Phase-I - DIV-B - AE - Pinkesh Patel

12/30/2021
Introduction to Automation & Control
Phase-I
This presentation is released under Creative Commons Attribution 4.0 License. You are free to use, distribute and modify it,
including for commercial purpose, provided you acknowledge the source.
Teaching Plan of
Automated Electronics (EC 614)
Module Content Hrs. ❑Text (T1):
I Introduction: Automation overview, Requirement of automation
systems, Architecture of Industrial Automation system,
5
Industrial Instrumentation & Control
Introduction of PLC and supervisory control and data acquisition
(SCADA). Industrial bus systems: modbus & profibus (TMH Publication, IIIrd Edi.) By S. K. Singh
II Automation components: Sensors for temperature, pressure, 6
force, displacement, speed, flow, level, humidity and pH
measurement. Actuators, process control valves, power
electronics devices DIAC, TRIAC, power MOSFET and IGBT. Supplementary Text(T2) :
Introduction of DC and AC servo drives for motion control.
Industrial Instrumentation, Control and
III Computer aided measurement and control systems: Role of
computers in measurement and control, Elements of computer
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Automation (Jaico Publishing House, 2013)
aided measurement and control, man-machine interface, By S. Mukhopadhyay, S.Sen and A.K. Deb)
computer aided process control hardware, process related
interfaces, Communication and networking, Industrial
OR
communication systems, Data transfer techniques, Computer
aided process control software, Computer based data acquisition https://nptel.ac.in/courses/108/105/1081050
system, Internet of things (IoT) for plant automation 88/
DHARMSINH DESAI UNIVERSITY 2
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Learning Objectives
❑ Learner should be able to understand the difference between the terms
‘Automation’ and ‘Control’
❑ Learner should be able to describe the architecture of Industrial Automation
System
❑Learner should be able to describe various elements of Industrial Automation
Systems and how they are organized hierarchally in levels
❑Learner should be able to appreciate the nature of technologies involved in
realizing these level
❑Learner should be able to appreciate the use of PLC and SCADA in Industrial
Automation System
Understanding the Title of the Course
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Automation
❑ The word ‘Automation’ ⇒ “Auto” (self) + “ Matos” (moving) in Greek word
❑ Hence Automation is the mechanism for systems that “ move by itself”
❑ Automated system also achieve superior performance compared to manual
systems, in terms of power, precision and speed of operation
❑ Definition
Automation is a set of technologies that results in operation of systems without
significant human intervention and achieves performance superior to manual
operation
Control
❑ Definition
Control is a set of technologies that achieves desired patterns of variations of
operational parameters and sequences for machines and systems by providing
the necessary input signals
❑ Differences in the senses that the terms ‘Automation’ & ‘ Control’ are generally
interpreted in technical contexts are as follows:
❑ Automation systems may include Control systems but reverse is not true
❑ The main function of Control systems is to ensure that the outputs follow the set
points. But Automation system have much more functionality , such as computing set
points for control systems, monitoring system performance, plant startup or shutdown,
job and equipment handling etc.
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Point to Think About -1
[A] Why does an automated system achieve superior performance compared to a

manual one?
Point to Think About -1: Answer
[A] Why does an automated system achieve superior performance compared to a

manual one?
ANS:
Because such systems can have more precision, more energy and more speed of
operation than possible manually. Moreover using computing techniques, much
more sophisticated and efficient operational solutions can be derived and applied in
real-time.
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Requirements of a Good Control System

[1] Accuracy:
Accuracy is the measurement tolerance of the instrument and defines the limits of the
errors made when the instrument is used in normal operating conditions.
[2] Sensitivity:
The parameters of a control system are always changing with the change in surrounding
conditions, internal disturbance, or any other parameters.
This change can be expressed in terms of sensitivity. Any control system should be
insensitive to such parameters but sensitive to input signals only.
Requirements of a Good Control System

[3] Stability:
It is an important characteristic of the control system. For the bounded input signal, the
output must be bounded and if the input is zero then the output must be zero then such
a control system is said to be a stable system.
[4] Bandwidth:
An operating frequency range decides the bandwidth of the control system. Bandwidth
should be as large as possible for the frequency response of a good control system.
[5] Speed:
It is the time taken by the control system to achieve its stable output. A good control
system possesses high speed. The transient period for such a system is very small.
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[A] Can you explain the above definition in the context of a common control system,
such as temperature control in an oven?
[B] Is the definition applicable to open-loop as well as closed loop control?

[A] Can you explain the above definition in the context of a common control system,
such as temperature control in an oven?
ANS:
Consider a temperature-controlled oven as found in many kitchens. A careful
examination of the dials would show that one could control the temperature in the
oven. This is a closed loop control operation. One can also control the time for which
the oven is kept on. Note that in both cases the input signal to the process is the
applied voltage to the heater coils. This input signal is varied as required to hold the
temperature, by the controller.
[B] Is the definition applicable to open-loop as well as closed loop control?

YES
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Type of Control Systems

1.Open-loop control systems
2.Closed-loop control systems
Open-loop control systems
Practical Examples of Open Loop Control

Systems
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Advantages of Open Loop Control

Systems
Disadvantages of Open Loop Control

System
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Type of Control Systems

1.Open-loop control systems
2.Closed-loop control systems
Close-loop control systems
Practical Examples of Close Loop

Control Systems
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Advantages of Close Loop Control

Systems
Disadvantages of Close Loop Control

System
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[A] Can you give an example of an automated system, which contains a control
system as a part of it?
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Role of Automation in Industry (1)

❑ Manufacturing Processes, basically , produce finished product from raw/unfinished
material using energy , manpower, equipment and infrastructure
❑ The fundamental objective of any industry is to make profit
❑ Profit = (Price/unit - cost/unit) * Production volume

❑ Profit = (Price/unit - cost/unit) * Production volume
❑ AGV, Industrial Robots, Automated Crane etc reduce material handling time
❑ Automation reduces cost of production significantly by efficient usage of energy, manpower
and material
❑ The product quality that can be achieved with automated precision machines and
processes cannot be achieved with manual operations and consistency will also be
maintained
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 Automation affects all of these factors. Firstly, automated machines have significantly
lower production times.
 For example, in machine tools, manufacturing a variety of parts, significant setup times
are needed for setting the operational configuration and parameters whenever a new part
is loaded into the machine.
 This can lead to significant unproductive for expensive machines when a variety of
products is manufactured.
 In Computer Numerically Controlled (CNC) Machining Centers set up time is reduced

significantly with the help of Automated Tool Changers, Automatic Control of Machines
from a Part Program loaded in the machine computer.

 The consequent increase in actual metal cutting time results in reduced capital cost and
an increased volume of production.
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Typical Industrial Product Life Cycle
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Economy of Scale and Economy of

Scope
In the context of Industrial Manufacturing Automation, Economy of Scale is defined as follows.
Obviously, Automation facilitates economy of scale, since, as explained above, it enables

efficient large-scale production.
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Scope
In the modern industrial scenario however, another kind of economy, called the economy
of scope assumes significance.

Scope
Economy of scope arises in several sectors of manufacturing, but perhaps the most
predominantly in electronic product manufacturing.
where complete product life cycle, from conception to market, are executed in a matter of
months, if not weeks. Therefore, to shrink the time to market drastically use of automated
tools is mandated in all phases of the product life cycle.
Additionally, since a wide variety of products need to be manufactured within the life period
of a factory, rapid programmability and re-configurability of machines and processes
becomes a key requirement for commercial success.
Such an automated production system also enables the industry to exploit a much larger
market and also protects itself against fluctuations in demand for a given class of products.
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[A] You give an example of an industry where economy of scope is more significant
than the economy of scale?
[B] Can you give an example of an industry where economy of scale is more
significant than the economy of scope?

[A] You give an example of an industry where economy of scope is more significant
than the economy of scale?
One such example would a job shop which manufactures custom machine parts by
machining according to customer drawings. Another example would be a factory to
manufacture Personal Computer components
[B] Can you give an example of an industry where economy of scale is more
significant than the economy of scope?
One such example would be a Power plant. Another one would be a Steel Plant.
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Types of Production Systems
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Types of Automation Systems

❑ Based on flexibility and level of integration in manufacturing process operations:
❑ Fixed Automation
❑ Programmable Automation
❑ Flexible Automation
❑ Integrated Automation
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Fixed Automation
❑ Preferred to perform fixed and repetitive operations
❑ Used in high volume production with dedicated equipment
❑ Continuous flow and Discrete Mass production system use this automation
❑ Example: Distillation process, conveyors, Paint Shops etc.
Programmable Automation
❑ Used for a changeable sequence of operation and configuration of the
machines using electrical controls
❑ Used in batch process where job variety is low and product volume is medium
to high
❑ Investment on programmable equipment is less, as production process is not

changed
❑ Example: Steel Rolling Mills, Paper Mills etc.
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Flexible Automation
❑ Used in manufacturing system which is invariably computer controlled
❑ Used in batch processes where product varieties are high and job volumes
medium to low
❑ Human operators give high level commands in form of codes (eg: G-code)
entered into computers , which provides instruction to production machine and
all further tasks to be carried out by machines are automated
❑ Example: Multi purpose CNC machines, Automated Guide Vehicles (AGV) etc.
Example of G-Code
❑ G00 : Positioning at rapid movement
❑ G01: Linear Interpolation
❑ G32: Thread cutting operation on a lathe
❑ G40: Cancel cutter compensation
❑ G74: Face grooving cycle
❑ G94: Per minute feed
❑ G95: Per revolution feed
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Integrated Automation
❑ It indicates complete automation of a manufacturing system , with all processes
functioning under computer control and coordination through digital information
processing
❑ It symbolizes full integration of process and management operations using ICT
❑ Technologies like CAD-CAM, CAPP, CNC machine tools, automated storage and
retrieval systems, automated material handling systems, computer scheduling used
❑ Example: Advance Process Automation System , DCS, Computer Integrated

Manufacturing
Architecture : Automation Pyramid

(1)
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Architecture : Automation Pyramid

(2)
❑ Sensors & Actuators layer: This layer is used to translate the parameter sensed in to
some useful form for analysis and decisions. This form the base layer of the pyramid
❑ Automatic Control layer: It consist of automatic control and monitoring systems,
which drive the actuators using the information given by sensors
❑ Supervisory Control layer: This layer sets the target/goal to the controller.
Supervisory control looks after the equipment, which may consists of several control
loop
❑ Production Control layer: This take care of decision problems like production targets,
resource allocation, maintenance management etc.
❑ Enterprise Control layer: This deals less technical and more commercial activities
like supply, demand, product marketing etc
Industrial Sensors & Instrument

Systems (1)
❑ Figure below shows the functional configuration of typical sensor system
❑ Physical Medium refers to the object where a physical phenomenon takes place and
some physical variable associated with it is measured. Eg: Furnace in case of
temperature measurement
❑ Sensing Element is affected by the phenomenon in the physical medium either
through direct or physical contact or through indirect contact. Eg: RTD, Thermocouple
etc
❑ Signal Conditioning Element serves the function of changing the nature of signal
generated in the sensor to some suitable signal form. Eg: RTD incorporated in
Wheatstone's bridge, ambient referencing in thermocouple
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Industrial Sensors & Instrument

Systems (2)
❑ Signal Processing Element is used to process the signal generated by signal

conditioned element for variety of purpose such as filtering (to remove noise),
linearisation ( to make output lineally related to physical measured parameter) etc
❑ Target-Signal Handling Element may perform variety of function depending on the

target application. Eg: temperature chart recorder, a digital display or an ADC followed
by an interface to a process control computer
Industrial Actuator Systems (1)

❑ Figure below shows the functional configuration of typical actuator system
❑ Signal Processing Element accepts command from the control system in electrical
form
❑ Power Amplifying Element sometimes contains power amplifying stages like servo-
amplifiers or in some cases power electronic drive circuits like motor driven actuators
❑ Variable Conversion Element serves the function of changing the nature of signal
generated by the power amplification element from electrical to non-electrical form,
generally in the form of motion. Eg: stepper/servo motors, electrohydraulic servo valve
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Industrial Actuator Systems (2)
❑ Energy Conversion Element
❑ Non-electrical power conversion elements are used to amplify power further, if

necessary, typically using hydraulic or pneumatic mechanisms
❑ Non-electrical variable conversion elements may be used further to transform the

actuated variable in desired forms. Eg: rotary to linear motion converters using some
mechanism etc
Industrial Control Systems (1)

❑ By industrial control systems, we denote the sensors systems, actuator
systems as a controller
❑ Controllers are essentially elements that accept command signals from humn
operators or Supervisory Systems, as well as f/b from the process sensors and
compute signals that are fed to actuators
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Industrial Control Systems (2)
❑ The controller objective is to provide inputs to the plant such that output y(t) follows the
input r(t) as closely as possible, in value and over time.
❑ The difficulties in achieving the performance is mainly due to unavoidable disturbances
such as sensor noise (ds) , the possible instability, uncertainty in plant dynamics (do) and
limitations in actuator capabilities (di)
❑ These control systems are classified into two kinds: Continuous Control ( P, PI or PID)
and Sequence / logic control (PLC)
Continuous Control or Sequence /

Logic Control Examples
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Supervisory Control Systems

❑ It controls at a hierarchically higher level over the automatic controllers, which
controls smaller subsystems
❑ Supervisory Control Systems perform, typically the following functions:
❑ Set point Computation

❑ Performance monitoring
❑ Start up / Shut down / Emergency operations
❑ Control reconfiguration
❑ Graphical Interface
Introduction to PLC (1)

❑ Definition Standardized by IEC (International Electrotechnical Commission)
❑ "PLC is a digitally operating electronic system, designed for use in harsh

industrial environment, which uses a programmable memory for the internal
storage of user-oriented instructions for implementing specific functions such as
logic, sequencing, timing, counting and arithmetic, to control, through digital or
analog inputs and outputs, various types of machines or processes.
❑ The biggest differences between PC and PLC are that a PLC can perform
discrete and continuous functions that a PC cannot do, and a PLC is much
better suited to rough industrial environments.
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Introduction to PLC (2)

❑ PLCs play a crucial role in the field of automation, using forming part of a
larger SCADA system.
❑ A PLC can be programmed as per the operational requirement of the process.
❑ In the manufacturing industry, there will be a need for reprogramming due to

the change in production.
❑ To overcome this difficulty, PLC-based control systems were introduced.
Basics of PLC (1)

❑ The main advantage of PLC over a “hard-wired” control system is that you can
go back and change a PLC after you’ve programmed it, at little cost (just the
cost of the programmer’s time).
❑ In a hard-wired control system, you’re essentially having to rip out wires and
start from scratch (which is more expensive and takes longer).
❑ Let's take an example and try to understand the above two lines.
❑ Now you are given a task that when you turn ON the switch, the light should
glow only after 30 seconds.
❑ With this hard- wired setup, we are stuck.
❑ The only way to achieve this is to completely rewire our circuit to add a timing
relay.
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Basics of PLC (2)

❑ In such scenario, a programmable logic controller (PLC) comes into the
picture, which doesn’t require any additional wiring and hardware to make sure
of a change.
❑ It just requires a simple change in code, programming the PLC to only turn on
the light 30 seconds after the switch is turned ON.
❑ So, by using a PLC, it is easy to incorporate multiple inputs and outputs.
Architecture / Physical Structure of

PLC (1)
❑ The structure of a PLC is almost like a computer’s architecture.
❑ Programmable Logic Controllers continuously monitors the input values from

various input sensing devices (e.g., accelerometer, weight scale, hardwired
signals, etc.) and produces corresponding output depending on the nature of
production and industry
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Architecture / Physical Structure of

PLC (2)
❑ A typical block diagram of PLC consists of five parts namely:
❑ Rack or chassis
❑ Power Supply Module
❑ Central Processing Unit (CPU)
❑ Input & Output Module
❑ Communication Interface Module
Input / Output Module (1)

❑ Have you ever thought about how to sense physical parameters like
temperature, pressure, flow, etc. using PLC ?
❑ Of course, PLC has an exclusive module for interfacing inputs and output,
which is called an input & output module.
❑ Input devices can be either start and stop pushbuttons, switches, etc. and
output devices can be an electric heater, valves, relays, etc.
❑ I/O module helps to interface input and output devices with CPU.
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Input / Output Module (2)

❑ The input module of PLC does four main functions.
❑ Input module interface receives the signal from process devices at 220 V AC
❑ Converts the input signal to 5 V DC that can be used by PLC
❑ Isolator block is used to isolate/prevent PLC from undergoing fluctuation
❑ After which the signal is sent to the output end i.e. the PLC
Example: PLC (Dishwasher) [1]

1. User pushes the cycle mode button (input detected)
2. User pushes the start button (input detected)
3. CPU verifies that the door is closed (input detected)
4. Fill valve opens and the dishwasher begins filling with water (output activated)
5. CPU waits until proper water level is reached (input detected)
6. Fill valve closes, and water flow stops (output activated/de-activated)
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7. Heating element is turned on (output activated)
8. CPU waits until proper water temperature is reached (input detected)
9. Soap dispenser opens (output activated)
10. Water pump turns on to force water through sprayers (output activated)
11. CPU begins timing depending on cycle type (logic timer activated)
12. Water pump turns off (output deactivated)

13. Heating element is turned off (output deactivated)
14. Drain valve opens and the dishwasher begins draining the dirty water (output activated)
15. CPU waits until it detects the water level to be low enough (input activated/de-activated)
16. Drain valve closes (output activated/deactivated)
17. Fill valve opens again to rinse dishes (output activated)
18. Water pump turns on to force water through sprayers (output activated)
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19. CPU begins timing (logic timer activated)
20. Water pump turns off (output deactivated)
21. Drain valve opens and the dishwasher begins draining rinse water (output activated)
22. CPU waits until it detects the water level to be low enough (input activated/de-activated)
23. Drain valve closes (output activated/deactivated)
24. Heating element turns on to heat the air inside the dishwasher and dry the dishes (output activated)

25. CPU waits until proper interior temperature is reached (input activated)
26. CPU begins timing (logic timer activated)
27. Heating element is turned off (output activated/deactivated)
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Types of PLC – based on rack

FIXED / COMPACT PLC MODULAR PLC
❑ Within a single case, there would be ❑ This type of PLC permits multiple
many modules. expansion through “modules”, hence
referred to as Modular PLC.
❑ It has a fixed number of I/O modules and
external I/O cards. ❑ I/O components can be increased.
❑ It does not have the capability to expand ❑ It is easier to use because each
the modules. component is independent of each other
❑ Every input and output would be decided
by the manufacturer.
❑ Example: Automatic Washing Machine
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Types of PLC – based on Output

❑ PLC are divided into three types based on output namely:
❑ Relay output PLC : It is best suited for both AC and DC output devices
❑ Transistor output PLC : It uses switching operations and used inside microprocessors.
❑ Triac output PLC : Preferred for high power applications
Major Manufacturers
❑ Some of the manufacturers of PLCs include:
❑ Allen Bradley
❑ ABB
❑ Siemens
❑ Mitsubishi PLC
❑ Hitachi PLC
❑ Delta PLC
❑ General Electric (GE) PLC
❑ Honeywell PLC
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PLC Programming
❑ A PLC program consists of a set of instructions either in textual or graphical form,
which represents the logic that governs the process the PLC is controlling.
❑ Textual Language
❑ Instruction list
❑ Structured text
❑ Graphical Form
❑ Ladder Diagrams (LD) (i.e. Ladder Logic)
❑ Function Block Diagram (FBD)
❑ Sequential Function Chart (SFC)
PLC or PAC
❑ PAC is an acronym for Programmable Automation Controller.
❑ The term was first coined by the market research firm ARC in 2001.
❑ The modern user interface, extra power and memory of most PACs make them easily
superior to most PLCs.
Allen-Bradley : PLC to PLC-5

PAC lines such as ControlLogix and CompactLogix
RSLogix 5000/Studio 5000 Logix Designer (programming software for ControlLogix/CompactLogix
PACs)
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1986 1991
RSLogix 5 (Programming Platform) RSLogix 500 (Programming Platform)
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NOTE:
Traditionally, PLCs have been programmed exclusively with Ladder Logic (LD).
Most newer programmable automation controllers (PACs) also allow you to program
with other languages such as Structured Text (ST), Sequential Function Chart (SFC),
Function Block Diagram (FBD) and Instruction List (IL).
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Introduction to SCADA (1)

❑ SCADA is an acronym for Supervisory Control and Data Acquisition.
❑ SCADA systems are used to monitor and control a plant or equipment in industries
such as telecommunications, water and waste control, energy, oil and gas refining and
transportation.
❑ It is a software application program for process control, which refers to do both Data
acquisition and Communication interface.
❑ SCADA system collects the data from one or more distant facilities as well as sending
basic control operations to the facilities and it makes unnecessary for a human operator
to be permanently present at the site of the facilities for normal operations.
Introduction to SCADA (2)

❑ SCADA is combination of telemetry and data acquisition
❑ Data acquisition refers to the method used to collect or send data/information from/to
the equipment being controlled and monitor.
❑ The data accessed are then forwarded to a telemetry system ready for transfer to the different
sites
❑ The data can be digital, or analogue gathered from sensors, actuators
❑ Telemetry is simply the communication system. Telemetry is the technique used in

transmitting and receiving information or data over a medium
❑ The information can be any measurement value
❑ The information is transmitted through cable, telephones or radio information
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Basic Architecture of SCADA(1)

❑ Basic components of SCADA system
are:
❑ Field instrumentation
❑ Remote Terminal Unit (RTU)
❑ Communication network
❑ Master Terminal Unit (MTU)
Basic Architecture of SCADA(2)

❑ Field instrumentation
❑ Sensors and actuators
❑ Remote Terminal Unit (RTU)

❑ PLC
❑ Communication network
❑ Switched Telephone Ntk
❑ Wireless Communication Systems
❑ Internet
❑ Master Terminal Unit (MTU)

❑ Front End Processor
❑ SCADA Server
❑ HMI Computer
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Example of SCADA (Water)
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Objectives of SCADA
❑ Monitoring: Continuous monitoring of the process parameters
❑ Measurement: Measurement of processing variables
❑ Data Acquisition: Frequent acquisition of data from RTUs/PLCs
❑ Data Communication: Transmission and receiving large amounts of data from the field
to control centre’s
❑ Control: Online real time control for closed loop and open loop processes
❑ Automation: Carrying out automatic tasks of switching the actuators as per the
requirement
Advantages of SCADA
❑ Saves Time and Money
❑ Less traveling for workers
❑ Reduces man-power needs
❑ Increases production efficiency of a company
❑ Continuous monitoring of Process
❑ Automation and protection
❑ Supervisory control ( remote control an operation)
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Industrial Communication Systems

❑ Field Bus are used to link sensors and actuators at process level with the PC’s/RTU’s
so that the information they supply can flow into the plant information systems
❑Features of Field Bus

❑ Bi-directional digital transmission
❑ Simple cabling and cross-wiring
❑ Easy expandability
❑ Variety of Field bus solutions have been developed in the market but the two widely
used Field Bus in Industrial Automation are MODBUS and PROFIBUS
MODBUS
Ethernet
(1) MODBUS TCP
Supervisory Computer
Serial Line
(1) MODBUS RTU
(2) MODBUS ASCII
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RS232
How does it work?
Modbus is transmitted over serial lines between devices. The simplest setup would be a
single serial cable connecting the serial ports on two devices, a Master and a Slave.
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MODBUS PROTOCOL (1)

❑ It is a transmission protocol for process control systems (preferred for point-to-point).
Specially no transmission medium is defined
❑ The user can choose between RS-232C, RS-422 , RS-485 4 to 20 mA current loop, all
of which are suitable for the transmission rates which the protocol defines
Port name RS-232 RS-422 RS-485
Half duplex (2 wires),
Transfer type Full duplex Full duplex
full duplex (4 wires)
1200 meters at 9600
1200 meters at 9600
Maximum distance 15 meters at 9600 bps bps (15 meters at
bps
100Mbps)
Topology Point-to-Point Point-to-Point Multi-point
32 (with repeaters
Max. Number of 1 (10 devices in
1 larger, usually up to
connected devices receive mode)
256)
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4 to 20 mA Current loop (for

understanding)
MODBUS PROTOCOL (2)

❑Modbus is a master/slave protocol, hence there is no way for a field device to "report an
exception" (except over Ethernet TCP/IP, called open-mbus) – the master node can
address individual slaves , or initiate a broadcast a message to slaves
❑ Slaves return a message (response ) to queries that are addressed to them individually
❑ This consumes bandwidth and network time in applications where bandwidth may be
expensive, such as over a low-bit-rate radio link.
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MODBUS PROTOCOL (3)

❑ Modbus is restricted to addressing 247 devices on one data link, which limits the
number of field devices that may be connected to a master station (once again, Ethernet
TCP/IP is an exception)
❑ MODBUS protocol are fixed, such as frame format, frame sequences , handling of
communication errors
❑ Other characteristics are user-selectable such as transmission medium, transmission

characteristics and transmission mode : serial mode - RTU or ASCII
MODBUS PROTOCOL (4)

❑ Frame Format for RTU Mode (24 function codes)
❑ Frame Format for ASCII Mode ((24 function codes)
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What is the Slave ID?
Each slave in a network is assigned a unique unit address from 1 to 247. When the
master requests data, the first byte it sends is the Slave address. This way each
slave knows after the first byte whether or not to ignore the message.
What is a function code?
The second byte sent by the Master is the Function code. This number tells the
slave which table to access and whether to read from or write to the table.
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What is a CRC?
CRC stands for Cyclic Redundancy check. It is two bytes added to the end of every modbus
message for error detection. Every byte in the message is used to calculate the CRC. The
receiving device also calculates the CRC and compares it to the CRC from the sending device.
If even one bit in the message is received incorrectly, the CRCs will be different and an error
will result.
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PROFIBUS PROTOCOL
❑ ProfiBus was created in 1989 by the German government in cooperation with several
manufacturers of automation equipment.
❑messaging format specifically designed for high-speed serial I/O in factory and building
automation applications.
❑It is based on RS485 and the European EN50170 Electrical Specification.
❑The DP suffix refers to "Decentralized Periphery",
❑ProfiBus DP uses only layers 1 & 2 of OSI model, plus the user interface.
❑It support master-slave architecture.
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ROLE OF PROFIBUS MASTER

❑ A ProfiBus master forms an "active station" on the network.
❑ ProfiBus DP defines two classes of masters. Class-1 & Class-2
❑ A class 1 master handles the normal communication or exchange of data with the slaves assigned
to it.
❑ A class 2 master is a special device primarily used for commissioning slaves and for diagnostic
purposes.
Class-1 Master Role:
❑ A class 1 master device is normally a central programmable controller (PLC), or a PC running special
software.
❑ The class 1 master sets the baud rate and the slave's auto-detect this rate.
❑ A master can communicate actively with its assigned slaves, but only passively (upon request) with
another class 2 master device.
WORKING OF PROFIBUS DP
❑ ProfiBus DP normally operates using a cyclic transfer of data between master(s) and slave(s)
on an RS485 network.
❑ That is, an assigned master periodically requests (polls) each node (slave) on the network.
❑All data communication exchanges between a master and slave originate from the master
device.
❑Each slave device is assigned to one master and only that master may write output data to that
slave.
❑Other masters may read information from any slave, but can only write output data to their
own assigned slaves.
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100
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PROFIBUS PROTOCOL (1)

❑ It is a transmission protocol for process control systems (can be used for point to multi-
point).
❑ The transmission medium used is RS-485 or Fiber Optic
❑ Profibus is a master/slave protocol, but it also includes token passing, a system in
which a “token” signal is passed between nodes. Only the node with the token can
communicate.
PROFIBUS PROTOCOL (3)

❑PROFIBUS protocol are fixed, such as frame format, frame sequences , handling of
communication errors
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Acknowledgement
❖ Power Point Presentation
Source: Presentation made in Microsoft office.
Some of the slides content are taken from the previous year lectures notes by
Prof. Smith Thavallapill
❖ Books/Materials
[1] https://nptel.ac.in/courses/108/105/108105063/
[2] http://www.http://www.modicon.com/techpubs/toc7.html
Thank You
Email id: [email protected]
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Introduction to Automation & Control

DHARMSINH DESAI UNIVERSITY 2

DHARMSINH DESAI UNIVERSITY 3

Understanding the Title of the Course

DHARMSINH DESAI UNIVERSITY 4

DHARMSINH DESAI UNIVERSITY 5

DHARMSINH DESAI UNIVERSITY 6

Point to Think About -1

[A] Why does an automated system achieve superior performance compared to a

DHARMSINH DESAI UNIVERSITY 7

Point to Think About -1: Answer

[A] Why does an automated system achieve superior performance compared to a

DHARMSINH DESAI UNIVERSITY 8

Requirements of a Good Control System

DHARMSINH DESAI UNIVERSITY 9

Requirements of a Good Control System

DHARMSINH DESAI UNIVERSITY 10

Point to Think About -2

[B] Is the definition applicable to open-loop as well as closed loop control?

DHARMSINH DESAI UNIVERSITY 11

Point to Think About -2: Answer

[B] Is the definition applicable to open-loop as well as closed loop control?

DHARMSINH DESAI UNIVERSITY 12

Type of Control Systems

Open-loop control systems

DHARMSINH DESAI UNIVERSITY 13

Practical Examples of Open Loop Control

DHARMSINH DESAI UNIVERSITY 14

Advantages of Open Loop Control

DHARMSINH DESAI UNIVERSITY 15

Disadvantages of Open Loop Control

DHARMSINH DESAI UNIVERSITY 16

Type of Control Systems

Close-loop control systems

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Practical Examples of Close Loop

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Advantages of Close Loop Control

DHARMSINH DESAI UNIVERSITY 19

Disadvantages of Close Loop Control

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DHARMSINH DESAI UNIVERSITY 21

Point to Think About -3

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Role of Automation in Industry (1)

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Role of Automation in Industry (2)

1 January 2021 DHARMSINH DESAI UNIVERSITY 24

Role of Automation in Industry (3)

 In Computer Numerically Controlled (CNC) Machining Centers set up time is reduced

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Role of Automation in Industry (4)

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Typical Industrial Product Life Cycle

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Economy of Scale and Economy of

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