This document discusses planning and implementing automation systems. It begins by outlining the need for automation in terms of productivity, accuracy, cost savings and safety. It then provides examples of simple automation systems using sensors, actuators and controllers. The document describes designing automation systems, including conceptual design, detail design, component selection, interfaces and programming. Finally, it discusses implementing automation by installing equipment, testing the system and programming controllers, noting different controller types like PLCs, pneumatic controllers and computer control.

1. PLANNING AND
IMPLEMETATION OF
AUTOMATION
By
Dr. Palitha Dassanayake

2. Content
 Need for automation
 Simple automation system
 Designing automation systems
 Implementation of automation system

3. Need for automation
Why do we automate
1. Productivity improvement
2. Accuracy
3. Cost saving
4. Safety of the employees

4. Automated System
Sensors and
Switches
Motors and
Actuators
Controller
Signal Conditioning
Signal Conditioning

5. Example
A1
Is
C1
C2
Fig:Two views of the system
Is-Inductive
sensor
A1-Pneumatic Actuator
C1-Collector
C2-Collector
Gear
Box
motor-m
item
Os-Optical sensor
A0
A0

6. 1. When Os detects an item, it should be pushed by A0 and conveyor
should start moving
2. If the item is metal, it has to be identified by Is.
3. Metal items are to be pushed by A1 and collected in C1.
4. Non-metal items are to be collected at the end of the belt to C2
5. If an item is in process, even if Os detects an item, it should not be
pushed by A1 until the previous item is fully processed.

7. Start -No item Os=0
Os=1 A0 should be ejected provided no other item is in process
If the item is metal, it is sensed by Is.
If Is=1 item is metal, this should be remembered
If Is had been 1 it has to pushed by A1 after a time interval
If the item is not metal, it should not be pushed and collected at
the end. The time required to travel is also required.

8. Sorting System I
Logo
Operating
Voltage –24 v
I s-
A1
C
C
Gear
Box
m
Os
I1
I2
PLC inputs
?
PLC outputs
Q1
Q2
A0
Q3
?

9. Sorting System II
Amplifier
Electro-pneumatic
valve
PLC S7-200
Operating
Voltage –24 v
I0.1
I0.0
Q0.0
Q0.1
I s-
C
C2
Gear
Box
m
Os
If output the sensor
is in mv
A/C motor
RelayA0
Q0.2
Electro-pneumatic
valve
A1

10. Design your automation
what do we automate
1. What functions or what sections are
to be automated
2. Partially, semi-automate, fully automate

11. Design your automation
Contd.
How to automate
1. Conceptual design
2. Detail design

12. Packing machines

13. Current orientation of
cups
Blow
Two options
1. Take it without blowing
2. Re-orient it after blowing

14. Conceptual Design
Do we need to use the same mechanism used in the manual methods ?
Orienting Cups

15. Milk Packet Machine

16. Detail Design
 Component Selection
 Interfaces and Connections between
sensors, instruments, controllers, motors
and actuators
 Automating, controlling and communication
requirement
(The main function)
 Safety requirements and interrupts
 Maintainability
 Cost and productivity analysis Objective

17. Component Selection
 Select sensors, signal conditioning,
motors, actuators
 Selection of the controller
Note – The selection should match the
objectives of automation

18. Interfaces and
connections
 The can be communicated via design
drawings.
1. Mechanical Flow diagram
2. ICM (Instrumentation, Control and
Monitoring ) flow diagram based on
mechanical flow diagram
3. Mechanical component diagram
4. Electrical component diagram
5. Electrical wiring diagram and wire cabinets
6. Communication network diagrams

19. Automating Controlling
The main requirement is documented.
Different approaches are used.
Written documents
UML (Unified modeling Language)
approach

20. Implementation of
automation system
 Installation of systems
1. Mechanical
2. Electrical/Communications
3. Instruments
4. Wiring
 Testing the system for basic working
conditions
 Programming the controllers according to
the detail design requirements

21. Programming Methods
Programming method depends on the
type of the controller and the selection
of the programming language
Types of Controllers

22. Type of Controllers
 Pneumatic controllers
 Fixed Electronic controllers
 Electro-mechanical relay types
 PLC
 Computer Control
 Embedded Controllers
 PAC
 Integrated controllers

23. Fixed Controllers
1. Electronic controllers or cards
2. Electro-mechanical controllers
3. Pneumatic controllers
The above mentioned controllers cannot change the
controlling system without changing the hardware
of the control system
The other types, can program the controller using
software so that one can change the way it is controlled
without changing hardware

24. PLC- Programmable Logic Controllers
Small Level
Medium Level
Advanced Level
Programming Languages
1. Ladder
2. Functional Block diagrams
3. Statement Lists
4. Structured text
5. Sequential functional charts

25. Data bus
Address bus
Control bus
CPU
clock
Memory
Input/
Output
unit
Program
panel
Input
channels
Output
channels
Architecture of a Programmable Logic Controller

26. Siemens S7-PLC
Programmable Logic Controllers (PLC)

27. Industrial
PLC

28. CNC Milling Machine
Main program is written using a PLC
Pneumatic actuators and Valves are used
Servo Motors are used for processing

29. Pneumatic Controllers
0.1 On/off valve with the filter
1.0 Double Acting Cylinder
1.1 5/2 way double pilot valve
1.2 3/2 way, push button
1.3 3/2 way roller lever valve
1.4 3/2 way, push button
1.6 shuttle valve (or)

30. Electro-mechanical Controllers
Relays and Contactors
Basic Relay
1 2 3
4 5
Coil
Supply
input outputs
No Supply
1-3 gets connected
1-2 no connection
With Supply
1-2 gets connected
1-3 no connection
Normally opened contact
1 2
Normally closed contact
1 3

31. Electro-Pneumatic Valve
1 2 3
4 5
Coil
Supply
Input pneumatic supply
outputs
No Electrical Supply
1-3 gets connected
1-2 no connection
With Electrical Supply
1-2 gets connected
1-3 no connection

32. Embedded Controllers
 Micro-controllers
 Complex Programmable Logic Device
 Field Programmable Gate Array

33. S1
S2
A1
M1
Computer Control
Serial Port
Parallel Port
USB port

34. Computer Control
Use the computer as the main controller
Programming Languages
1. C, C++ or C#
2. Visual Basic
Programming port
1. Parallel port
2. Serial port
3. USB port
For serial port and USB port the other end should support such
requirements and protocols or such a system has to be designed
and interfaced with an embedded controller

35. END