EJ 501 PROGRAMMABLE LOGIC CONTROLLER PLC AND AUTOMATION

EJ 501 PROGRAMMABLE LOGIC CONTROLLER (PLC) AND AUTOMATION SBO/ PMM/ EJ 501/ Jun 2011 1

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Objective ; 1. Understand automation system a. Understand type of automation b. Comparison type of automation 2. Understand relays, contactors, electromechanical timer and electromechanical counter (symbol, building diagram, operation and application examples) a. Develop simple logical control/ automation sequence SBO/ PMM/ EJ 501/ Jun 2011 2

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Automation System l l Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well Type of Automation system : l l l fixed/ hardwired automation programmable automation flexible automation SBO/ PMM/ EJ 501/ Jun 2011 3

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Fixed/ Hardwired Automation l l Custom-engineering, special – purpose equipment to automate a fixed sequence of operations. High production rates, inflexible product design Programmable Automation l l Equipment designed to accommodate a specific class of product changes. Batch production, medium volume Flexible Automation l l Design to manufactured a variety of product or parts Low production rates, varying product design and demand SBO/ PMM/ EJ 501/ Jun 2011 4

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Comparison Types of Automation When to consider Advantages Disadvantages Fixed High demand volume, long product life cycle § maximum efficiency § low unit cost § Programmable Batch production, products with the different options § flexibility to deal with changes in product § low unit cost for large batches § Flexible Low production rates, varying demand, short product life cycles § flexibility to deal with design variations § customized product § SBO/ PMM/ EJ 501/ Jun 2011 large initial investment § inflexibility new product requires long set up time § high unit cost relative to fixed automation large initial investment § high unit cost relative to fixed or programmable automation 5

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Relays l Define A relay is usually an electromechanical device that is actuated by an electrical current. The current flowing in one circuit causes the opening or closing of another circuit. Relays are like remote control switches and are used in many applications because of their relative simplicity, long life, and proven high reliability. Relays are used in a wide variety of applications throughout industry, such as in telephone exchanges, digital computers and automation systems. Highly sophisticated relays are utilized to protect electric power systems against trouble and power blackouts as well as to regulate and control the generation and distribution of power. In the home, relays are used in refrigerators, washing machines and dishwashers, and heating and air-conditioning controls l Symbol SBO/ PMM/ EJ 501/ Jun 2011 6

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM l Building Diagram SBO/ PMM/ EJ 501/ Jun 2011 7

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Relay Diagram SBO/ PMM/ EJ 501/ Jun 2011 Bottom View 8

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM l How does a relay work? l l All relays contain a sensing unit, the electric coil, which is powered by AC or DC current. When the applied current or voltage exceeds a threshold value, the coil activates the armature, which operates either to close the open contacts or to open the closed contacts. When a power is supplied to the coil, it generates a magnetic force that actuates the switch mechanism. The magnetic force is, in effect, relaying the action from one circuit to another. The first circuit is called the control circuit; the second is called the load circuit. There are three (3) basic functions of a relay: l l l On/Off Control: Example: Air conditioning control, used to limit and control a “high power” load, such as a compressor. Limit Control: Example: Motor Speed Control, used to disconnect a motor if it runs slower or faster than the desired speed. Logic Operation: Example: Test Equipment, used to connect the instrument to a number of testing points on the device under test. SBO/ PMM/ EJ 501/ Jun 2011 9

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM l Operation l When no voltage is applied to pin 1, there is no current flow through the coil. No current means no magnetic field is developed, and the switch is open. When voltage is supplied to pin 1, current flow though the coil creates the magnetic field needed to close the switch allowing continuity between pins 2 and 4. SBO/ PMM/ EJ 501/ Jun 2011 10

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM • Type of Relay / Application Examples This is a Single Pole Single Throw (SPST) relay. Current will only flow through the contacts when the relay coil is energized. This is a Single Pole Double Throw (SPDT) relay. Current will flow between the movable contact and one fixed contact when the coil is DEenergized and between the movable contact and the alternate fixed contact when the relay coil is energized. The most commonly used relay in car audio, the Bosch relay, is a SPDT relay. This is a Double Pole Single Throw (DPST) relay. When the relay coil is energized, two separate and electrically isolated sets of contacts are pulled down to make contact with their stationary counterparts. There is no complete circuit path when the relay is DEenergized. SBO/ PMM/ EJ 501/ Jun 2011 11

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM • Type of Relay / Application Examples This relay is a Double Pole Double Throw (DPDT) relay. It operates like the SPDT relay but has twice as many contacts. There are two completely isolated sets of contacts. This is a 4 Pole Double Throw (4 PDT) relay. It operates like the SPDT relay but it has 4 sets of isolated contacts. SBO/ PMM/ EJ 501/ Jun 2011 12

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Figure : Relay Contact Configuration SBO/ PMM/ EJ 501/ Jun 2011 13

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Pin no 1 – Common Pin no 2 – NC Pin no 3 – NO Figure : Wiring of relay SBO/ PMM/ EJ 501/ Jun 2011 14

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Contactors l Define SBO/ PMM/ EJ 501/ Jun 2011 15

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM l Building Diagram SBO/ PMM/ EJ 501/ Jun 2011 16

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM l Operation Normally Open Contact In the following illustration the circuit is first shown in the de-energized state. The contacts are shown in their normally open (NO) state. When the relay is energized, the contacts close, completing the path of current and illuminating the light. The contacts have been highlighted to indicate they are now closed. SBO/ PMM/ EJ 501/ Jun 2011 17

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM l Operation Normally Close Contact In the following illustration the contacts are shown as normally closed (NC), meaning the contacts is closed when the relay is de-energized. A complete path of current exists and the light is on. When the relay is energized, the contacts open turning the light off. SBO/ PMM/ EJ 501/ Jun 2011 Normally Close Contact 18

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Electromechanical Timer l Define Electromechanical timers are used to start or stop a machine or other device at preset or delayed intervals. They consist of both electrical and mechanical components, and often feature an electric motor that drives one or more gears. They typically accept electric or electronic inputs to operate a mechanical output such as rotating wheels or knobs. SBO/ PMM/ EJ 501/ Jun 2011 19

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM l Symbol Electromechanical Timer Contact symbols determine the time of timer action: On-delay action - TR energized, contacts change state after set time interval Off-delay action - TR de-energized, contacts change state after set time interval SBO/ PMM/ EJ 501/ Jun 2011 20

UNIT 1 INTRODUCTION TO AUTOMATION SYSTEM Electromechanical Counter l Define Electromechanical counters are used to detect, totalize, and indicate a sequence of events. They typically accept electric or electronic inputs to operate mechanical outputs such as rotating wheels or knobs. These devices may count UP and/or DOWN, support multiple functions, and provide reset capabilities. SBO/ PMM/ EJ 501/ Jun 2011 21