CHAPTER 1COMPANY PROFILE Wonder System is a dedicated team of Automation -Design (Hardware, Software & Systems) engineers, capable of, and committed to understand customer requirements, translate them to feasible design specification, develop performing solutions, validate, and help deploy to the end uses. Wonder system excellence in automation design services makes it a technology innovator and trusted partner for system engineering services. It provides intensive practical training. It believes in providing 50% theory and 50%practical.Wonder system is known for providing quality products which is effective in upgrading the knowledge and skills set of the student. Wonder system also provides exposure to the industrial environment to students and introduce to latest technology trends.Wonder Systems India, being system integrator for SSD Drives division of Parker Hannifin Corporation (formerly Eurotherm Drives), UK and Italy offers complete Engineering & cost effective solutions, covering Design Concepts, Assembly, Supply, Commissioning and Field services for various Industrial applications For the customers, it means: Shortened Time-To Market Cost Efficiency Certainty of Outcome Highest Quality 1.1 OBJECTIVE OF AUTOMATION TRAINING To train a new generation of skilled workers for service maintenance, programming operation of new range of machines and equipments being introduced for industrial and commercial use. To upgrade the skills of existing industrial workers through short term specialized courses in newly emerging Hi-Tech Area of industry. To provide diagnostic and development curriculum design and high live dialectic support for training system as well as industrial consultancy facilities.

1.2 PARTNERS BHARAT ISPAT UDYOG GIAN STEEL ROLLING MILLS GOLDEN STRIPS LTD ALLIED RECYCLING LTD KASHMIR STEELS LTD HIM ALLOYS LTD C.P. ROLLING MILLS PVT. LTD VIJAY STEEL LTD. 1.3 INTERNATIONAL PARTNERS STEEL MASTERS LTD, TANZANA GALAXY PROMOTERS, NIGERIA RAZAQUE STEEL, PAKISTAN ACCURATE STEEL MILLS,KENYA 1.4 APPLICATIONSWonder Systems India, being System Integrators for PARKER SSD Drives (formerly Eurotherm Drives), UK and SAEL, Italy offer complete Engineering & cost effective solutions, covering Design Concepts, Assembly, Supply, Commissioning and Field services for various Industrial applications. Hot Strip Mills TMT Mills Bar Mills Tube Mills Cold Rolling Mills PVC Extrusion mills Paper Mill Drawing mills Cable industries

CHAPTER 2INTRODUCTION TO AUTOMATION2.1 Definition Of AutomationIt is define as the replacement of muscular and mental efforts of human being by the use of hydraulic, pneumatic, electrical and electronics component or it is the use of machines, control system and information technologies to optimize productivity in the production of goods and delivery of services. Automation plays an increasingly important role in the world economy and in daily experience.

The dictionary defines automation as the technique of making an apparatus ,a process, or a system operate automatically.We define automation as the creation and application of technology to monitor and control the production and delivery of products and services.Using our definition, the automation profession includes everyone involved in the creation and application of technology to monitor and control the production and delivery of products and services; and the automation professional is any individual involved in the creation and application of technology to monitor and control the production and delivery of products and services. Automation provides benefits to virtually all of industry. Here are some examples: Manufacturing , including food and pharmaceutical, chemical and petroleum, pulp and paper Transportation , including automotive, aerospace, and rail Utilities , including water and wastewater, oil and gas, electric power, and telecommunications Defence Facility operations , including security, environmental control, energy management, safety, and other building automation and many othersAutomation crosses all functions within industry from installation, integration, and maintenance to design, procurement, and management. Automation even reaches into the marketing and sales functions of these industries.Automation involves a very broad range of technologies including robotics and expert systems,telemetry and communications, electro-optics, Cyber security, process measurement and control, sensors, wireless applications, systems integration, test measurement, and many, many more.2.2 Current Emphasis In Automation Currently, for manufacturing companies, the purpose of automation has shifted from increasing productivity and reducing costs, to broader issues, such as increasing quality and flexibility in the manufacturing process.

2.3 Need For Automation Economic advantage through increased Productivity. Reduced labour costs. Savings in supervision Reduction in operating cost. Improved accuracies with consistency of quality parameters. Safety concerns Automation of component handling for hazardous process. Elimination of human errors. Suitable for mass production with better material handling. Flexible with zero set-up change time.

2.4 Criteria For Automation Inaccessible areas of operation. Component handling difficult because of size. Process critical to quality of end product & calls for no manual intervention. Influence of process time i.e. Process time smaller than manual load / unload time. Enhancement of productivity and reduction in operator fatigue. Elimination of wrong loading Requirement of Fool proofing. Safety concerns, hazardous process.

2.5 Safety Issues Of Industrial Automation:-One safety issue with automation is that while it is often viewed as a way to minimize human error in a system, increasing the degree and levels of automation also increases the consequences of error. For example, The Three Mile Island nuclear event was largely due to over-reliance on "automated safety" systems. Unfortunately, in the event, the designers had never anticipated the actual failure mode which occurred, so both the "automated safety systems and their human overseers were inundated with vast amounts of largely irrelevant information. With automation we have machines designed by (fallible) people with high levels of expertise, which operate at speeds well beyond human ability to react, being operated by people with relatively more limited education (or other failings, as in the Bhopal disaster or Chernobyl disaster). Ultimately, with increasing levels of automation over ever larger domains of activities, when something goes wrong the consequences rapidly approach the catastrophic. This is true for all complex systems however, and one of the major goals of safety engineering for nuclear reactors, for example, is to make safety mechanisms as simple and as foolproof as possible (see safety engineering and passive safety).2.6 Automation Tools Different types of automation tools exist. ANN - Artificial neural network DCS - Distributed Control System HMI - Human Machine Interface LIMS - Laboratory Information Management System MES - Manufacturing Execution System PAC - Programmable automation controller PLC - Programmable Logic Controller SCADA - Supervisory Control and Data Acquisition 2.7 Advantages Of Automation Increased productivity Improved quality Improved robustness of product Economy improvement Time saving Reduce human efforts Low power consumption More accuracy

2.8 Limitation Of Automation Current technology is unable to automate all the desired tasks. As a process becomes increasingly automated, there is less and less labor to be saved or quality improvement to be gained. This is an example of both diminishing returns and the logistic function. Similar to the above, as more and more processes become automated, there are fewer remaining non-automated processes. This is an example of exhaustion of opportunities. Unemployment rate increases due to machines replacing humans and putting those humans out of their jobs. Technical Limitation: Current technology is unable to automate all the desired tasks Security Threats/Vulnerability: An automated system may have limited level of intelligence; hence it is most likely susceptible to commit error. Unpredictable development costs: The research and development cost of automating a process may exceed the cost saved by the automation itself. High initial cost: The automation of a new product or plant requires a huge initial investment in comparison with the unit cost of the product, although the cost of automation is spread in many product batches of things.

CHAPTER 3PROGRAMMABLE LOGIC CONTROLLER

3.1 IntroductionAutomation of many different processes, such as controlling machines, basic relay control, motion control, process control is done through the use of small computers called a programmable logic controller (PLC). This is actually a control device that consists of a programmable microprocessor, and is programmed using a specialized computer language. 3.2 What is PLCA Programmable Logic Controller, PLC, or Programmable Controller is anelectronic device used for Automation of industrial processes, such as control of machinery onfactory assemblylines. Aprogrammable controller is a digitally operating electronic apparatuswhich uses aprogrammable memory for the internal storage of instructions for implementingspecific functions,such as logic, sequencing, timing, counting and arithmetic, to control variousmachines or processes throughdigital or analoginput/output devices. Unlike general purposecomputers, the PLCis designed for multiple inputs and output arrangements, extendedtemperature ranges, immunityto electrical noise, and resistance to vibrations and impacts. Programs to control machine operation are typically stored in battery-backed or non-volatilememory. A PLC is an example of a real time system since output resultsare produced inresponse to input conditions within a bounded time, otherwise unintended operation results. A programmable logic controller (PLC) is a digital commuter used for automation of electro mechanical process. Such as control of machinery on factory assembly line, Amusement rides, Lighting fixture, Lifts, Ovens, Furness. DC MOTAR ACTUATOR, SOLENOID, ALARM, HEATING ELEMENTS etc. The switching voltage cans 12v, 24v, 110v, 240 voltages. In many case the PLC cannot switch on the device directly because of high current. PLC are used in many industries, it is designed for multiple inputs and output arrangement. A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or lighting fixtures. PLCs are used in many industries and machines, such as packaging and semiconductor machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory. A PLC is an example of a real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.A modern programmable logic controller is usually programmed in any one of several languages, ranging from ladder logic to Basic or C. Typically, the program is written in a development environment on a personal computer (PC), and then is downloaded onto the programmable logic controller directly through a cable connection. Programmable logic controllers contain a variable number of Input/output (I/O) ports the programmable logic controller circuitry monitors the status of multiple sensor inputs, which control output.

Fig.3.1 Programmable logic controller (PLC) A PLC is user friendly, microprocessor-based specialized computer that carries out control functions of many types and levels of complexity. Its purpose is to monitor crucial process parameters and adjust process A programmable logic controller (PLC) is a solid state device designed to perform logic functions previously accomplished by electromechanical relays. operations accordingly. The design of a PLC is similar to that of a computer. Basically, the PLC is an assembly of solid state digital logic elements designed to make logical decisions and provide outputs. Programmable logic controllers are used for the control and operation of manufacturing process equipment and machinery.3.3 PLC OriginThe PLC was invented in response to the needs of the American automotive manufacturing industry. Programmable controllers were initially adopted by the automotive industry where software revision replaced the re-wiring of hard-wired control panels when production models changed.Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was accomplished using hundreds or thousands of relays, cam timers, and drum sequencers and dedicated closed-loop controllers. The process for updating such facilities for the yearly model change-over was very time consuming and expensive, as the relay systems needed to be rewired by skilled electricians.In 1968 GM Hydramatic (the automatic transmission division of General Motors) issued a request for proposal for an electronic replacement for hard-wired relay systems.The winning proposal came from Bedford Associates of Bedford, Massachusetts. The first PLC, designated the 084 because it was Bedford Associates' eighty-fourth project, was the result. Bedford Associates started a new company dedicated to developing, manufacturing, selling, and servicing this new product: Modicon, which stood for Modular Digital Controller. One of the people who worked on that project was Dick Morley, who is considered to be the "father" of the PLC. The Modicon brand was sold in 1977 to Gould Electronics, and later acquired by German Company AEG and then by French Schneider Electric, the current owner.One of the very first 084 models built is now on display at Modicon's headquarters in North Andover, Massachusetts. It was presented to Modicon by GM, when the unit was retired after nearly twenty years of uninterrupted service. Modicon used the 84 moniker at the end of its product range until the 984 made its appearance.In short: Developed to replace relays in the late 1960s Costs dropped and became popular by 1980s Now used in many industrial designs

3.4 PLC History 12 K of memory and 1024 I/O points. The Hydramatic Division of the General Motors Corporation specified the design criteria for the first programmable controller in 1968 Their primary goal To eliminate the high costs associated with inflexible relay-controlled systems, The controller had to be designed in modular form, so that sub-assemblies could be removed easily for replacement or repair. The control system needed the capability to pass data collection to a central system. The system had to be reusable. The method used to program the controller had to be simple, so that it could be easily understood by plant personnel.

3.5 Programmable Controller Development 1968 Programmable concept developed 1969 Hardware CPU controller, with instructions, 1 K of memory and 128 I/O points . 1974 Use of several (multi) processors within a PLC - timers and counters;arthimetic operation. 1976 Remote input/output systems introduced 1977 Microprocessors - based PLC introduced 1980 Intelligent I/O modules developed Enhanced communications facilities 3.6 ProgrammingEarly PLCs, up to the mid-1980s, were programmed using proprietary programming panels or special-purpose programming terminals, which often had dedicated function keys representing the various logical elements of PLC programs. Programs were stored on cassette tape cartridges. Facilities for printing and documentation were very minimal due to lack of memory capacity. The very oldest PLCs used non-volatile magnetic core memory.

3.7 FunctionalityThe functionality of the PLC has evolved over the years to include sequential relay control, motion control, process control, distributed control systems and networking. The data handling, storage, processing power and communication capabilities of some modern PLCs are approximately equivalent to desktop computers. PLC-like programming combined with remote I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in certain applications.3.8 Architecture Of PLC

Fig 3.2 Architecture of PLC

Fig 3.3 Componenets of PLC3.8.1 Parts Of PLC Power Supply: PLC requires 24V switch mode power supply for its operation. MCU: Its full form is microcontroller unit. It is the processor of PLC. It is basically the brain of PLC. It performs various control operations of PLC. Inputs And Outputs: PLC has a set of isolated inputs and isolated outputs. Different PLCs have different number and different type of inputs and outputs. Like in Micrologix 1000 we have total number of 6 inputs and 4 outputs whereas in Micrologix 1100 we have 10 inputs and 6 outputs. Expansion Port: In PLC there is an expansion port which is used for the addition of any other equipment with PLC. For example analog cards. Memory Module: The memory module in PLC is used for the storage of program in PLC for future use. Communication Port: The communication ports are used in PLC to communicate with the computer. In PLC there are two types of communication ports i.e. RS 232 comport and Ethernet port. Display: In some of the PLCs there is display screen which is available on the PLC. This display screen is used as human machine interface i.e. it provides good visualization of operation running on PLC.3.9 Pin Diagram Fig3.4 PLC Pin Diagram.3.9.1 Inputs And Outputs Of PLCPLC programs are made up of a combination of the "gates" together with inputs, outputs, timers, counters, internal memory bits, analog inputs, analog outputs, mathematical calculations, comparators etc.

3.9.1.1Inputs These are the physical connections from the real world to the PLC. They can be limit switches, push buttons, and sensors, anything that can "switch" a signal on or off. The voltages of these devices are usually, but not always,24 Volt DC. Manufacturers make inputs that can accept a wide range of voltages both ac and dc. It should be remembered that an input will be ON,"status 1", when the voltage is present at the input connection and OFF, "status 0", when the voltage is no longer present at the input connection.3.9.1.1.1 Types Of Inputs Of PLC User Type: These are the inputs and outputs that are physically present and are practical to the inputs and outputs of the PLC. Bit Type: These are the inputs and outputs that are not physically present and are functional in the PLC only. These inputs/outputs are basically used to drive each other in the ladder logic programming. XIC (Examine if closed):I/PO/P

00

11

Tb3.1 XIC Truth table XIO (Examine if open):I/PO/P

01

10

Tb3.2 XIO Truth table3.9.1.2 Outputs

These are the connections from the PLC to the real world. They are used to switch solenoids, lamps, contactors etc on and off. Again they are usually 24 Volt DC, either relay or transistor, but can also be 115/220 Volt AC.

3.9.1.2.1 Types Of PLC Outputs Relay type output Transistor type output TRIAC type output3.10 PLC ManufacturesSIEMENSALLEN BRADLEYGENERAL ELECTRICALMITSUBISHI SCHENIDER ABB TOSHIBA L N T UNITRONICS COTRUST3.11 How The PLC Operates

Fig 3.5 Operation of PLC 3.12 Ladder LogicLadder logic is the main programming method used for PLCs. As mentioned before, ladder logic has been developed to mimic relay logic. The decision to use the relay logic diagrams was a strategic one. By selecting ladder logic as the main programming method, the amount of retraining needed for engineers and tradespeople was greatly reduced.Modern control systems still include relays, but these are rarely used for logic. A relay is a simple device that uses a magnetic field to control a switch.

Objectives Know general PLC issues To be able to write simple ladder logic programs Understand the operation of a PLC PLC History Ladder Logic and Relays PLC Programming PLC Operation

3.13 Basic Ladder Logic Symbols Normally open contact Passes power (ON) if coil driving the contact is ON (closed) Allen-Bradley calls it XIC - eXamine If Closed Normally closed contact Passes power (ON) if coil driving the contact is off (open) Allen-Bradley calls it XIO - eXamine If Open Output or coil If any left-to-right path of inputs passes power, output is energized Allen-Bradley calls it OTE - OuTput Energize Not Output or coil If any left-to-right path of inputs passes power, output is de-energized

For ExampleEg.1.There is only 1 output & 4 inputs. If I1 & I2 simultaneously pressed then Q1 output ON & if I3 & I4 is simultaneously pressed then Q1 OFF.

Types of PLCs and their Programming1. Simple programs with NO and NC a. If a 1st detent button is pressed then the 4 indicators will glow and if the 3rd and 4th detent button is pressed then the 2nd and 3rd output will goes off and the remaining will goes on.

Using Memory Bit:a. When only 1st , 3rd, 5th input is pressed then only the 1st output will glow and when 2nd ,4th, 6th input is pressed then only that output will goes off.

Program Using Timer:a. When 1st input is pressed then the 1st output will glow after the time delay of 5 seconds and when that 1st output goes on then again after 5 sec delay 2nd output will glow but 1st output will goes off.

In GE-Fanuc Program Using Timer And Counter Isa. When the momentary push button is pressed then the 4 outputs will goes on after 5 seconds. b. There is one timer and counter , when the counter takes 5 pulses then after that the timer starts and after 5 seconds the 1st output will goes on.

a. There are two counters when the 1st counter takes 5 pulses then the 1st output will glow and when 2nd counter takes 6 pulses then that output will goes off.

b. Addition and Multiplication of two numbers.

3.14 PLC Advantages & Disadvantages Flexibility: One single Programmable Logic Controller can easily run many machines. Correcting Errors:. Correcting errors in PLC is extremely short and cost effective. Space Efficient: Today's Programmable Logic Control memory is getting bigger and bigger this means that we can generate more and more contacts, coils, timers, sequencers, counters and so on. We can have thousands of contact timers and counters in a single PLC. Imagine what it would be like to have so many things in one panel. Low Cost: Prices of Programmable Logic Controlers vary from few hundreds to few thousands. This is nothing compared to the prices of the contact and coils and timers that you would pay to match the same things. Add to that the installation cost, the shipping cost and so on. Testing: A Programmable Logic Control program can be tested and evaluated in a lab. The program can be tested, validated and corrected saving very valuable time. Visual observation: When running a PLC program a visual operation can be seen on the screen. Hence troubleshooting a circuit is really quick, easy and simple.

CHAPTER 4COMPARISION AND MATH INSTRUCTIONS IN PLC PROGRAMMING

4.1 Comparison Instruction A comparison instruction compares values of data. Depending on the data to be compared it returns true or false logic. They are controlling instructions and can be used any-where in a ladder logic program, except at the right-most position of a rung. Some of the comparison instructions are as follows: Equal (EQU) Not Equal (NEQ) Less Than (LES) Less Than or Equal (LEQ) Greater Than (GRT) Greater Than or Equal (GEQ) Comparison (CMP) Limit (LIM)

4.1.1 EQU [Equal] This input instruction is true when Source A = Source B. The EQU instruction compares two user specified values. If the values are equal, it allows rung continuity. The rung goes true and the output is energized

You must enter a word address for Source A. You can enter a program constant or a word address for Source B.

4.1.2 NEQ [Not Equal] Use the NEQ instruction to test whether two values are not equal. If Source A and Source B are not equal, the instruction is logically true. If the two values are equal, the instruction is logically false.

Source A must be a word address. Source B can be a word address or program constant 4.1.3 LES [Less Than] This conditional input instruction tests whether one value (Source A) is less than another (Source B). If the value at Source A is less than the value at Source B, the instruction is logically true.

If the value at Source A is greater than or equal to the value at Source B, the instruction is logically false. Enter a word address for Source A. Enter a constant or a word address for Source B.

4.1.4 LEQ [Less Than or Equal] This conditional input instruction tests whether one value (source A) is less than or equal to another (source B). If the value at source A is less than or equal to the value at source B, the instruction is logically true.

If the value at source A is greater than the value at source B, the instruction is logically false. 4.1.4 GRT [Greater Than] This input instruction compares two user specified values. If the value stored in Source A is greater than the value stored in Source B, it allows rung continuity. The rung will go "true" and the output will be energized (provided no other instructions affect the rung's status).

If the value at Source A is less than or equal to the value at Source B, the instruction is logically false. 4.1.5 GEQ [Greater Than or Equal To] If the value stored in Source A is greater than or equal to the value stored in Source B, it allows rung continuity. The rung will go true and the output will be energized (provided no other instructions affect the rung's status).

If the value at Source A is less than the value at Source B, the instruction is logically false. 4.1.6 LIM [Limit Test] Use the LIM instruction to test for values within or outside a specified range, depending on how you set the limits. The instruction is true when the Test value is between the limits or is equal to either limit. If the Test value is outside the limits, the instruction is false.

4.2 Math InstructionsMathematical functions are controlled instructions which retrieve one or more values, perform an operation and store the result in memory. In a ladder logic program, when its rung is true, the mathematical operation is performed. Commonly used math instructions include: ADD (value,value,destination) - add two values SUB (value,value,destination) - subtract MUL (value,value,destination) - multiply DIV (value,value,destination) divide

Eg.1. Press start push button value stored in some memory word is added with another value in the memory & resulted value is the multiplied by some another value in other memory words.

4.2.1 Basic Logic Instructions AND INSTRUCTION OR INSTRUCTION NAND INSTRUCTION NOT INSTRUCTION X-OR INSTRUCTION X-NOR INSTRUCTION4.2.1.1The NOT functionThe simplest of all logic functions is the NOT gate.

It's sole function in life is to invert of flip the logic state. So an input of 1 will come out as a 0 and vica versa. Shown below is a truth table (it doesn't lie) showing all possible inputs and the resulting logical output.INPUTOUTPUT

1 0

0 1

Tb4.1 NOT Truth tableThe ladder logic equivalent for a NOT function looks like a normal contact but with a slash through it.

4.2.1.2The AND functionThe AND gate is associated with the following symbol that can have any number of inputs but only one output.

The truth table below shows that the output is only turned on when all the inputs are true that is 1. An easy way to remember this is AND works like multiplication operation.

INPUT A INPUT B OUTPUT

0 0 0

0 1 0

1 0 0

1 1 1

Tb 4.2 AND Truth Table The ladder logic equivalent for an AND function looks like two normal contacts side by side.

4.2.1.3The OR functionLast but not least the OR gate is associated with the following symbol that also can have any number of inputs but only one output.

INPUT A INPUT B OUTPUT

0 0 0

0 1 1

1 0 1

1 1 1

Tb4.3 OR Truth TableThe ladder logic equivalent for an OR function looks like two normal contacts on top of each other

4.2.1.4Combining AND or OR with NOTThe NOT gate might not look like much help if you haven't programmed much but you'll find yourself actually using it frequently. It's very common to use it in combination with AND and OR. So the engineering gods decided to make some symbols for these combinations. Putting the NOT and AND gates together forms the NAND gate. The truth table below shows that it is simply an inverted output of the AND gate.A little circle (or if you like, a bubble) at the end of a AND gate is used to signify the NAND function. It's symbol and corresponding ladder logic are shown below. Now pay close attention to the ladder logic because the contacts are in parallel and not in series like the AND function.

4.3 Basic instructionsPositive Logic (most PLCs follow this convention) True = logic 1 = input energized.False = logic 0 = input NOT energized.

Negative LogicTrue = logic 0 = input NOT energizedFalse = logic 1 = input energized.

Normally OpenThis instruction is true (logic 1) when the hardware input (or internal relay equivalent) is energized.

Normally ClosedThis instruction is true (logic 1) when the hardware input (or internal relay equivalent) is NOT energized.

Output Enable(OTE) - Output Enable.This instruction mimics the action of a conventional relay coil.

On Timer(TON) - Timer ON.Generally, ON timers begin timing when the input (enable) line goes true, and reset if the enable line goes false before setpoint has been reached. If enabled until setpoint is reached then the timer output goes true, and stays true until the input (enable) line goes false.

Off Timer(TOF) - Timer OFF.Generally, OFF timers begin timing on a true-to-false transition, and continue timing as long as the preceding logic remains false. When the accumulated time equals setpoint the TOF output goes on, and stays on until the rung goes true.

Up Counter(CTU)This instruction is used to count the event in increasing order.For instance it is used in car parking to count the no. of cars entered.Sometimes we want to continue a process after no. of times an event happens ,at that situation we make use of up counter .

Down Counter(CTD)This instruction is used to count the no. of events in reverse or decreasing order.For instance in car parking system to count the no. of cars leaving the space we make use of down counter.

CHAPTER 5HMI( HUMAN MACHINE INTERFACE)

5.1IntroductionA Human-Machine Interface or HMI is the apparatus which presents process data to a human operator, and through which the human operator controls the process.An HMI is usually linked to the SCADA system's databases and software programs, to provide trending, diagnostic data, and management information such as scheduled maintenance procedures, logistic information, detailed schematics for a particular sensor or machine, and expert-system troubleshooting guides.The HMI system usually presents the information to the operating personnel graphically, in the form of a mimic diagram. This means that the operator can see a schematic representation of the plant being controlled.The Human Machine Interface (HMI) includes the electronics required to signal and control the state of industrial automation equipment. These interface products can range from a basic LED status indicator to a 20-inch TFT panel with touchscreen interface. HMI applications require mechanical robustness and resistance to water, dust, moisture, a wide range of temperatures, and, in some environments, secure communication. They should provide Ingress Protection (IP) ratings up to IP65, IP67, and IP68. The unique capacitive Atmel QTouch technology, Atmel SAM9 microprocessors, and Atmel CryptoAuthentication devices enable designers to meet these requirements and more, with an optimized BOM.5.2Features and Benefits Supports high source and sink output IO capabilities up to 60mA for direct drive of LEDs. High-speed PWM units enable LED dimming and screen back lighting. Robust touch technology provides reduced wear and increased product lifetime. Due to its superior field penetration, Atmel Touch technology will operate through 6mm thick, non-conductive surfaces. The excellent signal-to-noise ratio of the AtmelQMatrix touch technology makes the design immune to water, moisture, or dust and enables operators to use gloves. Capacitive touch eases design of full hermetic or sealed products, while power efficiency minimizes heat dissipation. Free Atmel QTouch software library on the Atmel microcontroller lets designers avoid the cost of an additional component. The Atmel touch spread spectrum frequency implementation helps designers meet electro-magnetic emission requirements. The Atmel industrial microprocessor product portfolio with integrated LCD, combined with the Atmel QTouch technology, are the ideal candidates for your next control panel design. The Atmel CryptoAuthentication family of hardware security devices provides cost effective solutions for authenticated and encrypted communications between HMI and industrial equipment.5.3 DefinitionThe HMI quality may be defined by the system utility (usefulness), in terms of the user tasks, obtained by task analysis. This is in contrast with automated systems, for which the quality is typically defined by attributes such as performance, reliability and recovery costs of the system units.[1] Unlike automated systems, for which the system utility depends primarily on the system availability, performance and reliability, the utility of the HMI interaction is affected mainly by the users performance and reliability, in the context of the users expectations.HMI stands for Human Machine Interface and is the means by which a human operator will interact with a process controller. Put very simply, the Human Machine Interface is the process controllers input/output mechanism for humans. Unless the process being controlled is entirely automated, some form of HMI will be required.A human will depend on the output of the HMI to provide feedback about the current state of a particular industrial process. This may be as simple as reassuring the human that an automated process is running or has completed correctly, or that specific parameters are operating inside required limits. The HMI output is usually a visual display of some kind (e.g. alphanumeric characters or graphical images) but can also include audible feedback and alarms.The HMI will also allow a range of inputs by providing interaction controls such as dials, push buttons or, in a more advanced HMI, a touch screen display. These controls allow processes to be started, stopped, adjusted or programmed as necessary. 5.4 HMI Devices LED Indicators and Mechanical Switchesare a leading HMI for industrial applications, and Atmel AVR and AT91SAM microcontrollers offer a variety of benefits. Capacitive Touch Technology for HMIhelps protect industrial interface modules, while increasing design flexibility and enhancing look and feel. Industrial Control Panels with LCD Displaysprovide the operator an efficient, flexible way to monitor and control increasingly complex automated processes. Hardware Security Productsprotect firmware integrity from tampering to assure continuous and reliable performance.5.5 Attributes of the HMI quality Performance. The time it takes for the users to evaluate the system state and decide what to do next is typically higher by an order of magnitude than the system response time. Instead of measuring the system response time, we should measure the time elapsed from the moment the user decides to perform a task until its completion. Typically, most of the elapsed time is wasted because the user fails to follow the operational procedures, attempting to recover from unwanted system response to unexpected actions. Systems Engineering should regard user productivity, rather than system performance. Reliability. The operators Failure rate (MTBF) is about 10% of the overall operation time, higher by several orders of magnitude than that of the system. Instead of measuring component failure rates, such as by MTBF, we should measure operational failure rates, such as the rate of almost-accidents due to user errors. This is especially true for safety-critical systems, in which the costs of an accident are much higher than those of maintenance. Operational reliability is the key to task performance. Resilience. The interaction may go out of sync, namely, the system might get to an exceptional state. The exceptional states include failure of a system unit, or the result of a users action that does not match the interaction protocol. Resilience engineering methods may be applied to resume normal operation after getting to the exceptional state. Task-oriented System Engineering enables definition of an interaction protocol. The STAMP model may be used to constrain the system operation according to the protocol. Recovery costs. The operators' mean time to repair (MTTR) is about 50% of the overall operation time, higher by several orders of magnitude than that of the system. Instead of measuring maintenance costs, such as by MTTR, we should measure the time it takes for the users to recover from system failures. Logic. An application that is logical in its internal design and produces accurate results may nevertheless be difficult to use. The reason for this is that logic is not absolute. It is subjective, it is task related, and it changes over time. Typically, it applies to the internals of the application. Therefore, the user has difficulty following the developers logic.5.6 The Importance of the HMI When Selecting a Process ControllerChoosing the right HMI can be as important as considering the capabilities of the process controller behind it. The most obvious effect of a particular type of HMI will be on the ease of use of the product. A Human Machine Interface which is easy to understand and gives clear options to end users will produce fewer errors, as well as a more pleasant user experience. A manufacturer which consistently provides an easy to use product will benefit in terms of future orders and recommendations to other customers. A manufacturer whose products may perform very well on a technical level, will find themselves losing business if their end users experience difficulty and frustration when using the product, or if the rate of user error is negatively impacting on a clients business.The choice of HMI will also have an impact on the real cost of the product for the end user.An easier to use HMI means lower training costs. It also potentially means that less skilled personnel will be able to operate the product effectively. In addition, user errors can result in significant losses to a business in terms of time and materials wasted. So while one type of HMI may appear to be significantly cheaper in terms of the component costs, a more advanced HMI may well be more cost-effective when in the longer term.There are also cost benefits for manufacturers directly. It has been mentioned in other articles that a process controller with integrated HMI already offers manufacturers significant cost benefits in terms of reduced labour costs to integrate controllers with a separate HMI, as well as potentially faster development times. But there are other benefits of choosing a built-in HMI.Products which are easy to use generate fewer support requests to manufacturers. And advanced HMIs can reduce product obsolescence and make it easier and cheaper to upgrade or refresh a product range. A powerful PLC with HMI, for example, may well have spare capacity, which can be utilised in the future to add features and capabilities but without changing the hardware components. And if that PLC also has a built-in HMI which allows new screens to be added easily, or existing screens to be refreshed with new graphics or colour schemes, it becomes much cheaper to create a new product. Finally, an advanced HMI which can be easily used by a greater range of people offers the possibility of creating products which could have a customer base of many thousands, rather than a handful of very specialised industrial customers. An example of this potential is the HiFri fat-free frying system which uses the Unitronics Vision 570 PLC, and features a built-in advanced HMI, consisting of a 5.7 inch colour touch screen.5.7 How to select the right PLCGiven the importance of the Human Machine Interface and the significant variation in type of HMI available, how do you go about choosing the right one for your application?Correct selection requires analysis both of the back end process control requirements as usual (what I/Os are needed, required accuracy levels etc), and of the context in which it is to be used. This means defining the users task in terms of what information the operator needs at different stages of the process and what user actions are needed at different points of the task.This will indicate the complexity of the information that needs to be represented at any one time, including the number of items of information, whether they are numerical or text values, and whether a graphical representation would be helpful.It is also useful to define the expected level of knowledge of a user, which will help define how much contextual information needs to be provided by the display. A highly skilled user who already understands the process can exercise knowledge and memory to make informed decisions about what to do in response to a particular value (e.g. a lab technician monitoring a value relating to an experiment he is running). But a less skilled or novice user will not have this knowledge and must be given contextual information and context-sensitive options in order to prevent errors (e.g. a restaurant employee operating a frying machine).It is also essential to analyse the type of errors that are possible as a result of incorrect user behaviour, and the consequences of those errors. The more serious the consequences the more it is essential that the choice of HMI should allow the chance of error to be minimised or prevented altogether. A high-risk application is the most likely to require a context-sensitive user interface solution involving an advanced HMI with touch screen.Once these factors (task complexity, user knowledge and error risk) are clear, it then makes sense to base your choice on the best HMI to meet these user requirements. It is then a relatively straightforward task to check that the PLC behind the HMI has the necessary capabilities to deal with the technical side of the process.As always, Tecnologic can provide expert advice to help you choose the best process controller for your application. We can discuss your application requirements by phone, or arrange a site visit as necessary. We can also provide candidate models on a sale or return basis, allowing your design team to fully assess both the back end and HMI capabilities

Fig 5.1 HMITwo components are needed in a human machine interface. The first is an input. A human user needs some way to tell the machine what to do, to make requests of the machine, or to adjust the machine. Examples of input devices include keyboards, toggles, switches, touch screens, joysticks, and mice. All of these devices can be utilized to send commands to a system or even an interlinked set of systems.The interface also requires an output, which allows the machine to keep the human user updated on the progress of commands, or to execute commands in physical space. On a computer, for example, users have a screen which can display information. A robot, on the other hand, may move in response to commands and store data on a hard drive so that people can see how the robot responds, learns, and navigates the world. Outputs can also include things as simple as status lights which alert people when toggles or switches have been activated.The technology behind the human machine interface is constantly improving. Researchers have developed interfaces which can be controlled with the mind, for example, seeing applications for this technology among stroke patients and other people with severely restricted modes of communication. Likewise, outputs have become much more sophisticated over time.As many people have noted, a poorly designed human machine interface can be extremely frustrating. On one end of the scale, the interface may be buggy or nonfunctional, causing difficulty because it does not work as intended. On the other end of the scale, the interface works, but it is designed in such a way that it is confusing and challenging to operate because it is not intuitive for users. The art of designing intuitive interfaces requires a deep understanding of how humans interact with their environment and an awareness of the psychology of designing interfaces in a way which will be accessible to a broad spectrum of humans. What works for an engineer in a human machine interface, for example, might not be as easy for a member of the general public.The user interface (also known as human computer interface or man-machine interface (MMI)) is the aggregate of means by which peoplethe usersinteract with the system a particular machine, device, computer program or other complex tool. The user interface provides means of:

Input, allowing the users to manipulate a system. Output, allowing the system to indicate the effects of the users' manipulation. The design of a user interface affects the amount of effort the user must expend to provide input for the system and to interpret the output of the system, and how much effort it takes to learn how to do this. Usability is the degree to which the design of a particular user interface takes into account the human psychology and physiology of the users, and makes the process of using the system effective, efficient and satisfying.5.8 How To Connect An HMI With PCThe terminal of HMI can be connected with PC either by USB or Ethernet port. You must have to enter the panel address of your HMI in your browser (Internet Explorer, Mozilla firebox etc.)You can also transfer programmed by pen drive.For USBThe panel view component has a USB port to support communication with USB. You must first install ALLEN BRADLEY Panel view USB remote NDIS network device driver on your computer. The default address of Allen Bradley HMI is 169.254.2542.For EthernetFor Ethernet first install the drivers. The default address of single Allen Bradley HMI is 169.254.2542. If you install more than one HMI in the circuit then the address start from 169.254.0.0 to 169.254.255.255.

Fig5.2 An HMI Controlled System CHAPTER 6DC/AC Motors And Drives6.1 DC MotorsDC motors have been used in industrial applications for years. Coupled with a DC drive, DC motors provide very precise control. DC motors can be used with conveyors, elevators, extruders, marine applications, material handling, paper, plastics, rubber, steel, and textile applications to name a few.

PLC,SCADA And HMI

Fig 6.1 DC Motor44

6.2 Construction DC motors are made up of several major components which include the following: Frame Shaft Bearings Main Field Windings (Stator) Armature (Rotor) Commutator Brush AssemblyOf these components, it is important to understand the electrical characteristics of the main field windings, known as the stator, and the rotating windings, known as the armature. An understanding of these two components will help with the understanding of various functions of a DC Drive.

Basic Construction The relationship of the electrical components of a DC motor is shown in the following illustration. Field windings are mounted on pole pieces to form electromagnets. In smaller DC motors the field may be a permanent magnet. However, in larger DC fields the field is typically an electromagnet. Field windings and pole pieces are bolted to the frame. The armature is inserted between the field windings. The armature is supported by bearings and end brackets (not shown). Carbon brushes are held against the commutator.

Armature The armature rotates between the poles of the field windings.The armature is made up of a shaft, core, armature windings, and a commutator. The armature windings are usually form wound and then placed in slots in the core.Armature, the part of an electric generator or motor that contains the main current-carrying winding. The armature usually consists of a coil of copper wire wound around an iron or steel core. The coil and core are placed in a magnetic field produced by one or more permanent magnets or electromagnets. If the armature in a generator or motor is designed to rotate, it is called a rotor; if it is a stationary part, it is called a stator

Fig 6.2 Armature

6.3 DC Motor Operation

Magnetic Fields There are two electrical elements of a DC motor, the field windings and the armature. The armature windings are made up of current carrying conductors that terminate at a commutator. DC voltage is applied to the armature windings through carbon brushes which ride on the commutator.

In small DC motors, permanent magnets can be used for the stator. However, in large motors used in industrial applications the stator is an electromagnet. When voltage is applied to stator windings an electromagnet with north and south poles is established. The resultant magnetic field is static (non- rotational). For simplicity of explanation, the stator will be represented by permanent magnets in the following illustrations.

Fig 6.3 motor Magnetic FieldsA DC motor rotates as a result of two magnetic fields interacting with each other. The first field is the main field that exists in the stator windings. The second field exists in the armature. Whenever current flows through a conductor a magnetic field is generated around the conductor.

Right-Hand Rule for Motors A relationship, known as the right-hand rule for motors, exists between the main field, the field around a conductor, and the direction the conductor tends to move. If the thumb, index finger, and third finger are held at right angles to each other and placed as shown in the following illustration so that the index finger points in the direction of the main field flux and the third finger points in the direction of electron flow in the conductor, the thumb will indicate direction of conductor motion. As can be seen from the following illustration, conductors on the left side tend to be pushed up. Conductors on the right side tend to be pushed down. This results in a motor that is rotating in a clockwise direction. You will see later that the amount of force acting on the conductor to produce rotation is directly proportional to the field strength and the amount of current flowing in the conductor

.Fig 6.4 Electron flow

According to right hand rule Thumb points to direction of conductor motion Index finger points to magnetic field Middle finger points to current

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Armature FieldAn armature, as we have learned, is made up of many coils and conductors. The magnetic fields of these conductors combine to form a resultant armature field with a north and south pole. The north pole of the armature is attracted to the south pole of the main field. The south pole of the armature is attracted to the north pole of the main.This attraction exerts a continuous torque on the armature. Even though the armature is continuously moving, the resultant field appears to be fixed. This is due to commutation

Fig 6.5 Armature Field

In the following illustration of a DC motor only one armature conductor is shown. Half of the conductor has been shaded black, the other half white. The conductor is connected to two segments of the commutator.

In position 1 the black half of the conductor is in contact with the negative side of the DC applied voltage. Current flows away from the commutator on the black half of the conductor and returns to the positive side, flowing towards the commutator on the white half.

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Fig 6.6 forward current flow

In position 2 the conductor has rotated 90. At this position the conductor is lined up with the main field. This conductor is no longer cutting main field magnetic lines of flux; therefore, no voltage is being induced into the conductor. Only applied voltage is present. The conductor coil is short-circuited by the brush spanning the two adjacent commutator segments. This allows current to reverse as the black commutator segment makes contact with the positive side of the applied DC voltage and the white commutator segment makes contact with the negative side of the applied DC voltage.

Fig 6.7 reverse current flow

As the conductor continues to rotate from position 2 to position 3 current flows away from the commutator in the white half and toward the commutator in the black half. Current has reversed direction in the conductor. This is known as commutation.

Fig 6.8 Commutation

6.4 Types of DC Motors

The field of DC motors can be a permanent magnet, or electromagnets connected in series, shunt, or compound.

6.4.1 Permanent Magnet Motors : The permanent magnet motor uses a magnet to supply field flux. Permanent magnet DC motors have excellent starting torque capability with good speed regulation. A disadvantage of permanent magnet DC motors is they are limited to the amount of load they can drive. These motors can be found on low horsepower applications. Another disadvantage is that torque is usually limited to 150% of rated torque to prevent demagnetization of the permanent magnets.

Fig 6.9 Permanent Magnet Motor

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6.4.2 Series Motors: In a series DC motor the field is connected in series with the armature. The field is wound with a few turns of large wire because it must carry the full armature current. A characteristic of series motors is the motor develops a large amount of starting torque. However, speed varies widely between no load and full load. Series motors cannot be used where a constant speed is required under varying loads. Additionally, the speed of a series motor with no load increases to the point where the motor can become damaged. Some load must always be connected to a series-connected motor. Series-connected motors generally are not suitable for use on most variable speed drive applications.

Fig 6.10 Series Motor

6.4.3 Shunt Motors :In a shunt motor the field is connected in parallel (shunt) with the armature windings. The shunt-connected motor offers good speed regulation. The field winding can be separately excited or connected to the same source as the armature. An advantage to a separately excited shunt field is the ability of a variable speed drive to provide independent control of the armature and field. The shunt-connected motor offers simplified control for reversing. This is especially beneficial in regenerative drives. Fig 4.11 Shunt Motor Compound Motors Compound motors have a field connected in series with the armature and a separately excited shunt field. The series field provides better starting torque and the shunt field provides better speed regulation.

Fig 6.11 Compound Motor

6.5 Basic DC Drives

SIMOREG drives are designed for connection to a three-phase. AC supply. They, in turn, .supply the armature and field of Variable speed DC motors. SIMOREG drives can be selected for connection to 230, 400, 460, 575, 690, 830, and 950 VAC, making them suitable for global use.Siemens SIMOREG.DC MASTER 6RA70drives are available upto 1000.HP at 500.VDC in standard model drives.In addition drives can be paralleled, extending the range up to 6000.HP Siemens. SIMOREG drives have wide range of microprocessor-controlled internal parameters to control DC motor operation.

Fig 6.13 DC Drive SIMOREG.6RA70

6.5.1 Power Modules. The.SIMOREG.6RA70 is available in a power module and base drive panels.The power module contain the control electronics and power components necessary to control drive operation and the associated DC motor.

6.5.2 Base Drive Panels. The base drive panel consists of the power module mounted on a base panel with line fuses, control transformer and contactor.This design allows for easy mounting and connection of power cables..

6.5.2 High Horsepower Designs. High horsepower designs are also available with ratings upto 14,000amps.These drives have input ratings upto 700VAC & an operate motors with armature ratings upto 750VDC.

Fig4.14 Drive Panel

Fig 6.15 High Horsepower Panel

6.6 Converting AC to DC:

6.6.1 Thyristor. A primary function of a DC drive,such as the SIMOREG 6RA70 DC MASTER is to convert AC voltage into a variable DC voltage It is necessary to vary to DC voltage in order to control the speed of a DC motor.A thyristor is one type of device commonly used to convert AC to DC.A thyristor consists of an anode ,cathode and a gate.

Fig6.16 Thyristor Symbol

6.6.2 AC to DC Conversion. The thyristor provides a convenient method of converting AC voltage to a variable DC voltage for use in controlling the speed of a DC motor.In this example the gate is momentarily applied when AC input voltage is at the top of the sinewave.The thyristor will conduct until the inputs sinewave crosses zero. At this point the anode is no longer positive with respect to the cathode and the thyristor shuts off.The result is a half-wave rectified.DC.The amount of rectified DC voltage can be controlled by timing the input to the gate.Applying current on the gate at the beginning of the sinewave result in a higher average voltage applied to the motor.Applying current on the gate later in the sinewave results in a lower average voltage applied to the motor.

6.7 Basic Drive Operation:-

6.7.1Controlling a DC Motor. A thyristor bridge is a technique commonly used to control the speed of a DC motor by varying the DC voltage.Examples of how a DC rectifier bridge operates are given on the next few pages.The actual values for a given load speed and motor vary.

It is important to note that the voltage applied to a DC motor be no greater than the rated nameplate.Armature windings are commonly wound for 500 VDC The control logic in the drive must be adjusted to limit available DC voltage to 0-500 VDC.Likewise the shunt field must be limited to the motors nameplate value.

Fig 6.17 Siemens DriveBasic Operation A DC drive supplies voltage to the motor to operate at a desired speed. The motor draws current from this power source in proportion to the torque (load) applied to the motor shaft.

Fig 6.18 Drive Operation

6.8 Application Examples The Siemens SIMOREG.6RA70 DC MASTER drives are designed to handle the most challenging applications. The following examples are just some of applications the SIMOREG can be used on:Winders/Coilers. DCmotors offer superior characteristics at low speed for winder and coiler operation and performance.In winder applications maintaining tension at standstill is a very important operation.DC motors offer a wide speed range at rated torque.On many winder applications that run in an extended speed range a smaller horsepower .DC motor could do the same job as a larger horsepower AC motor.

Fig 6.19 Winder Crane/hoist:

Fig6.20 CraneMarine Applications.DC drives offer several advantages in marine applications.Compact sizing is one of the biggest advantages.DC drives also adapt well from generator supplies such as found in the marine industry.Extruding. Extruding is a price competitive industry.DC offers in the 60 to 1000 HP range which is commonly used in extruding Application.

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6.9 AC DRIVES 6.9.1 What Is An AC Drive?The word "drive" is used loosely in the industry. It seems that people involved primarily in the world of gear boxes and pulleys refer to any collection of mechanical and electro-mechanical components, which when connected together will move a load, as a "drive". When speaking to these people, an AC drive may be considered by them as the variable frequency inverter and motor combination. It may even include the motor's pulley - I am not sure.People in the electrical field and electrical suppliers usually refer to a variable frequency inverter unit alone, or an SCR power module alone (when discussing DC drives) as the "drive" and the motor as the "motor".Manufacturers of variable frequency drives (VFD) used to refer to the drive as just that, a "variable frequency drive". More manufacturers are referring to their drive as an "adjustable speed AC drive". To make matters worse when a motor is included in the package it may be referred to as an "adjustable speed AC drive system".A variable frequency drive is an adjustable speed drive. Adjustable speed drives include all types; mechanical and electrical.The main power components of an AC drive, have to be able to supply the required level of current and voltage in a form the motor can use. The controls have to be able to provide the user with necessary adjustments such as minimum and maximum speed settings, so that the drive can be adapted to the user's process. Spare parts have to be available and the repair manual has to be readable. It's nice if the drive can shut itself down when detecting either an internal or an external problem. It's also nice if the drive components are all packaged in a single enclosure to aid in installation but that's about it. Fig 6.21 Main Power Circuit Of AC Drive

6.9.2Where does the real action happen in a AC drive system?

Above is a cross-sectional view a motor rotor and field magnetic core. Looking from the side would look something like a looking at a can.We can add magnets (and torque) to our drive system by using a motor with a core that is either longer, larger in cross-sectional diameter, or some combination of both.A Side Note About Fishing, Electro-magnets, Current, and Magnetic Conductivity When we go fishing we put bait on a hook and throw it in water knowing that according to generally accepted theory, a hungry fish will sooner or later, bite. Well the truth is we don't know why the fish bite. No one to date, has talked to a fish (well maybe a few people talk to fish). The fact the we get hungry and therefore fish must too, seems like a safe assumption. But it doesn't really matter because we do know that putting bait on a hook will get fish into the boat.Magnetism and electricity are the same way. We have some well accepted theories that we can use to explain how magnets can move our load but no one really knows what magnetism and electricity are (regardless of what they say). When it comes to using magnetic force to move our load, how it works just doesn't matter. We do know that it works. We have even noticed a few peculiar things.We have noticed that when you wrap a coil of wire around a piece of iron and apply electric current the piece of iron becomes magnetic. We call this an electro-magnet.

PLC,SCADA And HMI

Fig 6.22 Coil With Iron Core

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Important Motor Formula

Synchronous RPM" is the RPM the motor would run if the rotor did not slip. All AC induction motors slip.

AC GeneratorIf a magnet is passed along the coils, an electric current is generated in each of the three phases. In fact, there is little difference between AC generator and motor field windings.

The faster you move the magnet the higher the AC output frequency. Variable frequency drives control the frequency electronically. AC Motor

4.10 AC Frequency Drive AC Frequency Drive is a drive which convert the incoming frequency of ac supply into desired frequency to make the desired change in speed of motor. AC Frequency Drive: Plenum rated drive Efficient Energy $aving algorithm PI control with inverse, square root and differential control via two feedback capability Sleep and Snooze function for optimum energy savings Built-in kW-hour and kW display Communication interface for Johnson Controls Metasys N2, Siemens APOGEE FLN, LonWorks as well as Modbus. Belt failure detection with or without sensor Display of process parameters in engineering units Multi-parameter display Wide voltage range: 380 to 480 VAC Static auto-tuning for faster commissioning Copy function for faster parameter loading Complete motor protection 12 pulse ready, unique low harmonic design

Motor SpeedThe speed and horsepower of an application must be known when selecting a motor and drive. Given the velocity in feet per minute (FPM) of the conveyor belt, the diameter in inches ofthe driven pulley, and the gear ratio (G) between the motor and driven pulley, the speed of the motor can be determined. The following formula is used to calculate conveyor speed.

A variable frequency drive is an adjustable speed drive. Adjustable speed drives include all types; mechanical and electrical. A variable frequency drive is an adjustable speed drive. Adjustable speed drives include all types; mechanical and electrical.

"A good AC drive technician understands the operation of the variable speed drive and the functions of its components.An outstanding AC drive technician also understands the effects of the load on the drive and the effects of the drive on the load."

CHAPTER 7SCADA 7.1 INTRODUCTIONSCADA (supervisory control and data acquisition) is a type of industrial control system (ICS). Industrial control systems are computer-controlled systems that monitor and control industrial processes that exist in the physical world. SCADA systems historically distinguish themselves from other ICS systems by being large-scale processes that can include multiple sites, and large distances. These processes include industrial, infrastructure, and facility-based processes, as described below: Industrial processes include those of manufacturing, production, power generation, fabrication, and refining, and may run in continuous, batch, repetitive, or discrete modes. Infrastructure processes may be public or private, and include water treatment and distribution, wastewater collection and treatment, oil and gas pipelines, electrical power transmission and distribution, wind farms, civil defense siren systems, and large communication systems. Facility processes occur both in public facilities and private ones, including buildings, airports, ships, and space stations. They monitor and control heating, ventilation, and air conditioning systems (HVAC), access, and energy consumption. Widely used in industry for Supervisory Control and Data Acquisition of industrial processes, SCADA systems are now also penetrating the experimental physics laboratories for the controls of ancillary systems such as cooling, ventilation, power distribution, etc. More recently they were also applied for the controls of smaller size particle detectors such as the L3 muon detector and the NA48 experiment, to name just two examples at CERN. SCADA systems have made substantial progress over the recent years in terms of functionality, scalability, performance and openness such that they are an alternative to in house development even for very demanding and complex control systems as those of physics experiments.7.2Communication Requirements Of SCADA

SCADA systems are indispensable in the operation and control of interconnected power systems.SCADA requires two-way communication channels between the Master Control Centre and Remote Control Centre.

Fig 7.1 SCADA CommunicationTraditionally, the SCADA systems were used by the operators in scanning mode, providing data regarding generating stations, Generating units, Transformer sub-stations etc. Traditional hard wired SCADA systems were arranged to perform several functions to supplement Automatic Control and Protection Systems. All the protective relays and most of the control relays and control systems are necessary for automatic control of generating stations and transmission systems even when the supervisory control is used. Only initiating devices may be different or omitted with fully automatic SCADA control. For example, tap changing may be initiated either by the sub- section control room operator or by the automatic voltage control relays connected in the protection panel of the transformer. With traditional SCADA systems, the function of protection and control were segregated. Controls systems were arranged to keep the values of controlled quantities within target limits. Protection equipment was arranged for sounding alarms and for tripping circuit- breakers. With the recent revolution in microprocessor technology, the size, performance and cost of digital automation systems have become acceptable in commercial installation.7.3 Common system components A SCADA system usually consists of the following subsystems: Remote terminal units (RTUs) connect to sensors in the process and converting sensor signals to digital data. They have telemetry hardware capable of sending digital data to the supervisory system, as well as receiving digital commands from the supervisory system. RTUs often have embedded control capabilities such as ladder logic in order to accomplish boolean logic operations. Programmable logic controller (PLCs) connect to sensors in the process and converting sensor signals to digital data. PLCs have more sophisticated embedded control capabilities, typically one or more IEC 61131-3 programming languages, than RTUs. PLCs do not have telemetry hardware, although this functionality is typically installed alongside them. PLCs are sometimes used in place of RTUs as field devices because they are more economical, versatile, flexible, and configurable. A Telemetry system is typically used to connect PLCs and RTUs with control centers, data warehouses, and the enterprise. Examples of wired telemetry media used in SCADA systems include leased telephone lines and WAN circuits. Examples of wireless telemetry media used in SCADA systems include satellite (VSAT), licensed and unlicensed radio, cellular and microwave. A Data Acquisition Server is a software service which uses industrial protocols to connect software services, via telemetry, with field devices such as RTUs and PLCs. It allows clients to access data from these field devices using standard protocols. A humanmachine interface or HMI is the apparatus or device which presents processed data to a human operator, and through this, the human operator monitors and interacts with the process. The HMI is a client that requests data from a Data Acquisition Server. A Historian is a software service which accumulates time-stamped data, boolean events, and boolean alarms in a database which can be queried or used to populate graphic trends in the HMI. The Historian is a client that requests data from a Data Acquisition Server. SCADA is used as a safety tool as in lock-out tag-out A supervisory (computer) system, gathering (acquiring) data on the process and sending commands (control) to the process. Communication infrastructure connecting the supervisory system to the remote terminal units. Various process and analytical instrumentation7.4 Hardware solutionsSCADA solutions often have Distributed Control System (DCS) components. Use of "smart" RTUs or PLCs, which are capable of autonomously executing simple logic processes without involving the master computer, is increasing. A standardized control programming language, IEC 61131-3 (a suite of 5 programming languages including Function Block, Ladder, Structured Text, Sequence Function Charts and Instruction List), is frequently used to create programs which run on these RTUs and PLCs. Unlike a procedural language such as the C programming language or FORTRAN, IEC 61131-3 has minimal training requirements by virtue of resembling historic physical control arrays. This allows SCADA system engineers to perform both the design and implementation of a program to be executed on an RTU or PLC. A Programmable Automation Controller (PAC) is a compact controller that combines the features and capabilities of a PC-based control system with that of a typical PLC. PACs are deployed in SCADA systems to provide RTU and PLC functions. In many electrical substation SCADA applications, "distributed RTUs" use information processors or station computers to communicate with digital protective relays, PACs, and other devices for I/O, and communicate with the SCADA master in lieu of a traditional RTU.Since about 1998, virtually all major PLC manufacturers have offered integrated HMI/SCADA systems, many of them using open and non-proprietary communications protocols. Numerous specialized third-party HMI/SCADA packages, offering built-in compatibility with most major PLCs, have also entered the market, allowing mechanical engineers, electrical engineers and technicians to configure HMIs themselves, without the need for a custom-made program written by a software programmer. The Remote Terminal Unit (RTU) connects to physical equipment. Typically, an RTU converts the electrical signals from the equipment to digital values such as the open/closed status from a switch or a valve, or measurements such as pressure, flow, voltage or current. By converting and sending these electrical signals out to equipment the RTU can control equipment, such as opening or closing a switch or a valve, or setting the speed of a pump.

7.5Supervisory stationThe term supervisory station refers to the servers and software responsible for communicating with the field equipment (RTUs, PLCs, SENSORS etc.), and then to the HMI software running on workstations in the control room,ss or elsewhere. In smaller SCADA systems, the master station may be composed of a single PC. In larger SCADA systems, the master station may include multiple servers, distributed software applications, and disaster recovery sites. To increase the integrity of the system the multiple servers will often be configured in a dual-redundant or hot-standby formation providing continuous control and monitoring in the event of a server failure. 7.6 Operational philosophyFor some installations, the costs that would result from the control system failing are extremely high. Hardware for some SCADA systems is ruggedized to withstand temperature, vibration, and voltage extremes. In the most critical installations, reliability is enhanced by having redundant hardware and communications channels, up to the point of having multiple fully equipped control centres. A failing part can be quickly identified and its functionality automatically taken over by backup hardware. A failed part can often be replaced without interrupting the process. The reliability of such systems can be calculated statistically and is stated as the mean time to failure, which is a variant of Mean Time Between Failures (MTBF). The calculated mean time to failure of such high reliability systems can be on the order of centuries7.7 Communication infrastructure and methodsSCADA systems have traditionally used combinations of radio and direct wired connections, although SONET/SDH is also frequently used for large systems such as railways and power stations. The remote management or monitoring function of a SCADA system is often referred to as telemetry Some users want SCADA data to travel over their pre-established corporate networks or to share the network with other applications. The legacy of the early low-bandwidth protocols remains, though.SCADA protocols are designed to be very compact. Many are designed to send information only when the master station polls the RTU. Typical legacy SCADA protocols include Modbus RTU, RP-570, Profibus and Conitel. These communication protocols are all SCADA-vendor specific but are widely adopted and used. Standard protocols are IEC 60870-5-101 or 104, IEC 61850 and DNP3. These communication protocols are standardized and recognized by all major SCADA vendors. Many of these protocols now contain extensions to operate over TCP/IP. Although the use of conventional networking specifications, such as TCP/IP, blurs the line between traditional and industrial networking, they each fulfill fundamentally differing requirementsWith increasing security demands , there is increasing use of satellite-based communication. This has the key advantages that the infrastructure can be self-contained (not using circuits from the public telephone system), can have built-in encryption, and can be engineered to the availability and reliability required by the SCADA system operator. Earlier experiences using consumer-grade VSAT were poor. Modern carrier-class systems provide the quality of service required for SCADARTUs and other automatic controller devices were developed before the advent of industry wide standards for interoperability. The result is that developers and their management created a multitude of control protocols.Recently, OLE for process control (OPC) has become a widely accepted solution for intercommunicating different hardware and software, allowing communication even between devices originally not intended to be part of an industrial network. 7.8 Alarm HandlingAlarm handling is based on limit and status checking and performed in the data servers. More complicated expressions (using arithmetic or logical expressions) can be developed by creating derived parameters on which status or limit checking is then performed. The alarms are logically handled centrally, i.e., the information only exists in one place and all users see the same status (e.g., the acknowledgement), and multiple alarm priority levels (in general many more than 3 such levels) are supported.It is generally possible to group alarms and to handle these as an entity (typically filtering on group or acknowledgement of all alarms in a group). Furthermore, it is possible to suppress alarms either individually or as a complete group. The filtering of alarms seen on the alarm page or when viewing the alarm log is also possible at least on priority, time and group. However, relationships between alarms cannot generally be defined in a straightforward manner. E-mails can be generated or predefined actions automatically executed in response to alarm conditions.

7.9Logging/Archiving The terms logging and archiving are often used to describe the same facility. However, logging can be thought of as medium-term storage of data on disk, whereas archiving is long-term storage of data either on disk or on another permanent storage medium. Logging is typically performed on a cyclic basis, i.e., once a certain file size, time period or number of points is reached the data is overwritten. Logging of data can be performed at a set frequency, or only initiated if the value changes or when a specific predefined event occurs. Logged data can be transferred to an archive once the log is full. The logged data is time-stamped and can be filtered when viewed by a user. The logging of user actions is in general performed together with either a user ID or station ID. There is often also a VCR facility to play back archived data7.10 ApplicationsThe following development tools are provided as standard: A graphics editor, with standard drawing facilities including freehand, lines, squares circles, etc. It is possible to import pictures in many formats as well as using predefined symbols including e.g. trending charts, etc. A library of generic symbols is provided that can be linked dynamically to variables and animated as they change. It is also possible to create links between views so as to ease navigation at run-time. 2.A data base configuration tool (usually through parameter templates). It is in general possible to export data in ASCII files so as to be edited through an ASCII editor or Excel. A scripting language An Application Program Interface (API) supporting C, C++, VB A Driver Development Toolkit to develop drivers for hardware that is not supported by the SCADA product.

CHAPTER 8 PROJECT

8.1 INTRODUCTION TO PROJECT: TRAFFIC LIGHTSWith the increasing speed of life, the demand to perform tasks at a higher speed is being laid out too. In todays world more emphasis is being laid on working with machines so that man labour can be decreased .Automation is the best way to reduce mans labour especially in industries. So there is need to develop more and more industrial project which depends upon machines not on man. In industries there are many operations which is not suitable for the human body. So to avoid the accidents, industries emphasis on automation to perform hazardous operations. Similarly,Traffic lights are necessary part of our daily life. If we not follow the traffic rules then the traffic cannot be controlled.Many kinds of accidents would occur.Thats why we need Traffic lights to control the Jams and to save the Human beings. 8.2Steps to make the project: Click on the on the icon of Siemens PLC software called LOGO!SOFT. Fig.8.1 Icon of LOGO!SOFT Then this main window of the software opens. Fig 8.2 Main Window

Then we select the File option to make the new project Ladder diagrams as shown in the below figure

Fig.8.3 Making a new file After this selection following window pops up before us,in which we can see all the contacts ,timers. Counters and many more functions using which we make the programs.

Fig.8.4Main window view

To make the single pole traffic light program we use Normally open (NO),Normally closed (NC) and Timers to give the proper timing to the lights to glow. Normally open contact Passes power (ON) if coil driving the contact is ON (closed)

Fig.8.5 Normally open symbol Normally closed contact Passes power (ON) if coil driving the contact is off (open).

Fig.8.6 Normally close symbol

Output or coil If any left-to-right path of inputs passes power, output is energized.

Fig.8.7 Coil symbol ON Delay Timer counts the time in seconds .It is called ON delay timer because it starts after the given value of time is passed. For setting the time we click on the timer then this window opens and we cn set the time according to our need. Fig8.8How to give the timer time We can use the contacts and Timers we bring them on the screen by dragging them. And then make the program for the single pole Traffic light system as shown in the following dig.

Fig 8.9 Single pole Traffic light

As we see we have given time for Red Light to glows for 60 sec,Yellow for 40 sec,Green for 100 sec with the help of timers. Then we click connect the program to the power bus (F3) to see the output as shown in the following dig.

Fig 8.10 program output

CONCLUSION

A Programmable Logic Controller(PLC) is a device that was invented to replace the necessary sequential relay circuit for machine control. A person knowlegde in relay logic system can master the major PLC functions.These are used extensively in nuclear reactor building and security control system.It is a reliable compare to other systems.These may be used to run a vibot.By using the PLC application logic we can control the air locks logic controlpanel of reactor building.these PLcs we used in many Real World applications.so using these PLCs nuclear reactor building doors namely main air locks and emergency airlocks.A Human-Machine Interface or HMI is the apparatus which presents process data to a human operator, and through which the human operator controls the process.The user interface (also known as human computer interface or man-machine interface (MMI)) is the aggregate of means by which peoplethe usersinteract with the system a particular machine, device and computer program.SCADA (supervisory control and data acquisition) is a type of industrial control system (ICS). Industrial control systems are computer-controlled systems that monitor and control industrial processes that exist in the physical world. It is useful in various process.Industrial processes include those of manufacturing, production, power generation, fabrication, and refining, and may run in continuous, batch, repetitive, or discrete modes. Infrastructure processes may be public or private, and include water treatment and distribution, wastewater collection and treatment, oil and gas pipelines, electrical power transmission and distribution, wind farms, civil defense siren systems, and large communication systems.Drives are used to control the frequency, speed and torque of motors. It is used in various industries in like paper mill,lifts,water supply distribution etc.All these devices are the main requirements to make the operations automatic. Automation involves a very broad range of technologies including robotics and expert systems, telemetry and communications, electro-optics, Cyber security, process measurement and control, sensors, wireless applications, systems integration, test measurement, and many, many more.New opportunities are emerging in the automation field. I