Industrial Automation: What it is?

Hi Greetings, here today we will try to find out answers of some basic questions asked about Automation those are 

What is Industrial Automation?

What are the Components of Automation?

What is a PLC ? What is DCS? 

Why We Need Automation?

What are the Advantages of PLC System?

What are the applications of PLC’s?

Difference between  PLC & DCS?






Why do we need automation?
  •      
    To improve productivity
  •  
         Reduce costs. 
  •        Increase
    flexibility to meet varying demand
What
does automation include?
  •   Automation is used to
    describe a broad array of processes, products and systems working together
    to automate manufacturing. What is important is appropriate automation.
  •   In the broader sense, it
    includes elements like robotics, drives, programmable logic controllers
    (PLC) and computerized numerical control (CNC), production planning,
    process optimisation, open control systems, human machine interfaces
    (HMI), vision systems and industrial networks.
  •   The trend towards
    programmable automation started over 30 years ago in the USA, only in the
    last few years that Indian companies have started incorporating software
    systems at all levels of production.Components of an automation
    system
  •  Instrumentation
  •  
    Main Controller (PLC, CNC, PC Based, DCS)
  •  
    HMI/MMI,
  •  
    Software (Soft Logic, Soft CNC, In Touch, I-Fix),
  •  
    Communications (Ethernet, Fieldbus, DeviceNet),
  •  
    Panel Components (starters, fusing etc.),
  •  
    Drives/Motors,
  •  
    Enterprise Software (SCADA, MES, MRP etc.),
  •  
    Sensors (flow meters, feedback, limit switches), and
  •  
    Actuators (valves, pumps, solenoids, heaters etc.).
Components
of an automation system: DCS
  •   DCS solutions grew out
    of the requirements of the heavy process industries, and still dominate
    the large-scale applications prevalent in continuous process applications.
    In such large applications, utilizing thousands of I/O points, DCSs will
    likely remain the preferred alternative, but not without continuing to
    respond directly to challenges from both PLC and PC-based control systems.
 PLCs
challenge DCS
  •   PLC suppliers are
    invading the process control markets with units that perform batch
    processing as well as the more traditional discrete functions. A PLC can
    do nearly everything today that a DCS can do, though DCS might still have
    advantages in terms of redundancy (because the large-scale continuous
    processes involved are so complex and difficult to restart if anything
    goes wrong).
  •   Also significant is the
    trend to use hybrid controls that incorporate PLCs into DCSs.
Is
industrial PC a threat?

   The industrial PC is not yet a threat.
Suppliers view it as an ally, providing the hardware and software components to
upgrade “traditional” PLCs out of the “outdated” label
 Why
PLCs dominate PCs on the shop floor?
PLCs were originally designed as fast, robust
controllers for discrete logic applications. Historically, PLC advantages
relative to PCs have included:
  •   A large base of
    maintenance personnel experienced in troubleshooting and servicing systems
    with relay ladder logic programming, rather than PC software languages
  •    Better power
    failure response
  •   Cost advantages for
    simple machine control applications
  •   Higher reliability that
    minimizes the expense of shutdown, troubleshooting, repair, & startup
  •  Industrially hardened
    packaging
  •   Long availability and
    support for product models without the rapid obsolescence
Industry
User Segments (Applications of PLC’s)
  •  
    Automotive, Building Automation, Cement & Glass, Chemical
  •  
    Electrical, Electronic, Elec Power, Fabricated Metals
  •  
    Food & Beverage, Machinery, Metals & Mining
  • Oil
    & Gas, Pharmaceuticals, Pulp & Paper
  •  
    Refining, Water & Waste

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