Introduction to Industrial Automation

Document Outline

• Cover
• Half Title
• Title Page
• Copyright Page
• Dedication
• Table of Contents
• Preface
• Authors
• Chapter 1: Industrial Automation
  • 1.1 The Industrial Control System
  • 1.2 Automation and Process Control
  • 1.3 Purpose of Industrial Automation
  • 1.4 Industrial Automation Circuits
  • 1.5 Computer-Based Industrial Control and Automation
  • Review Questions
• Chapter 2: Hardware Components for Automation and Process Control
  • 2.1 Actuators
    • 2.1.1 Electric Motors
    • 2.1.2 Pneumatic Actuators
    • 2.1.3 Micro-Electro-Mechanical Systems
    • 2.1.4 Relays
      • 2.1.4.1 Relays’ Operation Principle
    • 2.1.5 Power Relays
    • 2.1.6 General Purpose Relays
    • 2.1.7 Latching Relays
    • 2.1.8 Pulse Bistable Relays
    • 2.1.9 Solid State Relays
    • 2.1.10 Electric Contact Classification
    • 2.1.11 Solenoid Linear Actuators
  • 2.2 Sensors
    • 2.2.1 Thermal Overload Relay
    • 2.2.2 Proximity Switches
    • 2.2.3 Photoelectric Switches
    • 2.2.4 Limit Switches
    • 2.2.5 Level Switches
    • 2.2.6 Flow Switches
    • 2.2.7 Temperature and Pressure Switches
  • 2.3 Timers, Drum Switches, and Special Components
    • 2.3.1 Timers
    • 2.3.2 Cam Timers
    • 2.3.3 Three-Phase Monitoring Relays
    • 2.3.4 Reed Relays
    • 2.3.5 Specific Solenoid Actuators
    • 2.3.6 Counters and Hour Meters
    • 2.3.7 Encoders
  • Review Questions
• Chapter 3: Industrial Automation Synthesis
  • 3.1 Introductory Principles in Designing Automation Circuits
    • 3.1.1 The Latch Principle
    • 3.1.2 The Principle of “Command”
  • 3.2 Step-by-Step Basic Automation Examples Synthesis
    • 3.2.1 Motor Operation with Thermal Overload Protection
    • 3.2.2 Operation and Fault Indication
    • 3.2.3 Machine Operation with Starting Delay
    • 3.2.4 Machine Operation with Stopping Delay
    • 3.2.5 Periodic Operation of Machine with Two Time Constants
    • 3.2.6 Machine Operation with Automatic or Manual Control
    • 3.2.7 Operation of Two Machines with a Common Manual Command or Separate Automatic Commands
    • 3.2.8 Operation of Two Machines with a Common Automatic Command or Separate Manual Commands
    • 3.2.9 Operation of a Machine from Two or More Points
    • 3.2.10 Control Panel for Operating n Machines
  • 3.3 The Meaning of the Electrical and Mechanical Latch
    • 3.3.1 Sequential Start—Latch of Machines (Chain Latch)
    • 3.3.2 Motor Operation with Power Supply from Two Different Networks
  • 3.4 Automation Circuits for Motors
    • 3.4.1 Motor with Inversion in Rotation
    • 3.4.2 Motor with a Star-Delta (Y-Δ) Start
    • 3.4.3 Automation of Various Motor Types
  • 3.5 Automation Circuits with Sensors
    • 3.5.1 Starting a Machine with Canceling Ability
    • 3.5.2 Pump Operation Based on Level Control
    • 3.5.3 Operation of Two Pumps According to Demand
    • 3.5.4 Automation of a Garage Door
  • 3.6 Automation Circuit Design Regulations
  • 3.7 Implementation of Automation Circuits
  • 3.8 Applications
    • 3.8.1 Machine Operation Control from Multiple Positions
    • 3.8.2 Operation Control of a Power Transformer
    • 3.8.3 Operation of Two Pumps with a Cyclic Alteration, Based on a Low-High Demand
    • 3.8.4 Operation of Three Air Compressors with Predefined Combinations
  • Problems
• Chapter 4: Logical Design of Automation Circuits
  • 4.1 Introduction to Logical Design of Automation Circuits
  • 4.2 Boolean Logic Components
    • 4.2.1 Postulates and Theorems of Boolean Algebra
  • 4.3 State Diagrams
    • 4.3.1 Classical State Diagrams
    • 4.3.2 State Diagrams with Sensors
    • 4.3.3 Step-by-Step Transition due to a Discrete Successive Signal
    • 4.3.4 State Diagrams with Time Relays
    • 4.3.5 Components’ State Diagram Method
    • 4.3.6 State Diagrams and Minimum Realizations
    • 4.3.7 Sequential Automation Systems
  • 4.4 Applications
    • 4.4.1 Bidirectional Lead Screw Movable Worktable with Two Speeds
    • 4.4.2 Palindromic Movement of a Worktable with Memory
    • 4.4.3 Operation of N Machines with Pause under Specific Conditions
  • Problems
• Chapter 5: Elements of Electro-Pneumatic Components
  • 5.1 Introduction to Electro-Pneumatic Components
  • 5.2 Pressurized Air
  • 5.3 Production of Pressurized Air
  • 5.4 Distribution of Pressurized Air
  • 5.5 Pneumatic Devices
    • 5.5.1 Single-Acting Cylinders
    • 5.5.2 Double-Acting Cylinders
  • 5.6 Calculations in the Case of Pneumatic Cylinders
    • 5.6.1 Length of Piston Stroke
    • 5.6.2 Speed of Piston’s Translation
  • 5.7 Pressurized Air Flow Control Valves
    • 5.7.1 Directional Valves
    • 5.7.2 Manual Actuation of a Valve
    • 5.7.3 Mechanical Actuation of a Valve
    • 5.7.4 Electrical Actuation of a Valve
    • 5.7.5 Pneumatic Actuation of a Valve
  • 5.8 Circuits for Electro-Pneumatic Automation
  • 5.9 Electro-Pneumatic Applications
    • 5.9.1 Industrial Automation of an Arrangement for Separating Similar Balls
    • 5.9.2 Industrial Automation of an Object Stamping Machine
    • 5.9.3 Industrial Automation of a Conveyor Arrangement for Objects Shorting
  • Problems
• Chapter 6: Basic Operating Principles of PLCs
  • 6.1 Introduction to PLCs
  • 6.2 Modular Construction of a PLC
  • 6.3 PLC I/O Components
  • 6.4 Digital Input Modules
  • 6.5 Digital Output Modules
    • 6.5.1 Technical Specifications for Digital Input/Output Modules
  • 6.6 Analog Input/Output Modules
    • 6.6.1 Analog Input Modules
    • 6.6.2 Accuracy in the Conversion of Analog Signals
    • 6.6.3 Analog Output Modules
  • 6.7 Special Purpose Input/Output Modules
    • 6.7.1 Fast Input Response Modules
    • 6.7.2 Stepper Motor Control Modules
    • 6.7.3 Three Terms (PID) Control Modules
    • 6.7.4 Communication Modules
  • 6.8 Central Processing Unit
    • 6.8.1 Memory Organization
    • 6.8.2 Memory Types
      • 6.8.2.1 Read Only Memory (ROM)
      • 6.8.2.2 Random Access Memory (RAM)
      • 6.8.2.3 Erasable Programmable Read Only Memory (EPROM)
      • 6.8.2.4 Electrically Erasable Programmable Read Only Memory (EEPROM)
    • 6.8.3 Addressing I/Os and Other Internal Elements
  • 6.9 PLC Expansion and I/O Configuration
    • 6.9.1 Local and Peripheral I/O System
    • 6.9.2 I/O System Design
  • 6.10 On the Installation of PLCs
    • 6.10.1 Electrical Enclosure for the PLC Installation
    • 6.10.2 Electromagnetic Interference
    • 6.10.3 Grounding
    • 6.10.4 Electromagnetic Shielding of Cables
    • 6.10.5 Lightning Protection
    • 6.10.6 Input Devices with Leakage Current—Impedance Adjustment of I/Os
    • 6.10.7 Input Impedance Adjustment
    • 6.10.8 Output Impedance Adjustment
    • 6.10.9 Parallelizing Digital Outputs of PLCs—Transitional Protection of I/Os
    • 6.10.10 Starting the Operation of a PLC and Fault Detection
  • Review Questions and Problems
• Chapter 7: Basic Programming Principles of PLCs
  • 7.1 Introduction to Programming of PLCs
  • 7.2 The IEC 61131 Standard
  • 7.3 Structural Programming
  • 7.4 Basic Programming Instructions
    • 7.4.1 The Result of an Instruction Execution
    • 7.4.2 Boolean Logic Instructions
    • 7.4.3 Activation Instructions
    • 7.4.4 Complementary Instructions
  • 7.5 Programming According to the IEC 61131-3 Standard
    • 7.5.1 General Highlights and Restrictions in PLC Programming
    • 7.5.2 Programming with Boolean Logic and Activation Instructions
    • 7.5.3 Programming with Timers and Counters
    • 7.5.4 Using Structural Programming
    • 7.5.5 Programming Mathematical Operations
    • 7.5.6 Applications of PLC Programming
  • Problems
• Chapter 8: Industrial Networks of PLCs
  • 8.1 Topology of a Network
    • 8.1.1 Star Topology
    • 8.1.2 Ring Topology
    • 8.1.3 Bus Topology
  • 8.2 Communication Protocols
    • 8.2.1 Master/Slave Method of Access
    • 8.2.2 Carrier Sense with Collision Detection Method of Access
    • 8.2.3 Token Passing Method of Access
  • 8.3 Implementation of Industrial Networks
    • 8.3.1 Data Transmission Media
    • 8.3.2 The ISO/OSI Model
    • 8.3.3 Network Devices
    • 8.3.4 The Communication Task of PLCs
    • 8.3.5 The Actuator-Sensor Interface (AS-I) Network
    • 8.3.6 The Profibus Network
    • 8.3.7 SCADA Systems
  • Review Questions
• Chapter 9: PID Control in the Industry
  • 9.1 PID Control
  • 9.2 PID Control in PLCs
• Chapter 10: Industrial Applications
  • 10.1 Cyclic Operation of Traffic Lights
  • 10.2 Conveyor System for an Assortment of Objects by Pairs
  • 10.3 Packaging System of Different Balls
  • 10.4 Conveyor System for Transferring Granular Material with Weight Control
  • 10.5 The Food Industry: A Machine for Production of Tzatziki Salad
  • 10.6 Retentive Reciprocating Movement of a Worktable
  • 10.7 Wooden Plate Stacking, Painting and Transferring Process
  • 10.8 An Automated Billiard Table Controlled by a PLC
  • 10.9 Automated Filling of Two Milk Tanks
  • 10.10 Modular Programming for a Set of Processing and Repairing Stations
  • 10.11 Traffic Light Control of a Complex Intersection
  • 10.12 Combined Operation of Two Conveyor Belts
  • 10.13 A Machine with Three Operational States and an Acknowledgement Signal
  • 10.14 Chemical Cleaning Process of Metallic Objects
  • 10.15 Driving a Step Motor Through a PLC
  • 10.16 Stacking Machine of Light Objects
  • 10.17 A Simple Robotic Arm for Pickup and Placement of Light Objects
  • 10.18 Heat Treatment Process in a Chamber Furnace
  • 10.19 Working Time Monitoring of a Machine under a Three-Shift Schedule
  • 10.20 Feeding an Assembly Machine with Components in Bulk
  • 10.21 A Roller Conveyor System for Wrapping Plastic Membrane
  • 10.22 Color-Based Separation of Plastic Balls
  • 10.23 The Shearing Machine of an Unfolded Aluminum Sheet
  • 10.24 Inlet and Outlet Rate Monitoring of Transferred Objects In and Out of a Process Machine
  • 10.25 A Metal Plate Rolling Mill Machine and Control of Their Thickness
  • 10.26 An Object Painting and Transporting System
  • 10.27 A Multiple Bottle Packing Station
  • 10.28 A Barrel-Filling System for Dry Bulk Material
  • 10.29 An Electro-Pneumatic System for Pickup and Lay Down of Plastic Containers
• Appendix A: Arithmetic Systems
  • A.1 Introduction to Arithmetic Systems
  • A.2 Decimal Arithmetic System
  • A.3 Binary Arithmetic System
    • A.3.1 Negative Numbers
  • A.4 Binary-Coded Decimal Arithmetic System (BCD)
  • A.5 Octal Arithmetic System
  • A.6 Hexadecimal Arithmetic System
    • A.6.1 Parity Checking
  • A.7 ASCII Code
  • A.8 Gray Code
• Appendix B: Analog I/O Values Scaling
  • B.1 PLC Analog I/O Values Scaling
• Further Reading
  • Chapter 1
  • Chapter 2
  • Chapter 3
  • Chapter 4
  • Chapter 5
  • Chapter 6
  • Chapter 7
  • Chapter 8
  • Chapter 9
  • Chapter 10
• Index