A Report of 6 Months Training

on

Industrial Automation using PLC

for the fulfillment of the award of the degree of

BACHELOR OF TECHNOLOGY

In
Electronic and Communication Engineering

Submitted by: Parveet Kumar Under the guidance of:-

(2001670) Antali
Trainer

Jan 8 to June 2024

iii
 CONTENTS

Content Page No.

Candidate’s Declaration i

Acknowledgements ii

Contents iii-v

CHAPTER-1: INTRODUCTION
1-6
1.1 Industrial Automation 1
1.2 Advantages of Industrial Automation 1
1.2.1 Reduces Cost 1
1.2.2 Increases Productivity 1
1.2.3 Enhances Quality 2
1.2.4 Industrial Quality 3
1.2.5 Accurate Results
1.3 Engineering Tools 3
1.3.1 PLC (Programmable Logic Controller) 3
1.3.2 SCADA (Supervisory Control And Data Acquisition) 4
1.3.3 HMI (Human Machine Interface) 5
1.3.4 Distributed Control System 6

iv
Candidate Declaration

I hereby certify that the work that is being presented by “PARVEET KUMAR ” in partial fulfilment of
requirements for the award of a degree of B.Tech. (ECE) submitted to the Department of Electronics and
Communication Engineering at Sardar Beant Singh State University, Gurdaspur, is our own work carried out
during a period from January to June , 2024, under the supervision of our trainer Ms Antali. The matter
presented in this thesis has not been submitted by us to any other university or institute for the award of a
B.Tech. degree.

Signature of Student

v
Acknowledgement: -

I feel profound happiness in forwarding this industrial training report as an image of sincere efforts.
It is almost inevitable to ensure indebtedness to all who generously helped by sharing their valuable
experience & devoting their precious time with us. Without whom this seminar report would have never been
accomplished.
First & foremost, I extend my thanks & gratitude to the entire unit of “NOVEM CONTROL PVT. LTD.
MOHALI”. Ms. Antali whose guidance, teaching and invaluable suggestions provided me a deep
Insight in my chosen field of technology, enhanced my knowledge and supported in widening my outlook
towards the communication industry. I am also very thankful to all the engineers of my department for their
kind support throughout the training.

vi
 CHAPTER 1 INTRODUCTION

1.1 Industrial Automation

Industrial automation is a set of technologies that uses control systems and devices, such as computer
software and robotics, to enable automatic operation of industrial processes and machinery without the
need for human operators. Industrial automation eliminates the possibility of human error, reduces costs,
saves time, and achieves higher performance.

1.2Advantages of Industrial Automation

1.2.1 Reduces Cost
One of the top advantages of automation is reduction in manufacturing costs. Instead of having a floor full of
workers, you can now have just a few supervisors and have robots do the job. The initial investment will be a
little high, but then the operation costs will reduce, which will be beneficial in the long run. Your expenses
will only include maintenance, repairs, and energy. AI and data analytics have also helped reduce production
costs by providing insights and information to make the right production decisions. Automation helps
improve productivity, quality and system performance, which in turn reduces your operating expenses
(OPEX). At the same time, automated preventive maintenance can improve the life and performance of the
machines. It enhances the value of your assets and in turn decreases your capital expenses .

1.2.2 Increases Productivity

Automated productivity lines consist of workstations connected by transfer lines. Each work station takes
care of one part of the product process. Robotic process automation can be used to mimic many human
actions. The system can be configured to login to applications and take care of the administrative work
related to the business process.
Robots can also be used on the production floor to handle raw materials, clean equipment, operate high-
pressure systems, and do lots more. For example, in an automobile manufacturing unit, auto components are
cut and shaped in different press working stations. All the parts are then brought together to one place where
a robot puts them together to build the vehicle. Process automation greatly speeds up the production process.

1
1.2.3 Enhances Quality

Industrial automation also helps increase and maintain consistent quality of the output. In manual processes,
the error rate is around 1 to 1.15%. On the other hand, automated machines in the manufacturing industry
have an error rate that is as low as 0.00001%. Adaptive control and monitoring help check every level of the
manufacturing process to reduce the margin of errors.

2
1.2.4 Industrial Safety

A huge benefit of automation is improved safety at the workplace. Using robots for loading and unloading
materials or transferring huge machine parts reduce risks of accidents. Industrial automation also keeps
workers from going too close to the assembly lines, thereby improving safety. Thermal sensors continually
check the temperatures in the production area. In case, they identify any spike in temperature, the sensors will
send an alert. Immediately, precautions can be taken to ensure the safety of everyone on the production floor.

1.2.5 Accurate Results

Data automation is based on accurate data integration and connectivity. When accurate information is used in
the production process, you can be assured of precise results. AI and ML solutions help you get detailed data
that can be analyzed using data analytics tools to get accurate information.

Deep learning algorithms are used to build self-healing digital grids that use data analytics and intelligent
energy forecasts to manage energy generation. Machine Learning apps have been used to build a self-learning
quality control system for assembly line. ML and AI solutions are scalable and self-learning. Both these
features ensure that the automated systems deliver accurate results every time, without fail.

1.3 Engineering Tools

1.3.1 PLC (Programmable Logic Controller)

A programmable logic controller (PLC) or programmable controller is a digital computer used for
automation of electromechanical processes, such as control of machinery on factory assembly lines,
amusement rides, or light fixtures. PLCs are used in many industries and machines. Unlike general-purpose
computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact

1.3.2 SCADA (Supervisory Control And Data Acquisition)

SCADA (supervisory control and data acquisition) is a category of software application program for process
control, the gathering of data in real time from remote locations in order to control equipment and conditions.

3
SCADA is used in power plants as well as in oil and gas refining, telecommunications, transportation, and
water and waste control.

SCADA systems include hardware and software components. The hardware gathers and feeds data into a
computer that has SCADA software installed. The computer then processes this data and presents it in a
timely manner. SCADA also records and logs all events into a file stored on a hard disk or sends them to a
printer. SCADA warns when conditions become hazardous by sounding alarms.

4
 1.3. 3 HMI (Human Machine Interface)

A Human-Machine Interface or HMI is the apparatus which presents process data to a human operator, and
through which the human operator controls the process.

An HMI is usually linked to the SCADA system's databases and software programs, to provide trending,
diagnostic data, and management information such as scheduled maintenance procedures, logistic
information, detailed schematics for a particular sensor or machine, and expert-system troubleshooting
guides.

The HMI system usually presents the information to the operating personnel graphically, in the form of a
mimic diagram. This means that the operator can see a schematic representation of the plant being controlled.

1.3.4 Distributed Control System

A type of automated control system that is distributed throughout a machine to provide instructions to
different parts of the machine. Instead of having a centrally located device controlling all machines, each
section of a machine has its own computer that controls the operation. For instance, there may be one
machine with a section that controls dry elements of cake frosting and another section controlling the liquid
elements, but each section is individually managed by a DCS. A DCS is commonly used in manufacturing
equipment and utilizes input and output protocols to control the machine.

1.3.5 Drives
5
The main power components of an AC drive, have to be able to supply the required level of current and
voltage in a form the motor can use. The controls have to be able to provide the user with necessary
adjustments such as minimum and maximum speed settings, so that the drive can be adapted to the user's
process.

6
 CHAPTER 2
PROGRAMMING LOGIC CONTROLLER (PLC)
2.1PLC (Programmable Logic Controller)

Control engineering has evolved over time. In the past humans were the main methods for controlling a
system. More recently electricity has been used for control and early electrical control was based on relays.
These relays allow power to be switched on and off without a mechanical switch. It is common to use relays
to make simple logical control decisions. The development of low cost computer has brought the most recent
revolution, the Programmable Logic Controller (PLC). The advent of the PLC began in the 1970s, and has
become the most common choice for manufacturing controls. PLCs have been gaining popularity on the
factory floor and will probably remain predominant for some time to come. Most of this is because of the
advantages they offer.

• Cost effective for controlling complex systems.

• Flexible and can be reapplied to control other systems quickly and easily.

• Computational abilities allow more sophisticated control.

• Trouble shooting aids make programming easier and reduce downtime.

• Reliable components make these likely to operate for years before failure.

The term SCADA stands for Supervisory Control and Data Acquisition. A SCADA system is a common
process automation system which is used to gather data from sensors and instruments located at remote sites
and to transmit and display this data at a central site for either control or monitoring purposes. The collected
data is usually viewed on one or more SCADA Host computers located at the central or master site.

7
A real world SCADA system can monitor and control hundreds to hundreds of thousands of I/O points. A
typical Water SCADA application would be to monitor

water levels at various water sources like reservoirs and tanks and when the water level exceeds a preset
threshold, activate the system of pumps to move water to tanks with low tank levels.
Common analog signals that SCADA systems monitor and control are levels, temperatures, pressures, flow
rate and motor speed. Typical digital signals to monitor and control are level switches, pressure switches,
generator status, relays & motors.

A modern programmable logic controller is usually programmed in any one of several languages, ranging
from ladder logic to Basic or C. Typically, the program is written in a development environment on a
personal computer (PC), and then is downloaded onto the programmable logic controller directly through a
cable connection. Programmable logic controllers contain a variable number of Input/output (I/O) ports the
programmable logic controller circuitry monitors the status of multiple sensor inputs, which control output.

Programmable logic controller (PLC)

8
2..2 HISTORY

The PLC was invented in response to the needs of the American automotive manufacturing
industry. Programmable controllers were initially adopted by the

automotive industry where software revision replaced the re-wiring of hard-wired control panels when
production models changed.

Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was
accomplished using hundreds or thousands of relays, cam timers, and drum sequencers and dedicated closed-
loop controllers. The process for updating such facilities for the yearly model change-over was very time
consuming and expensive, as the relay systems needed to be rewired by skilled electricians.

In 1968 GM Hydramatic (the automatic transmission division of General Motors) issued a request for
proposal for an electronic replacement for hard-wired relay systems.

The winning proposal came from Bedford Associates of Bedford, Massachusetts. The first PLC, designated
the 084 because it was Bedford Associates' eighty-fourth project, was the result. Bedford Associates started a
new company dedicated to developing, manufacturing, selling, and servicing this new product: Mod icon,
which stood for Modular Digital Controller. One of the people who worked on that project was Dick Morley,
who is considered to be the "father" of the PLC. The Mod icon brand was sold in 1977 to Gould Electronics,
and later acquired by German Company AEG and then by French Schneider Electric, the current owner.

One of the very first 084 models built is now on display at MoD icon’s headquarters in North Andover,
Massachusetts. It was presented to Mod icon by GM, when the unit was retired after nearly twenty years of
uninterrupted service. Mod icon used the 84 moniker at the end of its product range until the 984 made its
appearance.

9
2.2.1 Programming

Early PLCs, up to the mid-1980s, were programmed using proprietary programming panels or special-
purpose programming terminals, which often had dedicated function keys representing the various logical
elements of PLC programs. Programs were stored on cassette tape cartridges. Facilities for printing and
documentation were very minimal due to lack of memory capacity. The very oldest PLCs used non- volatile
magnetic core memory.

2.2.2 Functionality

The functionality of the PLC has evolved over the years to include sequential relay control, motion control,
process control, distributed control systems and networking. The data handling, storage, processing power
and communication capabilities of some modern PLCs are approximately equivalent to desktop computers.
PLC-like programming combined with remote I/O hardware, allow a general-purpose desktop computer to
overlap some PLCs in certain applications.

10
 2.3 PARTS OF PLC

 POWER SUPPLY: PLC requires 24V switch mode power supply for its operation.

 MCU: Its full form is microcontroller unit. It is the processor of PLC. It is basically the brain of PLC. It
performs various control operations of PLC.

 INPUTS AND OUTPUTS: PLC has a set of isolated inputs and isolated outputs. Different PLC’s have
different number and different type of inputs and outputs. Like in Micrologix 1000 we have total number of 6
inputs and 4 outputs whereas in Micrologix 1100 we have 10 inputs and 6 outputs.

 EXPANSION PORT: In PLC there is an expansion port which is used for the addition of any other
equipment with PLC. For example analog cards.

 MEMORY MODULE: The memory module in PLC is used for the storage of program in PLC for future use.

 COMMUNICATION PORT: The communication ports are used in PLC to communicate with the computer.
In PLC there are two types of communication ports

i.e. RS 232 comport and Ethernet port.

 DISPLAY: In some of the PLC’s there is display screen which is available on the PLC. This display screen is
used as human machine interface i.e. it provides good visualization of operation running on PLC.

11
 2.4 PIN DIAGRAM OF PLC

PIN DIAGRAM OF PLC

2.4.1 INPUTS
These are the physical connections from the real world to the PLC. They can be limit switches, push
buttons, and sensors, anything that can "switch" a signal on or off. The voltages of these devices are
usually, but not always, 24 Volt DC. Manufacturers make inputs that can accept a wide range of voltages
both ac and dc. It should be remembered that an input will be ON, "status 1", when the voltage is present
at the input connection and OFF, "status 0", when the voltage is no longer present at the input
connection.

2.4.2 TYPES OF INPUTS OF PLC

12
 USER TYPE: These are the inputs and outputs that are physically present and are practical to the inputs
and outputs of the PLC.

13
 BIT TYPE: These are the inputs and outputs that are not physically present and are functional in the PLC
only. These inputs/outputs are basically used to drive each other in the ladder logic programming.

2.4.3 OUTPUTS

These are the connections from the PLC to the real world. They are used to switch solenoids, lamps, contactors etc. on
and off. Again, they are usually 24 Volt DC, either relay or transistor, but can also be 115/220 Volt AC.

2.4.4 TYPES OF PLC OUTPUTS

2.4.4.1 Relay type output.

2.4.4.2 Transistor type output

2.4.4.3 TRIAC type output

2.5 PLC MANUFACTURES

SIEMENS

DELTA

ALLEN BRADLEY

GENERAL ELECTRICAL

MITSUBISHI

SCHENIDER

ABB

14
2.5.1 WPL Delta software

WPL Soft is a program-editing software made for the Delta DVP-PLC series used under WINDOWS.
WPL Soft is a software for PLC (Programmable logic controller). When PLC is in operation, use WPL Soft
to monitor the set value or temporarily saved value in timer (T), counter (C), and register (D) and force on /
Off of output contacts. PLC is a control system using electronic operations.

2.5.1.1 Features of WPL delta software

15
 Benefits

 Compact design—Lets the MicroLogix 1000 controller thrive in limited panel space.
 Choice of communication networks—An RS-232-C communication port is configurable for: DF1 protocol
for direct connection to a programming device or operator interface; DH-485 networking through a 1761-
NET-AIC converter; Device Net networking through a 1761-NET-DNI interface; Ethernet/IP networking
through a 1761-NET-ENI interface; or for half-duplex slave protocol in SCADA applications.
 Simple programming with your choice of programming device—You can program these controllers in
familiar ladder logic with MicroLogix 1000 A.I. Series Software®, PLC 500 A. I. Series Programming
Software, wplsoft 500™ Windows Programming Software, or the MicroLogix Hand-Held Programmer
(1761-HHP-B30). This symbolic programming language is based on relay ladder wiring diagrams that
simplify the creation and troubleshooting of your control program.
 Comprehensive instruction set Over 65 instructions including simple bit, timer, and counter instructions, as
well as instructions for powerful applications like sequencers, high-speed counter, and shift registers.
 Fast—Execution time for a typical 500-instruction program is only 1.56 Ms.
 Choice of languages—Software and documentation are available in 5 languages. The hand-held programmer
has 6 languages built in.

16
 CHAPTER 3
PROGRAMMING ON PLC

PLC programs are typically written in a special application on a personal computer, then downloaded by a
direct-connection cable or over a network to the PLC. The program is stored in the PLC either in battery-
backed-up RAM or some other non- volatile flash memory. Often, a single PLC can be programmed to
replace thousands of relays.

Under the IEC 61131-3 standard, PLCs can be programmed using standards-based programming languages.
A graphical programming notation called Sequential Function Charts is available on certain programmable
controllers.
Recently, the International standard IEC 61131-3 has become popular. IEC 61131-3 currently defines five
programming languages for programmable control systems: FBD (Function block diagram), LD (Ladder
diagram), ST (Structured text, similar to the Pascal programming language), IL (Instruction list, similar to
assembly language) and SFC (Sequential function chart). These techniques emphasize logical organization of
operations.
While the fundamental concepts of PLC programming are common to all manufacturers, differences in I/O
addressing, memory organization and instruction sets mean that PLC programs are never perfectly
interchangeable between different makers. Even within the same product line of a single manufacturer,
different models may not be directly compatible.
In Allen Bradley PLC’s the logic used for the programming is ladder logic. Ladder logic is a programming
language that represents a program by a graphical diagram based on the circuit diagrams of relay-based logic
hardware. It is primarily used to develop software for Programmable Logic Controllers (PLCs) used in
industrial control applications. The name is based on the observation that programs in this language resemble
ladders, with two vertical rails and a series of horizontal rungs between them.

17
An argument that aided the initial adoption of ladder logic was that a wide variety of engineers and
technicians would be able to understand and use it without much additional training, because of the
resemblance to familiar hardware systems. This argument has become less relevant given that most ladder
logic programmers have a software background in more conventional programming languages, and in
practice implementations of ladder logic have characteristics—such as sequential execution and support for
control flow features—that make the analogy to hardware somewhat imprecise.
Ladder logic is widely used to program PLCs, where sequential control of a process or manufacturing
operation is required. Ladder logic is useful for simple but critical control systems, or for reworking old
hardwired relay circuits. As programmable logic controllers became more sophisticated it has also been used
in very complex automation systems.

Simple ladder logic

The language itself can be seen as a set of connections between logical checkers (contacts) and actuators
(coils). If a path can be traced between the left side of the rung and the output, through asserted (true or
"closed") contacts, the rung is true and the output coil storage bit is asserted (1) or true. If no path can be
traced, then the output is false (0) and the "coil" by analogy to electromechanical relays is considered "de-
energized". The analogy between logical propositions and relay contact status is due to Claude Shannon.

18
Ladder logic has contacts that make or break circuits to control coils. Each coil or contact corresponds to the
status of a single bit in the programmable controller's memory. Unlike electromechanical relays, a ladder
program can refer any number of times to the status of a single bit, equivalent to a relay with an indefinitely
large number of contacts.
So-called "contacts" may refer to physical ("hard") inputs to the programmable controller from physical
devices such as pushbuttons and limit switches via an integrated or external input module, or may represent
the status of internal storage bits which may be generated elsewhere in the program.
Each rung of ladder language typically has one coil at the far right. Some manufacturers may allow more
than one output coil on a rung.
--( )-- a regular coil, energized whenever its rung is closed

--(\)-- a "not" coil, energized whenever its rung is open

--[ ]-- A regular contact, closed whenever its corresponding coil is energized

--[\]-- A "not" contact, open whenever its corresponding coil is energized

The "coil" (output of a rung) may represent a physical output which operates some device connected to the
programmable controller or may represent an internal storage bit for use elsewhere in the program.

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 3.1 PLC INSTRUCTIONS

There are various instructions which are useful for making ladder logic for PLC programming. These are as
follows:

3.1.1 XIC (Examine if closed):

Use the XIC instruction in your ladder program to determine if a bit is ON. When the instruction is executed,
if the bit addressed is on (1), then the instruction is evaluated as true. When the instruction is executed, if the
bit addressed is off (0), then the instruction is evaluated as false.

Table 3.1

I/P and O/P of XIC

I/P O/P

0 0

1 1

Symbol of XIC
Examples of devices that turn on or off include:
 A push button wired to an input (addressed as I:0/4).

 An output wired to a pilot light (addressed as O:0/2).

20
  A timer controlling a light (addressed as T4:3/DN).

3.1.2 XIO (Examine if open):

Use the XIO instruction in your ladder program to determine if a bit is OFF. When the instruction is
executed, if the bit addressed is off (0), then the instruction is evaluated as true. When the instruction is
executed, if the bit addressed is on (1), then the instruction is evaluated as false.

Table 3.2

I/P and O/P of XIO

I/P O/P

0 1

1 0

Symbol of XIO

Examples of devices that turn on or off include:

• Motor overload normally closed (N.C.) wired to an input (I:0/10).

• An output wired to a pilot light (addressed as O:0/4).

• A timer controlling a light (addressed as T4:3/DN).

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 3.1.3 Output Energize (OTE):

Use the OTE instruction in your ladder program to turn on a bit when rung conditions are evaluated as true.
An example of a device that turns on or off is an output wired to a pilot light (addressed as O:0/4).

OTE instructions are reset when:

• The SLC enters or returns to the REM Run or REM Test mode or Power is restored.
• The OTE is programmed within an inactive or false Master Control Reset (MCR) zone.

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 3.1.4 Output Latch (OTL) and Output Unlatch (OTU):

OTL and OTU are retentive output instructions. OTL can only turn on a bit, while OTU can only turn off a
bit. These instructions are usually used in pairs, with both instructions addressing the same bit. Your program
can examine a bit controlled by OTL and OTU instructions as often as necessary.

Symbol of Latch output and Unlatch output.

3.1.5 Timers

Timers are used to perform the timing operations. Time base is the minimum value of time in second that can
be taken by the timer. Preset value is the total number of the seconds for which the timing operation has to
be done Accumulator starts increasing the time in seconds upto the preset value. Upto the preset value of the
accumulator the enable bit of timer is high & the timer runs. When accumulator reaches the preset value then
the timer stops and the done bit of the timer becomes high.

3.1.6 Counters

Counters are used to count the number of operations. Its function is same as the timer accepts that the timer
counts the number of seconds and the counter counts the number of operations or pulses. At each operation
the value of the accumulator increases and when the value of the accumulator comes to the preset value of the
counter then the counter stops.
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 3.1 PLC PROGRAMS

Program no. 1:

Construct the logic diagram of all the basic logic gates (AND Gate, OR Gate, Not Gate, NAND Gate,
NOR Gate, EXOR Gate and EXNOR Gate) .

3.1.1 AND Gate :-

7In this program we have used two inputs and one output of PLC i.e. I:0/0 & I:0/1 as inputs and O:0/0 as
output. We have used two NO switches in series to get the desired output. As in And Gate when both the
inputs are high then the output is high otherwise the output is low. As in the logic circuit when we give high
signal to both the NO switches then we obtain the high output otherwise the output is low

Program on AND Gate

24
3.1.2 OR Gate:-
7In this program we have used two inputs and one output of PLC i.e. I:0/0 &
I:0/1 as inputs and O:0/0 as output. We have used two NO switches in parallel
to get the desired output. As in OR Gate when both the inputs are low then
the output is low otherwise the output is high. As in the logic circuit when we
give low signal to both the NO switches then we get the low output but in
other cases we got the high output.

Program on OR Gate

25
3.1.3NOT Gate: -

7In this program we have used one input and one output of PLC i.e. I:0/0 as input and O:0/0 as output. We
have used one NC switch in series to get the desired output. As in NOT Gate when the input is high then the
output is low and Vice-Versa. As in the logic circuit when we give high signal NC switch then we obtain the
low output and when we give low signal to NC switch then we got high output.

NOT Gat

26
 3.1.4 NAND Gate: -
In this program we have used two inputs and one output of PLC i.e. I:0/0 & I:0/1 as inputs and O:0/0 as
output. We have used two NC switches in series.

7to get the desired output. As in NAND Gate when both the inputs are low then the output is high otherwise
the output is low. As in the logic circuit when we give low signal to both the NC switches then we obtain the
high output otherwise we got low output.

NAND Gate

3.1.5 NOR Gate:-

7In this program we have used two inputs and one output of PLC i.e. I:0/0 & I:0/1 as inputs and O:0/0 as
output. We have used two NC switches in parallel to get the desired output. As in NOR Gate when both the
inputs are low then the output is high otherwise the output is low. As in the logic circuit when we give low
signal to both the NC switches then we get the high output but in other cases we got the low output.

27
 Fig 3.24 Program on NOR Gate

3.1.7 EX-OR Gate:-

In this program we have used two inputs and one output of PLC i.e. I:0/0 & I:0/1 as inputs and O:0/0 as
output. We have used two NO switches in series and combination of two NC switches parallel to those
combination of series NO switches to get the desired output. As in EX-OR Gate when both the inputs are
same then the output is low otherwise the output is high. As in the logic circuit when we give same signal to
both the inputs then we get the low output but in other cases we got the high output.

28
EX-NOR Gate:-

In this program we have used two inputs and one output of PLC i.e. I:0/0 & I:0/1 as inputs and O:0/0 as
output. We have used combination of one NO switch and one NC switch in series and combination of other
NC switch and NO switch parallel to those combination of one NO switch and one NC switch in series to get
the desired output. As in EXN-OR Gate when both the inputs are same then the output is high otherwise the
output is low. As in the logic circuit when we give same signal to both the inputs then we get the high output
but in other cases we got the low output.

Program on EX-NOR Gate

29
 CHAPTER 4
FUTURE SCOPE OF PLC

Most of the industries use control systems and automation entirely deals with it. It uses the information
technologies and control system and reduces the human manual work in the production of goods and
services. Most of the people say automation as a step beyond mechanization because in mechanization the
human operators do the work with applying their muscles for work, but the automation has reduced it.
Beyond manufacturing industries, it has been used in wide range of industries and the automation plays a
major role in world economy and has replaced all manual systems. Most of the industries prefer for people
who were well trained in plc automation training. A doubt may arise in your mind, why industries are looking
for automation training? What is the advantage of this automation? The automation have many advantages
such as it replaces human operators involving in tough or monotonous work that involves physical strain and
also replaces humans in tasks that are dangerous. Last, but not least is it improves the economy of industries,
society and humanity. Scada and plc are the most important automation tools and without this, the automation
fails to meet the demands.

The PLC is a small computer that has dedicated operating system and the operating system processes the
interrupts that are incoming in realtime and it is what it is called as a realtime operating system. Through
input lines, the interrupts are fed and the output sensors monitor various variables. The plc program evaluates
the input events and generates the output values which are sent via output lines. So that's why the automation
industries use this system and scada is used for controlling and monitoring activities. The automation field is
more versatile than before and the plc programs are send for monitoring data to a central control place called
scada. These two are essential in automation industries and if you are interested in pursuing training in
automation, then learn the plc scada training in Chennai so that you can get yourself placed in most
reputed industries.

PLCs are used in various places and many of the previous automation processes have been upgraded. This
upgraded automation has more flexibility and is simple to alter also. This in turn lends itself to have a more
efficient and portable process. On the other hand, PLCs come in various varieties. The

30
 sensors connected to the PLCs are smarter than in earlier years. PLC has a great impact on future of industrial
automation as the name indicates; it is a programmable logic controller. We are controlling the devices using
automation and using PLC programs can be logically done. PLC is mainly designed for multiple input and
output arrangements and it can withstand extreme temperatures with resistance to vibration and impact.

Let us understand the following topics in future of industrial automation article:

 Latest trends in industrial automation

 Scope of plc programming
 Future scope of industrial automation
 Latest plc technology
 New technology in industrial automation

4.1 Latest trends in industrial automation

Latest trends in industrial automation include increased use of analytics, growing use of PLCs, PACs, and
increased cloud-based supervisory control and data acquisition (SCADA) systems. These trends will
influence the industrial automation control market, according to a report. The report also predicts that these
trends will also result in an eight percent compound annual growth rate (CAGR) for the Asia-Pacific region,
but the trends are likely to be seen globally. Automation industry is moving towards a future of unparalleled
productivity spurred by superior energy efficiency, better design and operator visualization, and rigorous
safety standards.

4.2 Scope of plc programming

PLCs are continuously growing and evolving to be the best option for a variety of industrial automation
applications. Scope of plc programming is increasing rapidly because of greater programming flexibility and
ease, scalability, more memory, smaller sizes, very high-speed (gigabit) Ethernet, and built-in wireless
features. PLCs are getting benefits from USB technology and thus make it

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 easier than ever before to get online, program, and monitor your control systems. PLC programming will
evolve, and with the availability of smaller micro and mini USB connectors, you can expect to see this
option on more of the smaller PLCs. In the future, PLCs will continuously evolve while adapting technology
enhancements in communications, hardware, and software.

4.3 Future scope of industrial automation

Future scope of industrial automation would be good enough as every technology is involved with
automation techniques. It is the use of various control devices such as PC’s, DCs, and PLCs to control
various operations of an industry without significant intervention from humans and to provide automatic
control performance. In industries, there would be a set of technologies that are implemented to get the
desired performance or output, making the automation systems most essential for industries. On the other
hand, industrial automation involves usage of advanced control strategies such as cascade controls, control
hardware devices and other instruments for sensing the control variables etc.

4.4 Latest PLC technology

Latest PLC technology helps to monitor and control distributed server/multi user applications. It also
provides a comprehensive and accurate picture of operations, meeting the demands of multiple stakeholders
including maintenance, engineering, operations, and production information technology (IT). Reliable and
robust functionalities can be obtained using the latest technologies of PLC. These technologies enable you to
take advantage of visualization, mobility and other new technologies, meeting various challenges in process,
discrete applications and delivering critical visibility when you need it.

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4.5 New technology in industrial automation

New technology in industrial automation is the driver of progress for companies. From the conception to the
introduction of the collaborative robots, we have seen a major change in the technological developments
continuously shape the industrial automation landscape. These new technologies in automation industry will
shape industry in the year ahead. However, global automation industry has been progressing and enhancing
functionalities. Risk to security has enhanced interest in open-source software maintained by an active
community eager to fix errors.

4.6 Conclusion

Future of PLC in industrial automation has been rising since 1947 and most of the industries including
automation are using PLCs and install control systems to reduce the manual labor and improve the
precision and efficiency. PLCs are very popular because of their precision.

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