Introduction to Course

In this Course cover

1.Automation Engineer
2.Electrical concepts
3.PLC
4.SCADA
5.Industry 4.0(OPC , Kepware)
6.Digitalization
7.Smart Industries(AI,ML in Automation Industry)
 Introduction
Lecturer -
Syed Ameer- Around 15+ years of work experience in
Industry 4.0/ Smart Factory and Shop floor OT, IIOT, PLC’s and
HMI SCREEN DEVELOPER/design programming, Automation,
DCS, field Instrumentation devices
linkedin Link: https://www.linkedin.com/in/syed-ameer-
026bba9a/
WhatsApp Number : +9198855487

Student-…
 Introduction to
Automation
Industries
1. What is Automation
The word Automation is derived from Greek words “Auto” and
“Mation”
AUTO- SELF
MATION-MOTION

Automation is a set of technologies that result in operation of

machine without significance of human
• Automation is encompassing virtually every walk of life
• Automation solution are required right from Agricultural to
space technology
• Plant automation is the necessity for the manufacturing
industry to survive in today globally competitive market
Overview of
automation
industries
1. What is Industrial Automation?
Industrial automation is the use of control
systems, such as computers or robots, and
information technologies for handling different
processes and machineries in an industry to
replace a human being
 Importance of
automation in
various sectors
Automation is important in many sectors because it can improve
efficiency, reduce costs, and increase safety:
Improved safety: Automation can reduce the risk of accidents by
using robots to load and unload materials, or by using safety
curtains to keep workers away from assembly lines.
Increased productivity: Automation can help businesses produce
more products in less time, which can lead to increased profits.
Cost reduction: Automation can reduce the cost per unit of
productivity by allowing businesses to perform tasks more
efficiently. In some cases, automation can also replace human
labor.
Improved product quality: Automation can lead to improved
product quality because it provides unmatched precision and
consistency throughout production batches.
Enhanced resource utilization: Automation can help businesses use
resources more efficiently.
Innovation: Automation can free human potential from mundane
tasks, which can foster innovation.
Adaptability: Automation can help businesses adapt to dynamic
market landscapes swiftly.
Introduction to key
concepts and
technologies in
automation
Automation is the use of technology to carry out tasks with minimal human intervention. Key concepts and
technologies in automation include:

1. Robotics: Robots are machines programmed to perform tasks autonomously or with remote control. They
are commonly used in manufacturing, healthcare, and maintenance.

2. Artificial Intelligence (AI): AI enables machines to learn from data, adapt to new inputs, and perform tasks
that typically require human intelligence. This technology is used in automation for decision-making
processes.

3. Internet of Things (IoT): IoT refers to the network of interconnected devices that can communicate and
exchange data. Automation systems can utilize IoT to monitor and control various processes remotely.

4. Machine Learning: Machine learning algorithms enable systems to improve performance without being
explicitly programmed. This technology is crucial for optimizing automation processes.

5. Industrial Automation: Industrial automation involves the use of control systems such as PLCs
(Programmable Logic Controllers) and SCADA (Supervisory Control and Data Acquisition) to automate
machinery and processes in industries.

6. Process Automation: Process automation aims to streamline repetitive tasks within a workflow. It involves
the use of software to automate tasks like data entry, document processing, and customer communication.

By integrating these key concepts and technologies, automation can enhance efficiency, productivity, and
safety in various industries and applications.
The history of
industrial
automation
First Industrial Revolution-1760
Second Industrial Revolution-1871
Digital Revolution-1914
Industry 4.0- 2014- Present
Industry 5.0- coming soon……
 Industry 1.0 (mechanization with the rise of
steam power)-1760-1870
Advantages of Industry 1.0: Disadvantages of Industry 1.0:
• 1. Increased productivity: The • 1. Poor working conditions:
introduction of machines Workers in factories often faced
powered by steam engines led to long hours, low wages, and
a significant increase in . unsafe working conditions.
production. • 2. Environmental impact: The
• 2. Creation of new job increased use of coal and other
opportunities: The shift from resources led to pollution and
manual labor to machine- environmental degradation.
operated processes created jobs
in factories and manufacturing. • 3. Social inequality: The
Industrial Revolution widened
• 3. Economic growth: The mass the gap between the rich factory
production of goods made them owners and the poor working
more affordable and accessible to class, leading to social unrest.
Industry 2.0 (mass production with electricity)-1871-1914
Advantages of Industry 2.0: Disadvantages of Industry 2.0:
• 1. Increased productivity: Mass • 1. Labor exploitation: The working
production techniques allowed for goods conditions in factories during this time
to be manufactured more quickly and were often harsh, with long hours and low
efficiently. wages leading to labor exploitation.
• 2. Standardization: The use of assembly. • 2. Environmental impact: The rapid
lines led to products being made more industrialization during this period led to
consistently and of higher quality. increased pollution and environmental
degradation.
• 3. Technological advancements: The
introduction of electricity and other new • 3. Social inequality: The benefits of the
technologies revolutionized many Second Industrial Revolution were not
industries, leading to further innovation. evenly distributed, leading to widening
wealth gaps and social inequality.
• 4. Economic growth: The Second
• 4. Urbanization challenges: The mass
Industrial Revolution played a significant
migration of people from rural areas to
role in the economic growth of many
cities in search of work resulted in
countries during this time period. overcrowding and inadequate living
conditions in urban areas.
Third Industrial (automation with the introduction of
computers and electronics)-1914-2014
Advantages of Industry 3.0: Disadvantages of Industry 3.0:
1. Increased productivity: 1. Job loss: Automation and
Automation and computerization technology advancements can lead
streamline processes, leading to to unemployment as machines
higher output. . replace human workers.
2. Skills gap: Workers need to
2. Improved quality: Machines acquire new skills to operate and
can produce goods with greater maintain automated systems.
precision and consistency.
3. Dependence on technology:
3. Cost efficiency: Reduced labor System failures or cyber-attacks can
costs and increased efficiency disrupt operations.
result in lower production costs. 4. Environmental impact: Increased
4. Technological advancements: industrialization can lead to greater
Industry 3.0 paved the way for energy consumption and waste
Industry 4.0(automation with the introduction of
computers and electronics)-2014-Present
Advantages of Industry 4.0 include: Disadvantages of Industry 4.0 may
include:
1. Increased efficiency: Automation and
data integration lead to improved 1. Cost: Implementing Industry 4.0
productivity and reduced downtime. technologies can be expensive,
especially for smaller companies.
2. Enhanced connectivity: IoT 2. Workforce displacement:
.
technologies allow for real-time Automation may lead to job losses in
monitoring and communication between certain industries, requiring
machines and systems. retraining for employees.
3. Customization and flexibility: 3. Data security risks: Increased
Production processes can be tailored to connectivity can make systems more
individual customer needs more easily. vulnerable to cyber attacks.
4. Predictive maintenance: Data analytics 4. Skill gaps: Workers may require
new skills to operate and maintain
can predict equipment failures before advanced technologies.
they occur, reducing costly downtime.
5. Dependency on technology:
5. Sustainability: Industry 4.0 technologies Reliance on digital systems can lead
can help reduce waste and energy to disruptions if there are technical
Evolution of automation in
industries
• The third industrial revolution, also
known as the digital revolution,
began in the mid-20th century with
the advent of computers and
automation technologies like
programmable logic controllers
(PLCs) and computer-aided
manufacturing (CAM). This era saw
a significant increase in the use of
automation in industries such as
automotive manufacturing and
electronics
INSTRUMENTATION in Automation
industry
• Objectives for topic will be cover
• Termonology ,symbols,Standards
• Measuring Means
Pressure, Temperature ,Level,Flow
• Controllling
• Simple closed Loop Control
Instrumentation
• Measurement
• Monitoring
• Control
Definitions of Instrumentation:
An electrical or Pneumatic device
placed in the filed to provide
measurement and/or control
capabilities for the system.
 Measurement:
Sensor is part of Measurement.
• What is the sensor?
A device which detects or measures a physical property and records, indicates,
or otherwise responds to it is called sensor
Types of sensors and their
applications
TEMPERATURE SENSORS
• LARGEST COMMERICALLY
AVAILABLE SENSORS FOR BUY
• RANGE -40 deg C TO 100 deg C
TYPES OF TEMPERATURE
SENSORS
• Thermocouples
• Thermistors
• Radiation Pyrometer
• Radiation thermometers
• Resistance Temperature
Detector(RTD)
• Fiber Optic Temperature Sensors
• Silicon Temperature Sensors
 Importance of sensor technology in
industrial processes
Sno Topic description
1. Real-time data Sensors provide up-to-the-second data that helps with decision-making and process control.

2. Monitoring and control Sensors monitor and control critical parameters like temperature, pressure, flow, and
level. This helps optimize efficiency and quality.
3. Safety and security Sensors detect people and objects, and monitor noise levels.
4. Predictive maintenance Sensors gather data that helps predict equipment failures, which allows for proactive
maintenance.

5. Quality control Sensors monitor and control product quality, detect defects, and ensure correct assembly.

6 Sustainability Sensors can track output in real-time, which helps enhance sustainability.
7 Maintenance costs Automated control systems can minimize potential factory maintenance costs.

8 Production mobility Digitalization can improve production mobility, which gives advanced manufacturing firms a
competitive advantage
Scope of Instrumentation
• Information technology
• Electronics and communication engineering
• Computer engineering
• Aerospace
• Marine Sciences/Biology
• Metrology
• Automation(Mechincal and Process)
• Power Instrumentation
• Nuclear Instrumentation
• Biomedical
• Analyitcal
 Automation Technology
Instrumentation plays an Important role in almost every aspect of automation
Technology

• Industrial Automation
• Manufacturing
automation
• Process Automation
• Building Automation
Everyone needs to measure and/or control something- and that what
instrumentation is all about
Instrumentation
Type of Signal
signal Transmission
1. Electrical Signal – The value of Current or voltage represent the
value of the measured variable(4-20 mA 1-5 Vdc)
2. Pneumatic Signal- The value of the air or gas pressure represent
the value of the measured variable(3-15 PSIG)
3. Hydraulic Signal- The value of the fluid pressure represent the
value of the measured variable
Controllers : These are the devices
that do the controlling
• Programmable Logic
controllers(PLCs)
• Programmable Automation
Controller(PAC)
• Distributed Control Systems(DCS)
• Proportional, Integral, Derivative(PID)
Controllers
• Supervisory Control and Data
Acquisition(SCADA)
• Building Automation Controller(BAC)
• Energy Management System(EMS)
Control Elements
These are the devices the controller
operates
• Pneumatic valves
• Solenoid valves
• Rotary valves
• Motor
• Switches
• Relays
• Variables frequency drives
Understanding Wire Diagrams
• What is Electrical wiring Diagram?
A Simple visual representation of the
physical connections and physical
layout of an electrical system or circuit
It is a conceptual representation of
components of wire connection . It
shows the layout of the wirings to
show the physical relation of all
devices in the system .Mapping the
details and information of the daigram
Wire Diagram
SCHEMATIC DIAGRAM
• A schematic diagram is a
fundamental two- dimensional
circuit representation showing
the functionality and
connectivity between different
electrical components
WIRING VS SCHEMATIC DIAGRAM
• Wiring Diagram- also Called Connection diagram ,
However do show low equipment ia laid out and the
connections between them
• Schematic Diagram – Then diagrams uses Symbols to
Identify components and interconnecting lines to display
the electrical continuity of a circuit
 The Basics of Reading PLC
Panels and Wiring Diagrams
• PLC Panel Overview
• In industrial applications, an electrical panel is basically a service box that
connects the main power line to an electrical device and distributes electric
currents to various other circuits within the system. In an industrial setting,
you don’t simply plug a PLC controller into a wall socket, instead, an electrical
panel is used. A PLC panel is simply an electrical control panel consisting of
electrical components which use electric power to control a variety of
mechanical functions of industrial machinery or equipment.
PLC Panel Overview
• In order for industrial machinery and equipment to accomplish their
various process goals, they require user-defined functions and well-
organized control. Thus, electrical control panels like the PLC panel are
used to perform these functions within manufacturing machinery. Any
electrical control panel you’ll ever come across will always consist of two
main categories: panel structure and electrical components. Similarly, a
PLC panel consists of a special stainless steel box containing electrical
components required to run a machine or process in a factory setting.
The electrical components are of two types: power and control
components.
Structure of a PLC Panel

• The PLC panel structure is a

combination of an enclosure and
a back panel. You can relate a
PLC control panel to an electrical
breaker box in an office or
home.
Structure of a PLC Panel
• Panel Enclosure: This is typically a
stainless steel or aluminum metal
box and it comes in varying sizes. In
most industrial applications, the
size of the enclosures is
determined by the numbers on the
enclosure doors of the PLC panel.
Moreover, all enclosures have a UL
safety rating, IP rating, and/ or a
NEEMA classification which is
printed on a metal plate attached
to the enclosure.
Structure of a PLC Panel
• Back Panel: This is a metal sheet that
is mounted on the inside of the
enclosure to provide structural
support for wiring ducts and DIN rail
mounting. The wiring ducts provide
routing options and allow for neat
organization of the wires used while
assisting in controlling electrical noise
between the electrical components
inside the PLC panel. DIN rails feature
standardized dimensions and provide
a mounting structure for the electrical
components.
Components of a PLC Panel
• As previously stated, a PLC panel consists of two types of
electrical components: power components and control
components. To be able to read an electrical wiring diagram of
a PLC panel, you should have an understanding of these
components. Let’s take a look at these two types of electrical
components
 A)PLC Panel Power Components
• Rotary Disconnect: It is used for connecting incoming power lines/wires. It can include fuses or not. To
turn the power ON or OFF, it is usually rotated using the black or yellow PLC panel door handle.
• Power Distribution Block: It is mainly made of machined aluminum. The top of this block has a couple of
holes for larger connecting wires, while its bottom has multiple holes for smaller connecting wires. The
power distribution block is used to split a large connecting wire into smaller wires to be used with many
other different electrical components in the PLC panel.
• Relays and Contactors: These are ON/OFF switches that control mechanized functions based on control
commands from the PLC controller. Smaller relays control simple functions such as fans and lights. The
larger relays are known as contactors, and they control more advanced functions like three-phase
motors.
• Main Circuit Breaker: We are all familiar with the main disconnect of electric circuits in our homes or
offices. Well, the main circuit breaker in a PLC panel is similar to such an electrical disconnect. In most
industrial control applications, the main circuit breakers in PLC panels handle between 120V to 480V.
• Branch Circuit Breakers: These provide short circuit protection and in some cases, they prevent overload
conditions for each type of load controlled by the PLC, such as a heater, motor, etc.
• Surge arresters: They are used to prevent utility power surges or lightning strikes from damaging the
electrical components inside a PLC panel due to overvoltage.
• Transformer: Normally, a step-down transformer is used to reduce the incoming AC voltage to 120V for
various components while in other cases it is used to step down the incoming voltage to 24V. This is
applicable in instances where the PLC panel is connected to a 120V AC power line.
• Power Supply: This is used to convert high power AC voltage, normally 120V or 240V AC to a lower and
safe control DC voltage (24V DC) for the various control components in the PLC panel like HMI, or PLC
controller.
• Power Contacts: These are used to manually disable/enable power flow to a machine using e-stop
buttons.
• Motor Starter: Also known as a motor contactor, it turns ON motors at full speed and full voltage.
• Variable Frequency Drive (VFD): This is a type of motor controller which is used to adjust the motor
speed as well as monitor other motor data.
• Motor Soft Starter: This is also a type of motor controller which is used to start a motor gradually over
time, then ramp up to full motor speed.
• Grounding: This connection is necessary as it provides a current flow pathway in the event of an
electrical fault.
B) PLC Panel Control
Components
• upplementary Circuit Breaker: It is used to protect high-end and expensive control devices and components of the PLC panel.
• Master Control Relay (MCR): It is used to implement a safety circuit that transfers power from all output devices in case of an emergency. In most
cases, the MCR will be paired mushroom-head Stop pushbutton.
• Network Switches: They make up the communication hub of the PLC panel. They facilitate communication between the PLC system and a variety of
other network-compatible devices on the assembly line. An example of a network switch is the Ethernet switch which is used for network
communications between the PLC, the HMI, and other smart devices.
• Programmable Logic Controller (PLC): This is essentially the CPU of the PLC contained inside the panel. This unit has the Arithmetic and Logic Unit
(ALU) which is responsible for data manipulation, arithmetic functions, and logic operations. A control unit is also included to regulate the timing of
the PLC control operations.
• Human Machine Interface (HMI): HMIs provide a Graphical User Interface (GUI) that enables operators to interact with the PLC control system. So
an operator can use an HMI graphical display to monitor and review real-time input and operational data or configure and control certain functions
of machinery or process. Examples of HMIs include keypads, text-readouts, joysticks, video monitors, or large touch screen panels like Liquid Crystal
Displays (LCDs).
• Input/Output Module: I/O modules provide an interface from the PLC to the input field devices and the components or devices being controlled.
The output module connects the PLC to the input devices such as sensors, start/stop pushbuttons, and switches. On the other hand, the output
module is used by the PLC to control output field devices like relays, solenoid valves, motors, pumps, and electric heaters. You can have either
analog or Digital Input/Output modules.
• Operator Pushbutton: This is located on the front of the PLC panel and is used by the operator to control the process or machine.
• Terminal Blocks: They are used to connect and splice field device wiring and internal PLC panel wiring. They also assist in organizing and distributing
the array of wires emanating from various sources to different electrical devices
How do you read PLC Panel
Wiring Diagrams?
• here are some rules to be followed whenever
you’re reading a PLC panel wiring diagram:
Rule #1: You should read a PLC Panel wiring
diagram from left-to-right and top-to-down, just
like when you’re reading a book.
Rule #2: To understand the addressing system of
a PLC panel wiring diagram use the combination
of the provided column numbers and page
numbers. For example, if you find a number like
38.7 below or beside an electrical component in
a PLC panel wiring diagram, it means that the
component has been used on page 38, column
7. This rule applies when you’re reading an
actual PLC panel wiring diagram in a booklet
with multiple pages.
Okay, now let’s look at some examples of PLC
Panel wiring diagrams.
 Example 1: A PLC Controlled
Three-phase Motor System
• In this example, the motor is required to operate in both
directions, which is only possible through a
Forward/Reverse Control Logic circuit or Relay circuit. A
simple Forward/Reverse PLC control logic would be the
most viable solution in this case. Thus, a PLC system is
used for Forward and Reverse control of the three-phase
asynchronous motor.
• Two relays or contactors for motor control are used
because two different directions are needed. The first
contactor is for Forward Direction control while the
Second contactor is for providing Reverse Direction
control of the Motor. Also, three pushbuttons are used
for Stop, Forward and Reverse functions of the motor. So,
the operator will use the Forward Pushbutton (FWD PB)
for forward motor operation, and Reverse Pushbutton
(REV PB) for reverse motor operation and Stop
Pushbutton (STOP PB) for stop function. The resulting
wiring diagram is as shown below:
•
Note: The dashed lines in the wiring diagram above (Figure 1) indicate a single purchased
component, which in this case is the PLC system.
 Example 2: PLC-based Motor Controller System
In this motor controller system, three phase AC power
is connected at the terminal block and then supplied
to a power interrupter (the main circuit breaker). After
which all the three phases (L1, L2, and L3) are
supplied to a motor starter with three contacts,
labeled as M. Next, it is connected to three thermal
overload relays(branch circuit breakers). Two
phases(L2 and L3) of the three phase AC power are
then connected to a step-down transformer, which is
connected to a PLC system for powering the logic. The
resulting electrical wiring diagram is as shown below:
 Example 3: PLC Panel Ladder Logic Wiring
Diagram

• To better understand the logic control provided

by the PLC system, a ladder logic circuit
diagram is included in the motor electrical
schematic in Figure 2 in place of the PLC
system. Generally, a Ladder Logic wiring
diagram of a PLC panel can be sub-divided into
two distinct parts. The first part is the power
circuit which shows the flow of power to the
system. The power circuit is normally denoted
by bold lines. The second portion is usually
denoted by thin lines and is the control circuit. Figure 3: Electrical Schematic and Ladder Logic
In cases where an external power supply is Diagram of a PLC Controlled Motor
used to power the PLC control panel, this is
usually not shown. The figure below shows a
good example of a ladder logic wiring diagram
with both power circuit and control circuit:
Example 3: PLC Panel Ladder Logic Wiring
Diagram

• In the above example (Figure 3), the power circuit shows

how a three phase AC (L1, L2, and L3) supply voltage flows
to the motor; first, it flows to the terminals, it is then
connected to a power interrupter(main circuit breaker),
the three phases are then supplied to three contacts, M,
and three thermal overload relays(branch circuit
breakers). In this case, an external PLC power supply is not
required as two phases (L2 and L3) of the three phase AC
power are connected to a step-down transformer that
powers the PLC system. Figure 3 also includes a control
circuit (shown as a Ladder Logic diagram) that focuses on
how the motor is being controlled.
• In the PLC-based control portion of the electrical
schematic in Figure 3, standard Ladder Diagram symbols
are used. However, electrical components like fuses and
disconnect devices can also be used in control circuits. In
Figure 3, the control circuit includes a fuse. Look at some
of the standard Ladder Diagram symbols shown below,
which will be helpful in reading the PLC-based control
circuit in Figure 3.
Figure 4: Most Common Ladder Diagram Symbols
Building the PLC Panel
• Transformers
• Power contacts
• Terminals
• Fuses or circuit breakers
• Grounding
• Enclosure
Motor controller example
• Dashed lines indicate a single
purchased component. This
system uses 3 phase AC
powet(L1,L2,L3) connected to
the terminals. the three phases
are then connected to a power
interrupter.Next, all three Phases
are Supplied to a motor starter
that container three contacts,M,
and three thermal overload
relays(breakers)
Motor controller example
• The Contacts,M,will be controlled
by coil ,M.the output of the motor
starter goes to a three phase AC
motor.Power is supplied by
connecting a step down
transformer to the control
electronics by connecting to
phases L2 and L3.The lower
voltage is then used to supply
power to the left and right rails of
the ladder.The neutral rail is also
grounded.
PLC controller example
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