in Programming Phases

Complex Operation None Yes Yes

Ease of Changes Very Difficult Quite Simple Very Simple

Easy of Maintenance Poor-large No. Poor-several Good-few

Of Contacts Custom Boards Standard Cards
Structure

Programmable controller Process

Programming Program Input Input

panel memory circuits devices
Control
unit
Work Output Output
memory circuits devices

Power supply
Central Processing Unit
“CPU”(1)
KThe CPU controls and supervises all operation within PLC,
carrying out programmed instructions stored in the memory.
KAn internal communications highway or bus system carries
information to and from CPU, memory and I/O units, under
CPU control.
KThe CPU is supplied with a clock frequency by a quartz crystal
or RC oscillator with speed depending on the microprocessor
type.
KThe clock determines the operating speed of the PLC and
provides timing/synchronization of all system elements.
Central Processing Unit
“CPU”(2)

ROM with fixed operating

system program

Control unit ALU Registers

Control Section

Analysis

I/P scan Logic scan O/P scan Interface with

Peripherals
block program block other CPUs

I/P Modules O/P Modules

Central processing unit
“CPU” (3)
B
u
f Address Bus
f
e
r Control Bus

B
a C
Optional tt l
User Program µp System Data I/O
Program e o
RAM CPU ROM RAM Unit
Storage r c
y k

Buffer Data Bus

System memory
Can be subdivided into two types :
Executive Memory and Scratchpad Memory.
Executive memory contains the executive operating system .Such
system is provided by PLC manufacturer and rarely changed, so it
is loaded on a PROM.
It provides the translation between the high level programming
language and the binary machine language,scans PLC to update
system status and reads inputs and updates outputs.
During administration of these functions, the executive often
needs an area of memory to store data temporarily: the memory is
called Scratchpad Memory, it is a RAM which is not accessible by
the user
I/O Status Memory

RIt is a portion of RAM dedicated for storage of

current I/O status.
RAs the executive program requires I/O status update,
the I/O status memory can be considered as part of
system memory
Application Memory

H Itcan be subdivided into two types :

Data memory & User memory.
H Data memory holds generally the preset values (like
timers,…).
H User memory is the most accessible by the user where all
program sequence and specific functions are handled. It is
scanned by CPU for instructions when it is directed for
scan by the executive.
I/O scanning
Output Scan Input Scan

Program Scan

INPUT OUTPUT
T T
E E
R R
M Input User Input M
I status table program status table I
N N
A A
L L
S S

Input Scan Program Scan Output Scan

Output terminals are read During program scan data in I/P Data associated with O/P
and input status table is table is applied to user program, status table is transferred
updated accordingly. program is executed and O/P to O/P terminal.
table is updated accordingly.
Power Supply
•PLCs internal circuitry operates at +/-5V DC.
•Whether the available supply is AC or DC, a power supply
is required to condition, regulate, ... this supply to the
adequate need of the circuitry.

~ Rectifier Filter Regulator protection

Discrete Input

Opto-isolator
converter
Terminal 1

Input
(switch,
sensor,…) CPU

common

Input module point

Discrete Output

Load
Terminal 1 Input logic Opto-isolator Converter

Trigger control

CPU

Output module point

Analog I/O

I/P signal transducer I/P module A/D converter CPU

1.1A 100% 10V 256
0A 0% 0V 0

Analog Input

CPU D/A converter O/P module transducer O/P signal

256 20mA 100% +50V

0 4mA 0% -50V

Analog Output
I/O Modules

™ PLCs operate at 5V DC to 15V DC, whilst process signals

can be much greater or of different levels.
™ The I/O units from the interface between the
microelectronics of PLC and the real world outside.
™ These units provide all necessary signal conditioning and
isolation functions.
™ I/O modules are available (Digital, analog) with all different
process signals which allow PLC to be directly connected to
process.
Special Modules

4 These modules are intelligent ones which perform certain

tasks independent of the CPU.
4 The use of such modules in process control is Known as
distributed processing.
4 Such modules are dedicated computers that perform preset
calculations on data received from detectors or other devices
connected to it.
4 PLC CPU is thus freed to handle larger control functions.
Housing

H Small PLCs are build of individual printed circuit cards

within single compact unit
H small PLCs are constructed modular basis with function
modules slotted into the back plane connectors of the
mounting rack
H modular systems housing or mounting racks are equipped
with buses to exchange all information required to run the
system: data, control, address,….
Communication - Point to Point

Links: Links:
•PLC w/ programming terminal. •PLC w/ other PLC.
•PLC w/ Man Machine Interface. •PLC w/ any intelligent device.
Communication - Networking

Peer to Peer
Remote I/O
Master/slave
Programming Equipment

H Allowing writing, editing and monitoring a program as well

as performing various diagnostic procedures.
H Three types of programming tools are in common use:
1. Hand held programmer
2. Portable programming terminal
3. S/W to run on PC
H the third type is commonly used and have larger
capabilities.
Programming
Languages
IEC 1131

•1979 :The International Electromechanical Commission assigned the

research committee 65A to define a PLC standard.
•Objective :to meet the increasing complexity requirements of control
and monitoring systems and the large number of PLCs which are
incompatible with each other.
•Its contents :
– IEC1131-1 :General information (1992).
– IEC1131-2 :Specifications & equipment testing (1992).
– IEC1131-3 : Programming languages (1993)
– IEC1131-4 : Recommendation to the user.
– IEC1131-5 :Message handling functions specifications.
IEC 1131-3
This standard describes:-

• Instruction list IL
Two textual languages
• structured Text ST

• Ladder Diagram LD
Two graphic languages
• Function Block FB

A graphic chart • Sequential Fn. Chart SFC

Instruction List (IL)

Series of instructions, each one must start on a new line.

One instruction = operator + one or more operations
separated by commas.
Function Blocks lunched using a special operator.

Label Operator Operation Comment

Run: LD %IX1 (*pushbutton*)
ANDN %MX5
ST %QX2 (*run*)
Structured Text (ST)
Syntax similar to that of Pascal enabling a description of
complex algorithmic structure
succession of statements for assigning variables, controlling
functions and function blocks, using operators, repetition,
conditional executions.
Function blocks launched using a special operator.

J:=1
WHILE J<=100 & X1<>X2DO
J:=J+2
END_WHILE
Ladder Diagram (LD)
Graphic elements organized in networks connected by
power supply rails.
Elements used :contacts, coil, functions, function blocks
control elements (jump, return, etc.)

Start 1 Start 2 run

Start 3
Function Block Diagram (FBD)
Representation of functions by blocks linked to each other.
Network evaluation :from the O/P of a function block to the
I/P of the connected function block.

auto >=1
& run
start

manu &
cmd
Sequential Function Chart (SFC)
To describe sequential control function.
steps & transitions represented graphically by a block or
literally.
Transition conditions in LD, FBD, IL or ST languages.
Actions associated with the steps :Boolean variables or a section
of the program written in one of the five languages.
Association between action and steps in graphical or literal
form.
VA1
NOT_FILL
FILL SILO_VALVE
READY
LD Language - Graphic Elements

N/O contact
N/C contact
Rising edge detection p
N
falling edge detection
Direct coil
Inverse coil
Set coil s
Reset coil R
LD Language - Rung Structure
X columns
Test zone Action zone

Y lines
How a Ladder Rung is Executed
Connected network = independent equation

%M0 %M1 %T1.D Connected

network 1

%M2 %T1

Connected
network 2

%M0 %M5

Connected
%M12 %M3 network 3

A network is executed from connected network, and within a connected

network, in the direction of the equation: from top to bottom, line by
line, and in each line from left to right
How a Ladder Rung is Executed
Example
%M0 %M2 %M10

%M1 %M10 %M13

%I1.2 %MW2:X0

%M11

%M12

First coil evaluation (%M10)

Second coil Evaluation (%M13)
Third coil evaluation (%MW2:X0)
I/P Addressing
Each input or output is assigned a number on its module, which is
referenced to within the program which is refereed to as “address”.
I/P#1 physically O/P#1 physically
%I0.0 %Q0.0
common T1 ∼ common T1 ∼
I/P#1 T2 O/P#1 T2
I/P#2 T3 O/P#2 T3 R
I/P#3 T4 O/P#3 T4 L
I/P#4 T5 O/P#4 T5 M
Gnd T6 neutral T6

Group of I/Ps on Group of O/Ps on

an AC I/P module an AC I/P module
Ladder Logic Vs Conventional Control

L1 L2 start
3 L1 L2 L3
4
M 3 aux
L1
4 T1 T2 T3
M-aux. stop

common common
%I0.1 %I0.2 %Q0.1
I/P#1 P O/P#1 M
I/P#2 L O/P#2
I/P#3 C O/P#3
%Q0.1
I/P#4 O/P#4
Registers
Register is a storage of individual bits.
Data other than simple two state binary can be handled in and out
by registers.

1/0

1 0 1 1 0 1 0 1

1 1
0 0
Data in 1 1 Data out
0 0
1 1
Timers
On
OF DELA
FD Y.
lim E
ited LAY
“on ON .
Mu e shot TIM
l ” E
Ind tiple o oper .
NPLC TIMER u
Dig strial n dela tion.
a
ital ti y.
Nprogrammable variable Ele ,
ctro Solid ers.
m
time as well as fixed etc… nic stat
…… time e.
time with large time . rs.
span
Time Charts
%TMi
IN Q IN

TYPE TON Q
TB I min
ADJ Y PV
%TMi.P 9999 CV

%TMi
IN Q IN

TYPE TOF Q
TB I min
PV
ADJ Y
%TMi.P 9999 CV

%TMi
IN Q IN

TYPE TTP Q
TB I min
ADJ Y
PV
%TMi.P 9999 CV
Counters

Count x
Reset
Pv
Cv
O/P
Up Counter
Up/Down Counters

%C8 Up
R E Down
S Reset
C.P:9999 D
CU
Modify:Y PV
CD F CV
O/P
Arithmetic Functions
Add & Subtract

Operands

%I1.1
%MW0:=%MW9+100

%I1.1
%MW0:=%MW9-100

OPERAND: a register containing a numerical value used in an arithmetic operation as

an input
Multiply & Divide
%I1.1
%MW0:=%MW9*100

%I1.1
%MW0:=%MW9/100

Square Root
%I1.1
%MW0:=SQRT(%MW9)
Comparison Instructions
%Q0.1

%MW20 > 100

G> Greater Than
G >= Greater Than or Equal
%M 0 %Q0.2
G< Less Than
%MW10< %MW35
G <= Less Than or Equal
G= Equal
G <> Different From %M 1 %Q0.3

%MW30>= %MW40
 Jump Instructions

%M8 %L20 %L10

%L20 %L10
%M20 %Q0.1 %M20 %Q0.1
 Data Move

%MW1 %MW11

%MW2 %MW22

%MWx %MWy
%MW1 1st
%MW2
%MW3 2nd %MW9
%MW4
%MW5 3rd

%MW1
1st %MW2
%MW9 2nd %MW3
3rd %MW4
%MW5
Bit Operations
Permanently change to ‘1’
when %M20 is on
%I0.1 %MW20
0 1 1 1 1 0 0 0 0 1 0 1 0 0 0 1
Bit set
Permanently change to ‘0’
when %M30 is on
%I0.4 %MW30
0 1 1 1 1 0 0 0 0 1 0 1 0 0 0 1
Bit clear
Bit Operations - Bit Follow

%I0.1 %MW4 0

“ 0 ” when %MW40 is on
“ 1 ” when %MW40 is off

0 1 1 1 1 0 0 0 0 1 0 1 0 0 0 1
Shift Register

Coil status Coil status

Out Out

In In

Shift Left Shift Right

Shift Register - Rotate Full

Coil status Coil status

Out Out

Reenter Reenter

Rotate Left Rotate Right

Shift Register-Rotate Partial

Coil status Coil status

Out Out

Reenter Reenter

Rotate Left Rotate Right

Shift Register - Multi - bit

Coil status Coil status

Out N bits per step N bits per step Out

N bits per step In In N bits per step

Shift Left Shift Right

E/M Drum Sequencer

Electromechanical Up
Left Handle End Right
drum controller is a 3
position / 6 terminal Forward Off Reverse
device it is an
economical control
device for handling
applications with a
fixed sequence and a
limited number of
required contacts
PLC Sequencer
PLC sequencer operates on a similar
a principle to an electromechanical drum
controller, which changes step according
to external events. On each step, the high
point of a cam gives a command which is
executed by the control system. In the
case of a drum controller (PLC
sequencer), these high points are
symbolized by state 1 for each step and
are assigned to output bits or internal bits,
known as control bits.
Operating Diagram

I/P U:

I/P R:

STEP 0 1 2 3 N-1 0 1 0
#

O/P
Matrix Function
%I2.1 %MW40
%I2.1 %MW40

%I3.4
%I2.2 %MW41
%I2.2 %MW41

%I2.3 %MW42
%I3.5

%I9.1 %MW55
%I6.8 %MW60
%I8.4
 Advanced
Programming
Analog Operation

120 120
105
90
75
Volts 60
45
30
15
0 0
100% 100%
True Analog 8 steps
Examples:- Analog I/P / Analog or BCD
O/P 1024
O/P 20ma
M
o Analog
CPU d O/p
u device
10 v I/P l
M scale
0 e 4mA
o
Conversion BCD
I/P (if needed)
d value
u 9999
O/P
l Binary / BCD M
0v e o
BCD
value d
display
u
l
0 e
Examples:- 2 Analog In /2 Analog Out
+10 v I/P 1024 O/P 20ma
A M M
%MW28 o o Analog
Conversion
I/P (if needed)
d CPU d O/p
u u device
l %MW28 l
-10 v e 0 e 4mA
%MW17
I/P O/P 20ma
B M ADD M
%MW17 o o Analog
Conversion
I/P (if needed)
d Subtract d O/p
u u device
l l
e e 0mA
pt100
PID Principles

Proportional
Process
block
Variable

Error Integral Summing Controller

amplifier block amplifier output

Set point
Derivative
block
Ideal PID Control Curve

Desired final
position

Initial position
Time
Typical Process Control Curves
Position
120
(degree) Desired final
100 position
80
60 Initial position
Time
40
20 Desired final
position
0
1 2 3 4 5 6 7 8
Elapsed time in seconds Initial position
Time
Position
120
(degree) Desired final
100 position
80
60 Initial position
Time
40
Desired final
20 position
0
1 2 3 4 5 6 7 8
Elapsed time in seconds Initial position
Time
PID Example
Flow control tachometer
servo-motor
Hydraulic
Oil flow Oil out
Motor

Pump & Control panel

Oil in
Motor control device
control diagram
motor control
Motor
Control
Electronic controller
solid state devices
OP-Amps To other
rectifier processes
Incoming Set point
power PLC
Position Indicator with PID Control
Elec. Power to
rotate o/p device O/P device
Motion

Signal detector
Setting & Amplifier
Signal
difference O/P position
(If any) indicator
Dial Error detector

Elec. signal Elec. signal

indicating input indicating output
position position