Date: 24 January 2019

Reg no: 2016-MC-303

Lab no 1
Objective:
Introduction to industrial automation and PLCS.
Introduction:
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. It is the second step beyond mechanization in the scope of industrialization.
Industrial automation:
Industrial automation is the control of machinery and processes used in various industries by
autonomous systems through the use of technologies like robotics and computer software.

Industries implement automation to increase productivity and reduce costs related to employees,
their benefits and other associated expenses, while increasing precision and flexibility.

Fig no1 (industrial automation)

Effect of industrial automation on industries

Most industrial operations are automated with the goal of boosting production and reducing the
cost of labor. A manufacturing organization that uses the latest technologies to fully automate its
processes typically sees improved efficiency, production of high-quality products and reduced
labor and production costs.

Page | 1
Date: 24 January 2019
Reg no: 2016-MC-303

Application of industrial automation

 High productivity
 High quality
 High flexibility
 High information accuracy
 High safety
Disadvantages of industrial automation
 High initial cost
Programmable logic control (PLC):
A Programmable Logic Controller, or PLC for short, is simply a special computer device used for
industrial control systems. They are used in many industries such as oil refineries, manufacturing
lines, conveyor systems and so on.
The basic units have a CPU (a computer processor) that is dedicated to run one program that
monitors a series of different inputs and logically manipulates the outputs for the desired
control. They are meant to be very flexible in how they can be programmed while also providing
the advantages of high reliability (no program crashes or mechanical failures), compact and
economical over traditional control systems.

General Types of PLC

1. An integrated or compact PLC
2. A modular PLC
3. Small PLC
4. Medium-sized PLC
5. Large PLC

Types of PLC:
 (AB)
 ABB PLCs (Asea Brown Boveri)
 Siemens PLCs
 Omron PLCs
 Mitsubishi PLCs
 Hitachi PLCs
 Delta PLCs
 General Electric (GE) PLCs
 Honeywell PLCs
 Modicon PLCs
 Schneider Electric PLCs
 Bosch PLCs

Page | 2
Date: 24 January 2019
Reg no: 2016-MC-303

The PLC System:

Typically PLC system consists of five basic elements.
 Processor unit
 Memory
 Power supply unit
 Input/output
 Programming device

Fig no 2 (PLC processing)

Processor unit:
It interprets the input signals and carries out the control actions, according to the program stored
in its memory, communicating the decisions as action signals to the outputs.
Power supply:
The power supply unit is needed to convert A.c. voltages to the low dc voltage (5v) necessary for
the processor and the circuits in the inputs and output interface modules.
Programming device:
It is used to enter the required program into the memory of processor.
Memory unit:
It is where the rules are stored that are to be used for the control actions by the microprocessors.
I/P & O/P:
The input and output sections are where the processor receives information from external devices
and communicates information to external devices.
Mechanical design of PLC:
There are two common types of PLC.
 Single box type
 Rack types
Conclusion:
In this lab session I learned about the plc and winpro ladder in which using ladder logic we
develop program and different aspects of software.

Page | 3