Lecture 1 Introduction
Lecture 1 Introduction
Lecture 1 Introduction
INDUSTRIAL CONTROL
Lecture 1: Introduction
Emergency
Evacuation
Emergency
Evacuation
Procedure Procedure
Teaching Staff
Lecturer:
E-mail:
Dr Octavian Bass
[email protected]
JO 5.216
Dr Gary Allwood
[email protected]
5
Class Times
Lecture1
Laboratory2
Day
Monday
Tuesday
Wednesday
Time
15:30 17:30
08:30 11:00
11:30 14:00
14:30 17:00
08:30 11:00
11:30 14:00
Room
JO 21.202
JO 23.223
You must have received the email below from CIH. Please respond to it if you are
concerned. Send me an email if you cannot remember your lab mark.
Dear students,
If you are repeating a unit this semester and you passed the lab component of the
same unit in semester 2 of last year then be advised that you can opt to be exempted
from completing the labs this year. If you wish to go ahead with this exemption from
the lab component then please reply to this email indicating the unit code and
title of the unit or units for which you wish this lab exemption to apply. This will
result in you being moved into a dummy lab session timetabled on the weekend,
you will not need to attend at this time, this is just to overcome the fact that the
system requires you to be enrolled into a lab activity in order to confirm your
enrolment in the unit. Your lab marks from your previous attempt will be carried
forward to this semester. Note that if you completed the lab component more than
one year ago then you will not be able to apply for this exemption and will need to
repeat the labs.
If you previously passed the lab component, but wish to repeat the labs this semester
then you do not need to do anything.
Regards,
Course Information Hub on behalf of Dr Alex Rassau, Associate Dean Teaching 7&
Learning, School of Engineering
Resources
Pre-requisite units: Instrumentation and Measurement and Control Systems.
No prescribed textbook - teaching, training and technical reference materials
provided in class and on Blackboard; plenty of relevant online resources.
Website: http://blackboard.ecu.edu.au (Blackboard)
The primary on-line mode of communication. Please make sure you are
familiar with the unit site and you access it regularly for announcements,
along with your student email, which must be the only address used in
communication with the teaching staff.
Updated continuously with important information, including teaching
materials, announcements, assignments and various resources. The main
unit content including undergraduate lecture slides and lab handouts will be
accessible from the Unit Materials link. Assignments will be available under
Assessments.
First Blackboard announcement asked you to study the Professional
Competencies and the Unit Plan under the Unit Overview link.
Professional Competencies
Assessment
Component
Laboratory work
Project
End-of-semester examination
Weighting
25%
25%
50%
Assessment (cont.)
Laboratory work: There will be five hardware-based practical laboratory
exercises for this unit. Their objective is to put into practice the knowledge
gained from the lectures. The practical sessions require preparation by
studying the lecture materials, active participation and completion of a test at
the end of the session. The report and test will contribute equally to the lab
mark.
Project: The objective of the project is to combine all the learning from the
previous lab sessions in order to design and implement an automation
project. The project must be completed and presented both in class and in
writing.
Exam (Invigilated): One, three-hour exam, at the end of the course, will
cover all aspects of the unit. The primary emphasis will be to test if the
student has an understanding of the material outlined in this unit, is able to
articulate this understanding and is able to apply this knowledge to solve
engineering problems.
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Assessment (cont.)
Marking criteria: The criteria by which each piece of assessment will be
evaluated will be presented and discussed at the presentation of the
assignment or test.
Two main skills you are supposed to develop:
Creative thinking,
Critical thinking.
Please have realistic expectations:
If your work shows only simple reproduction of techniques and solutions
presented and contains no errors, you can expect a minimum passing
grade.
To get more credit, your work should indicate high-level analysis and/or
critical and/or creative thinking.
UTEI comment: No compromises, you either study and pass, or you
fail. Non-academic criteria cannot influence the marking.
12
Collaboration Policy:
Discussion Encouraged, Sharing Not Permitted!
We encourage you to discuss assignments in this unit with other
students and with the teaching staff to better understand the
concepts. However, when you submit an assessment under your
name, I assume that you are certifying that the details are
entirely your own work and that you played at least a substantial
role in the conception stage. You should not use results from
other students (from this year or from previous years) in
preparing your solutions. You should not take credit for computer
code or graphics that were generated by other students.
Students should never share their solutions with other students.
Any student caught plagiarizing will be reported to the Head of
School.
15
Academic Misconduct
Edith Cowan University regards academic misconduct of any form as
unacceptable! Any detected case of any academic misconduct will be
treated very seriously. In accordance with the University Rules these
cases will be reported to the Head of School.
See: http://www.ecu.edu.au/GPPS/governance_services/uni_rules.html
Academic Misconduct means any conduct by a student in relation to
academic work that is dishonest or unfair and includes, but is not limited to:
a) plagiarism;
b) unauthorised collaboration;
c) cheating in assessment; and/or
d) theft of another students work;
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ECU Values
Integrity
Rational Inquiry
Respect
Personal Excellence
18
Automation:
Control:
Managed or regulated
Definition:
Why Automation?
Process optimisation
Energy, material and time savings
Quality improvement and stabilisation
Reduction of waste, pollution control
Compliance with regulations and laws, product tracking
Increase availability, safety
Fast response to market
Connection to management and accounting
Acquisition of large number of Process Variables, data mining
Personal costs reduction
Simplify interface
Assist decision
Require data processing, displays, data base, expert systems
Human-Machine Interface (MMC = Man-Machine Communication)
Asset optimisation
Automation of engineering, commissioning and maintenance
Software configuration, back-up and versioning
Life-cycle control
Maintenance support
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Engineering Tools
Process
Water
Oil &
Gas
Energy
Power
Defense
Waste
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Automation Applications
Power generation: hydro, coal, gas, oil, shale, nuclear, wind, solar.
Transmission: electricity, gas, oil.
Distribution:
electricity, water.
Process:
paper, food, pharmaceutical, metal production
and processing, glass, cement, chemical,
refinery, oil &
gas, mining, desalination, waster
treatment.
Manufacturing: computer aided manufacturing (CIM), robots, flexible
fabrication, appliances, automotive, aircrafts.
Storage:
silos, elevator, harbour, retail houses, deposits,
luggage handling.
Building:
heat, ventilation, air conditioning (HVAC),
access control, fire, energy supply, tunnels,
parking lots,
highways, warehouses, airports
Transportation: rolling stock, street cars, suburban trains,
busses, trolley busses, cars, ships, airplanes,
rockets,
satellites, traffic control, harbours
etc.:
practically all industries and activity fields...
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Mechanical
Engineering
Process
Engineering
Electrical
Engineering
Industrial
Control
I.T.
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Manufacturing process
Finished Product
Manufacturing requires:
Energy, Manpower and Infrastructure
25
Economic Process
26
Price
Demand
Quality
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Cost/unit
Materials
Production Volume
Production Material
Idle Time Quality
Time
Handling Time
Assurance Time
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Increased production
More effective use of infrastructure
More efficient on energy and pollution
Reduction of manpower
More effective use of materials
Better quality control and standard
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Economy of Scope
31
Production Systems
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Automation systems
Fixed
Programmable
Flexible
Integrated
33
Enabling Technologies
35
spinal cord
data networks
field buses
neurons
muscles
organs
skeleton
Automation =
the neural system
36
Hierarchical View
File
Edit
23
4
33
12
2
Engineering
vertical Comm.
SCADA level
Operator
horizontal
Control level
communication
Control Bus (Ethernet)
programmable
controllers
direct I/O
Field level
Sensor-Actuators bus (ASI..)
transducers / actuators
microPLCs
Fieldbus
SCADA
SCADA refers to the combination of telemetry and data
acquisition.
SCADA encompasses the collecting of the information,
transferring it back to the central site, carrying out any
necessary analysis and control and then displaying that
information on a number of operator screens or displays.
The required control actions are then conveyed back to the
process.
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PLCs
Programmable Logic Controllers (PLC) represent state-of-the-art specialized
microprocessor-based electronics that make up technologically advanced
control systems with applications in virtually every segment of industry
where automation is required.
Used for discrete control of machines and manufacturing processes.
Most of the inputs and outputs for discrete control are binary, meaning they
have only two states: on and off, like a switch. Little processing power is
needed for computing on/off signals so PLC tend to be very fast and are
used in machine tool and other industries.
Offer standard hardware solution.
Very economically priced.
They have revolutionized control engineering!
40
DCSs
DCS (Distributed Control System) are designed to control processes,
not discrete operations.
As such, a large number of the inputs and outputs are analog like a
4-20mA signal or 0-10V signal. These signals generally represent
temperature, flow, pressure, pH, conductivity or some other process
variable.
Complex algorithms are programmed into the DCS to provide
accurate control of processes like food and medicine manufacturing.
Speed isn't as critical as it is with the PLCs but accuracy and
complexity is.
41
ERP
(Enterprise Resource
Planning)
MES
(Manufacturing
Execution System)
Execution
Level
SCADA
(Supervisory Control
and Data Acquisition)
Supervisory
Level
DCS
(Distributed
Control System)
Control
Level
PLC
(Programmable
Logic Controller)
ms
seconds
hours
days
weeks
month
years
43
Reaction Speed
ERP
months
MES
days
Command level
Supervision
Group Control
Individual Control
Field
minutes
seconds
0.1s
0.1s
Site
44
man-machine
communication
operator
history
logging
process
database
simulation
instructor
maintenance
engineer
actualization
process data
plant
46
Syllabus
The semester schedule provides a tentative guideline on the topics covered each week.
This information may be updated and amended during the semester. To ensure you
have the correct schedule, please check the announcements on Blackboard and on your
student email.
Week
Dates
Topic/s
Lab exercises
Assignment due
Introduction
1, 2, 3 August
PLC Programming
Lab 1
Lab 1
8, 9, 10 August
SCADA Systems
Lab 2
Lab 2
HMI
Lab 3
Lab 3
Ladder Programming
Lab 4
Lab 4
Ladder Logic
Lab 5
Lab 5
5, 6, 7 September
Project
Ladder Design
Project
Project
No
teaching
Break
10
3, 4, 5 October
Field Devices
Project
11
Project
12
Project
13
25, 26 October
activities
Project
48
49
Microprocessor-Controlled Systems
Instead of hardwiring each control circuit for each control situation,
we can use the same basic system for all situations if we use a
microprocessor-based system and write a program to instruct the
microprocessor how to react to each input signal from, say, switches
and give the required outputs to, say, motors and valves.
52
Flexible
Less expensive
53
Simplicity
Eliminates much of the hard wiring that was associated with conventional
relay control circuits
54
Reliability
Once a program has been written and tested it can be downloaded to
other PLCs.
55
Flexibility
Original equipment manufacturers (OEMs) can provide system updates for
a process by simply sending out a new program.
It is easier to create
and change a
program in a PLC
than to wire and
rewire a circuit.
End-users can
modify the program
in the field.
56
Cost
Originally PLCs were designed to replace relay control logic. The cost
savings using PLCs have been so significant that relay control is
becoming obsolete, except for power applications.
Generally, if an application
requires more than about 6
control relays, it will usually
be less expensive to install
a PLC.
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Communications
A PLC can communicate with other controllers or computer equipment.
Response Time
PLCs operate in real-time which means that an event taking place in the
field will result in an operation or output taking place.
Troubleshooting
PLCs have resident diagnostic and override functions allowing users to
easily trace and correct software and hardware problems.
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Components of a PLC
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Modular/Rack Design
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63
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Power Supply
Supplies DC power to other modules that
plug into the rack.
In large PLC systems, this power supply
does not normally supply power to the field
devices.
In small and micro PLC systems, the power
supply is also used to power field devices.
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67
Processor (CPU)
Is the brain of the PLC. Consists of a
microprocessor for implementing the logic and
controlling the communications among the modules.
Designed so the desired circuit can be entered in
logic form.
The processor accepts
input data from various
sensing devices,
executes the stored user
program, and sends
appropriate output
commands to control
devices.
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M340 Processors
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70
71
72
75
76
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Discrete Inputs
Discrete Outputs
A discrete output is an output that is either
on or off.
Solenoids, contactor coils, and lamps are
examples of actuator devices connected to
discrete outputs.
In this example, a lamp can be turned on or
off by the PLC output it is connected to.
A simple lamp circuit is useful to illustrate
discrete I/O control. For example, the lamp
is off when the switch is open and on when
the switch is closed.
To accomplish this task, a switch is wired to
an input terminal of the PLC and an
indicator light is wired to an output terminal:
Next week you will develop a simple
program that allows the toggle switch to
control the lamp
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80
Analog Inputs
An analog input is a continuous, variable signal.
Typical analog inputs may vary from 4 to 20mA, or 0 to
10V. Analog signals are used to represent changing
values such as speed, temperature, weight, and level.
In this example, a level transmitter monitors the level
of liquid in a tank. Depending on the level transmitter,
the signal to the PLC can either increase or decrease
as the level in the tank increases.
In order to process an input of this type, a PLC must
convert the analog signal into a digital representation.
This means that a module capable of converting the
analog signal into digital representation must be used.
The digital values are transferred to the PLC for use in
word locations.
The number of bits in the output from an analog-todigital converter determines the resolution, and hence
accuracy, that is possible.
Conversion from analog to digital takes time and, in
addition, the use of a multiplexer means that an
analog input card of a PLC only takes snapshot
samples of input signals. For most industrial systems,
signals from a plant rarely vary so fast that this
presents a problem. Conversion times are typically a
few milliseconds.
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Analog Outputs
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Communication Modules
I/O modules communicate with the
PLC CPU in one of 3 ways:
Backplane - The I/O modules can be
located in the same rack or station.
Communication then takes place
across the backplane or within the
rack.
Backplane extension modules allow
I/O modules to be located in racks or
stations which are separated from
the controller.
Device network - Modules can
communicate with a controller over a
network. Industrial networks are
used to interconnect field level
devices with controllers. Common
I/O networks are FieldBus, Profibus,
and DeviceNet. Note the NOC0401
communication module that acts as a
switch.
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Review Questions
1.
2.
3.
4.
input.
output.
17. Decide whether each of these statements is true (T) or false (F): A
transistor output channel from a PLC:
(i)