A Seminar Report

On

Basics Of Industrial Automation

Submitted in partial fulfilment of the requirements

of the degree of

Bachelor of Technology

In

Electronics & Communication Engineering

by

Aayushi Tomar
139107338

Seminar Incharge

Prof. (Dr.) Manish Tiwari

Department of Electronics and Communication Engineering

School of Electrical, Electronics and Communication Engineering
Manipal University Jaipur
Dehmi Kalan, Off Jaipur-Ajmer Expressway, Ajmer Road, Jaipur – 303007
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 Candidate’s Declaration

I, hereby certify that the work, which is being presented in the report, entitled Basics of Industrial
Automation in partial fulfilment of the requirement for the award of the Degree of Bachelor of
Technology, submitted to the Department of Electronics and Communication Engineering,
Manipal University Jaipur, is based on my work / study done during summer internship / industrial
training at Industrial Automation Training Centre-SIEMENS during the programme.

_________________________________
(Signature)

________________________________
(Name of the student)

_________________________________
(Registration No.)
Date: __________

iii
 ACKNOWLEDGMENTS

I wish to express my sincere thanks to Mr. Jaskaran Singh and Mr. Saurabh Bhatnagar, Manager
and Asst. Manager(Training) respectively for providing me with all the necessary facilities for
the research.
I place on record, my sincere thank you to Dr. Amit Rathi, Head of Department, Electronics and
Communication Engineering, Manipal University, Jaipur for his continuous encouragement.
I am most grateful to Mr. Ashish Vijay, Associate Professor in the Department of Electronics
and Communication Engineering who convincingly conveyed a spirit of adventure in regard to
research and an excitement in regard to teaching. Without his guidance and persistent help, this
project would not have been possible. I am extremely thankful and indebted to him for sharing
his expertise, sincere and valuable guidance and encouragement extended to me.
In addition to this, I thank all the respective department faculty guides and teachers who
supported me throughout the project and whose fervour, passion and zeal had a lasting effect.
I also thank my parents for the unceasing encouragement, support and attention. I also place on
record, my sense of gratitude to one and all, who directly or indirectly, have lent their hand in
this venture.

Aayushi Tomar
139107338

i
 ABSTRACT

PLC’s and HMI’s have wide no. of applications are seemed to be even more widen and increased
in the near future. They were first developed in the automobile industry to provide flexible,
ruggedized and easily programmable controllers to replace hard-wired relays and timers. Since
then they have been widely adopted as high-reliability automation controllers suitable for harsh
environments. There PLC is licensed only at their reliable centres for teaching how to be familiar
with them.

ii
 LIST OF FIGURES
Figure No Figure Title Page No.
1.1 Block Diagram of PLC 4
1.2 CPU of PLC 5

1.3 Power Supply 6

1.4 Working of PLC 7
1.5 Updating PIQ Area 7

1.6 Sending Output Image to Output Area 8

1.7 CPU Scan Cycle 8
1.8 Ladder Logic 9

1.9 FBD 9
1.10 PG/PC Interface 10
1.11 Basic Connection 11

1.12 SIMATICS S7-1200 12

2.1 Example of SCADA Animation 14
2.2 Simulation Panel and Working of HMI 17

2.3 Engineering Framework 17

2.4 Active Running Program in TIA 18
3.1 Pop up Display in the beginning of TIA Portal 20

3.2 Basic Details Window in TIA Portal 20

3.3 New Project Creation Window in TIA Portal 21
3.4 Selection of externally connected processor Window in TIA 21
Portal
3.5 PG/PC Interface Window in TIA Portal 22
3.6 Fan Fault System Window 1 23

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3.7 Fan Fault System Window 2 23
3.8 Fan Fault System Window 3 24
3.9 Car Parking System Window 1 26
3.10 Car Parking System Window 2 26
3.11 Car Parking System Window 3 27
3.12 Car Parking System Window 4 27
3.13 Car Parking System Window 5 28
3.14 Car Parking System Window 6 28
4.1 HMI Panel Window 1- Car Parking System 29
4.2 HMI Panel Window 2- Car Parking System 30
4.3 HMI Panel Window 3- Car Parking System 30
4.4 HMI Panel Window 4- Fan Fault System 31

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 Contents
Page No
Acknowledgement i
Abstract ii
List of Figures iii

Chapter 1 INTRODUCTION
1.1 Introduction 01
1.2 Automation 02
1.3 Programmable Logic Controllers 03
1.4 How PLC Works? 06
1.5 Programming Languages for PLC 08
1.6 Introduction to PLC Module (S7-1200) 11

Chapter 2 BACKGROUND THEORY – SOFTWARE USED

2.1 Human- Machine Interface 13
2.2 Totally Integrated Automation (TIA) 17

Chapter 3 METHODOLOGY- PROJECT

3.1 PROBLEM- FAN FAULT 18
3.2 PROBLEM: - CAR PARKING 25

Chapter 4 RESULT ANALYSIS

4.1 Program Performed in HMI Panel-FAN FAULT 29
4.2 Program Performed in HMI Panel-CAR PARKING 30

Chapter 5 CONCLUSIONS & FUTURE SCOPE

5.1 Work Conclusions 32
5.2 Future Scope of Work 32
5.3 Applications 35
REFERENCES 39
PROJECT DETAILS 40

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 INTRODUCTION

1.1. AUTOMATION

Control engineering has evolved over time. In the past humans were the main method 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, most of this is because of the advantages
they offer.
Automation or automatic control, is the use of various control systems for operating equipment
such as machinery, processes in factories, boilers and heat treating ovens, switching in telephone
networks, steering and stabilization of ships, aircraft and other applications with minimal or
reduced human intervention.
 The speed of a motor can be controlled by using some type of electronic drive equipment,
referred to as variable or adjustable speed drives. Variable speed drives used to control dc
motors are called dc drives. Variable speed drives used to control ac motors are called ac
drives. The term inverter is also used to describe an ac variable speed drive. The inverter
is only one part of an ac drive, however, it is common practice to refer to an ac drive as an
inverter.
 A programmable logic controller (PLC), also referred to as a programmable controller, is
the name given to a type of computer commonly used in commercial and industrial control
applications. PLCs differ from office computers in the types of tasks that they perform and
the hardware and software they require to perform these tasks. While the specific
applications vary widely, all PLCs monitor inputs and other variable values make decisions
based on a stored program, and control outputs to automate a process or machine.

 In an electric power system, switchgear is the combination of electrical disconnect

switches, fuses or circuit breakers used to control, protect and isolate electrical equipment.

1
 Switchgear is used both to de-energize equipment to allow work to be done and to
clear faults downstream. This type of equipment is directly linked to the reliability of
the electricity supply.

1.2. AUTOMATION

Automation is basically the delegation of human control functions to machines aimed towards
achieving
 Higher productivity
 Greater efficiency
 Less assembly or production time
 Reduced errors

History of process control and automation:

Manual control: In this all the actions related to process control and automation are taken by
operators. One of the major drawbacks of this method is the likely human errors and in
consequence its effect on the quality of the final project.
Hard wired logic control: This was considered to be the first step towards automation. Here the
contactors and relay together with timers and counters were used in achieving the desired level of
automation.
Limitations: bulky and complex wiring, involves lot of rework, to implement changes in control
logic.
Dedicated electronic control: With the advent of electronics, the logic gates and further
microprocessors started replacing the relay and auxiliary contactors in control circuits. the
bimetallic and motorised timers were replaced by electronic timers.
Advantages: reduced wiring and space requirements, energy saving, less maintenance and greater
reliability.
Limitations: in case of any change requirement in the control a lot of rework had to be done which
was time consuming and the technology up gradation was costly.

2
Programmable logic control: as the desired logic control is achieved through a program these
controllers are referred to as programmable logic controllers, the programmable controller have
in recent years experienced an unprecedented growth as universal element in industrial
automation.

1.3. PROGRAMMABLE LOGIC CONTROLLERS

Introduction
Control engineering has evolved over time. In the past humans were the main method 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, . Most of this is because
of the advantages they offer.

Advantages of PLCs:
PLCs not only are capable of performing the same tasks as hard-wired control, but are also capable
of many more complex applications. In addition, the PLC program and electronic communication
lines replace much of the interconnecting wires required by hard-wired control. Therefore, hard-
wiring, though still required to connect field devices, is less intensive. This also makes correcting
errors and modifying the application easier. Some of the additional advantages of PLCs are as
follows:
• smaller physical size than hard-wire solutions.
• easier and faster to make changes.
• PLCs have integrated diagnostics and override functions.
• diagnostics are centrally available.
• applications can be immediately documented.
• applications can be duplicated faster and less expensively.

3
What constitutes a PLC: The PLC is basically a programmed interface between the field input
elements like limit switches, sensors, transducers, push buttons etc and the final control elements
like actuators solenoid valves, dampers, drives, led’s, hooters etc...

The interface called as programmable logic controller or to be precise, programmable controller

consists of the following:

1. Input modules.
2. CPU with processor and program memory.
3. Output modules.
4. Bus system.
5. Power supply

Fig 1.1: Block Diagram of PLC

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Functions of various blocks:
Input module:

The input module acts as an interface between the field control inputs and the CPU. The voltage
or current signals generated by the sensors, transducer, limit switches, push buttons etc are
applied to the input module.
Purpose of input module:
 It converts the field signal into a standard control signal for processing by PLC. The
standard control signal delivered by input module could be 5v or 9v whereas the field
signal receiving by it could be say 24v or 230v ac
 It isolates the field signals from the CPU.

Central processing unit:

The central processing units or the CPU consists of the following blocks:
 Arithmetic logic unit
 Program memory
 Process image memory
 Internal timers and counters and
 Flags

Fig 1.2: CPU of PLC

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The heart of the CPU is the microprocessor or microcontroller chip, working of a CPU is fully
controlled by the instructions stores in user program memory, the user program directs and
controls the CPU’S memory.
Output module:
The output module act as a link b/w the CPU and the output devices located in the field. The
field devices could be relays, contactor, lamps, and motorized potentiometers, actuators. The
output module converts the output signal delivered by CPU into an appropriate voltage level
suitable for output field devices. but the output module converts this voltage level into say 24 v
dc, 120 v dc or 230 v ac etc. Thus, the output module in receiving signal from the processor
switches voltage to the respective output terminals.
Power supply:
The power supply modules generate the voltage required by the electronic module of the PLC
from the main supply. Typically, one phase, 230v ac supply is converted into 24 v dc supply by
the power supply module, it should be noted that the CPU needs 24 v dc input and other voltages
required by the PLC hardware such as 5v dc etc. is generated by CPU.

Fig 1.3: Power Supply

1.4. HOW PLC WORKS?

As discussed earlier, the field signals are connected to the input module. At the output of the
input module the field status is converted into a voltage level that is required by a CPU.
At the beginning of each cycle the CPU brings in all the field input signals from input
module and stores into its internal memory as process image of input signal, this internal
memory of CPU is called process image input.

6
 Fig 1.4: Working of PLC
Processing of the signals using program and updating PIQ
Once the field input status is brought into the internal memory of the CPU i.e. in PII, the
program execution of user program, statement by statement begins. Based on the user program
the CPU performs logical and arithmetic operations on the data from PII .it also processes times
and counts as well as flag status based on the instructions.
The result of the user program i.e. decisions are then stored in the internal memory of the
CPU.i.e. PIQ (process image output)

Fig 1.5: Updating PIQ Area

Sending process output image to the output module.

At the end of program run i.e. at the end of the scanning cycle, the CPU transfers the signal states
in the process image output to the output module and further to the field control.

7
 Fig 1.6: Sending Output Image to Output Module

PLC scan cycle:

The PLC program is executed as part of a repetitive process referred to as a scan. A PLC scan
starts with the CPU reading the status of inputs. Next, the application program is executed. Then,
the CPU performs internal diagnostics and communication tasks. Finally, the CPU updates the
status of outputs. This process repeats as long as the CPU in the run mode. The time required to
complete a scan depends on the size of the program, the number of i/os, and the amount of
communication required.

Fig 1.7: CPU Scan Cycle

1.5. PROGRAMMING LANGUAGES FOR PLC
Ladder logic programming a program consists of instructions that accomplish specific tasks. The
degree of complexity of a PLC program depends upon the complexity of the application, the
number and type of input and output devices, and the types of instructions used.
Ladder logic (lad) is one programming language used with PLCs. Ladder logic incorporates
programming functions that are graphically displayed to resemble symbols used in hard-wired
control diagrams. The left vertical line of a ladder logic diagram represents the power or
energized conductor. The output coil instruction represents the neutral or return path of the
8
circuit. The right vertical line, which represents the return path on a hard-wired control line
diagram, is omitted. Ladder logic diagrams are read from left-to-right and top-to-bottom. Rungs
are sometimes referred to as networks. A network may have several control elements, but only
one output coil.

Fig 1.8: ladder logic

Statement list and function block diagrams while ladder logic programs are still common, there
are many other ways to program PLCs. Two other common examples are statement list and
function block diagrams. Statement list (STL) instructions include an operation and an operand.
The operation to be performed is shown on the left. The operand, the item to be operated on, is
shown on the right.
Function block diagrams (FBD) include rectangular functions with inputs shown on the left side
of the rectangle and outputs shown on the right side in the following example, the program
segments perform the same function.

Fig 1.9: FBD

Putting it together
The user memory of a PLC, such as the s7-200 PLC shown in the following illustration, includes
space for the user program as well as addressable memory locations for storage of data. The
amount of program and data space available depends on the CPU model.

9
User program space stores instructions that are executed repetitively as part of the PLC scan. The
user program is developed using a programming device, such as a personal computer (pc) with
programming software, then loaded into the user program memory of the PLC.

Fig 1.10: PG/PC interface

Basic requirements: Throughout this course we will be using the s7-200 PLC for specific
examples of PLC concepts. The s7-200 PLC is used for this purpose because of its ease of use
and wide-spread application.
The items shown in the following illustration are needed to create or change an s7-200 PLC
program. The program is created using step 7-micro/win programming software which runs on a
windows-based personal computer (win2000, windows xp, and higher operating system).
A special cable is needed when a personal computer is used as a programming device. Two
versions of this cable are available. One version, called an rs-232/PPI multi-master cable, connects
a personal computer’s rs-232 interface to the PLC’s rs-485 connector. The other version, called a
USB/PPI multi-master cable, connects a personal computer’s USB interface to the PLC’s rs-485
connector.

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 Fig 1.11: Basic Connection
1.6. INTRODUCTION TO PLC MODULE (S7-1200)

Modular simatic s7-1200 controller is at the core of our new offering for simple but highly precise
automation tasks. The simatic s7-1200 controller is modular and compact, versatile, a secure
investment, and is perfectly suited to a whole range of applications.

The s7-1200 CPUs with safety integrated handle both standard and safety-related tasks. A compact
design with integrated i/o, communication interfaces that meet the highest industry requirements
and a range of powerful integrated technological functions make this controller an integral part of
a comprehensive automation solution.

The compact simatic s7-1200 system consists of different CPU performance classes: CPU 1211c,
CPU 1212c, CPU 1214c, CPU 1215c and CPU 1217c and the failsafe versions CPU 1212fc, CPU
1214fc and CPU 1215fc. Each of these may be expanded according to the machine requirements.

Signal modules can be connected to the right side of the CPU to further expand the digital or analog
i/o capacity. CPU 1212c accepts two, CPU 1215c and CPU 1217c accept eight signal modules.

11
 Fig 1.12: SIMATIC S7-1200

Basic controller covering

System flexibility and modularity: Modular board concept provides the ability to add additional
i/os without increasing the CPU’s footprint. So, if our application calls for a single RTD input
just add the correct signal board and this reduces space and cost. Integrated profinet/ethernet
interface eliminates the need for additional proprietary programming cables and no ethernet
expansion module; which reduces space and cost.
Powerful integrated functionality: Extensive built-in technology like motion control i/o, PID
controllers, high speed counting i/o, and analog i/o eliminates the need for additional specialty
modules reducing space and cost. Simple configuration tools are used for both motion and pid
control functions; which saves engineers considerable development time. Rapid realization of
our application is achieved with integrated control panels that dramatically reduce start-up and
commissioning time.

Engineering usability: Intelligent drag and drop between editors allows engineers to be much
quicker during development. This intuitive functionality saves considerable time and overall
engineering costs. Single engineering framework for logic, HMI and networking with common
navigation, icons, and menus are consistent throughout all views. This makes it easy to learn and
even easier to maintain saving our time.

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 SOFTWARES USED

The software Siemens uses for most of its Automation and Drives is given below:
PLC S7200 - Step7 Microwin
PLC S7300/S7400 - Simatic Manager
PLC S71200 – TIA Portal
SCADA – WinCC Explorer
HMI - WinCC Flexible

2.1 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. For example, a picture of a pump connected to a pipe can show the
operator that the pump is running and how much fluid it is pumping through the pipe at the
moment. The operator can then switch the pump off. The HMI software will show the flow rate
of the fluid in the pipe decrease in real time. Mimic diagrams may consist of line graphics and
schematic symbols to represent process elements, or may consist of digital photographs of the
process equipment overlain with animated symbols.
The HMI package for the SCADA system typically includes a drawing program that the
operators or system maintenance personnel use to change the way these points are represented in
the interface. These representations can be as simple as an on-screen traffic light, which
represents the state of an actual traffic light in the field, or as complex as a multi-projector

13
display representing the position of all of the elevators in a skyscraper or all of the trains on a
railway.

An important part of most SCADA implementations is alarm handling. The system monitors
whether certain alarm conditions are satisfied, to determine when an alarm event has occurred.
Once an alarm event has been detected, one or more actions are taken (such as the activation of
one or more alarm indicators, and perhaps the generation of email or text messages so that
management or remote SCADA operators are informed). In many cases, a SCADA operator may
have to acknowledge the alarm event; this may deactivate some alarm indicators, whereas other
indicators remain active.

Fig 2.1: Example of SCADA Animation

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2.1.1 HARDWARE SOLUTIONS

SCADA solutions often have distributed control system (DCS) components. Use of "smart"
RTUs or PLC, which are capable of autonomously executing simple logic processes without
involving the master computer, is increasing. A standardized control programming language, iec
61131-3 (a suite of 5 programming languages including function block, ladder, structured text,
sequence function charts and instruction list), is frequently used to create programs which run on
these RTUs and PLCs. Unlike a procedural language such as the c programming language, iec
61131-3 has minimal training requirements by virtue of resembling historic physical control
arrays. This allows SCADA system engineers to perform both the design and implementation of a
program to be executed on an RTU or PLC.

Since about 1998, virtually all major PLC manufacturers have offered integrated HMI/SCADA
systems, many of them using open and non-proprietary communications protocols.

Remote terminal unit: The RTU connects to physical equipment. Typically, an RTU converts the
electrical signals from the equipment to digital values such as the open/closed status from a switch
or a valve, or measurements such as pressure, flow, voltage or current. By converting and sending
these electrical signals out to equipment the RTU can control equipment, such as opening or
closing a switch or a valve, or setting the speed of a pump. It can also control the flow of a liquid.
Supervisory station: The term supervisory station refers to the servers and software responsible
for communicating with the field equipment (RTUs, PLCs, etc.), and then to the HMI software
running on workstations in the control room, or elsewhere. In smaller SCADA systems, the
master station may be composed of a single pc. In larger SCADA systems, the master station
may include multiple servers, distributed software applications, and disaster recovery sites. To
increase the integrity of the system the multiple servers will often be configured in a dual-
redundant or hot-standby formation providing continuous control and monitoring in the event of
a server failure.

2.1.2 HMI ARCHITECTURES

HMI systems have evolved through 3 generations as follows:

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First generation: "MONOLITHIC”

In the first generation, computing was done by mainframe computers. Networks did not exist at
the time SCADA was developed. Thus, SCADA systems were independent systems with no
connectivity to other systems. Wide area networks were later designed by RTU vendors to
communicate with the RTU. The communication protocols used were often proprietary at that
time. The first-generation SCADA system was redundant since a back-up mainframe system was
connected at the bus level and was used in the event of failure of the primary mainframe system.

Second generation: "DISTRIBUTED"

The processing was distributed across multiple stations which were connected through a LAN
and they shared information in real time. Each station was responsible for a particular task thus
making the size and cost of each station less than the one used in first generation.

The network protocols used were still mostly proprietary, which led to significant security
problems for any SCADA system that received attention from a hacker. Since the protocols were
proprietary, very few people beyond the developers and hackers knew enough to determine how
secure a SCADA installation was.

Third generation: "NETWORKED"

Due to the usage of standard protocols and the fact that many networked SCADA systems are
accessible from the internet, the systems are potentially vulnerable to remote cyber-attacks. On the
other hand, the usage of standard protocols and security techniques means that standard security
improvements are applicable to the SCADA systems, assuming they receive timely maintenance
and updates.

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Fig.2.2: This is a simulation panel of HMI and shows the working of HMI, and how the cars can
come and place at their appropriate positions and once the room is full. An automatic barrier comes
and it is linked to TIA’s portal program and both run simultaneously.

2.2 TOTALLY INTEGRATED AUTOMATION (TIA)

Tia portal – the integrated engineering framework for controller, HMI and drives.

Fig 2.3: Engineering Framework

The totally integrated automation portal (TIA portal) provides we with unrestricted access to
our complete range of digitalized automation services, from digital planning and integrated
engineering to transparent operation.

The new version shortens our time to market, for example by means of simulation tools, increases
the productivity of our plant through additional diagnostics and energy management functions, and
17
offers we broader flexibility by connecting to the management level. The new options benefit
system integrators and machine builders as well as plant operators. The TIA portal is thus our
perfect gateway to automation in the digital enterprise. As part of the digital enterprise suite along
with PLM and MES, it complements the comprehensive range of offerings from siemens for
companies on their path to industry 4.0.

With the totally integrated automation portal (TIA portal), siemens follows a vision of providing
an engineering framework for implementing automation solutions in all industries around the
globe. From designing, commissioning, operating and maintaining to upgrading automation
systems, TIA portal saves engineering time, cost, and effort.

Totally integrated automation in the digital enterprise.

Fig.2.4-: It shows the active running program in TIA, where green switched and green wire are
active and dotted blue lines are a path way to perform program.

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 PROJECT UNDERTAKING

3.1 PROBLEM- FAN FAULT

IF A CONNECTION OF THREE PARALLEL FANS, ONE LED AND ONE HOOTER IS
PROVIDED SUCH THAT THE CONNECTION IS PROVIDED FOR SWITCH 1 WHICH WILL
TURN ON FAN 1, FAN 2, AND LED 1. IF THERE IS A FAULT IN ONE OF THE FANS,
SWITCH 2 WILL BE ON, WHERE FAN 3 WILL SUBSTITUTE THE FAULTY FAN 1. IF THERE
IS A FAULT IN FAN 2, THEN SWITCH 3 WILL BE TURNED ON GIVING FOLLOWING
COMBINATIONS OF APPLIANCES. WHEN THERE IS A FAULT IN BOTH FAN 1 AND 2,
THEN FAN 3 WILL BE ON WITH THE HOOTER. LED 1 WILL BE ALWAYS ON.
FAN 1 FAN 2 FAN 3 LED 1 HOOTER
SWITCH 1 ON ON OFF ON OFF
SWITCH 2 OFF ON ON ON OFF
(FAULT)
SWITCH 3 ON OFF ON ON OFF
(FAULT)
SWITCH 2 + OFF OFF OFF ON ON
SWITCH 3

SOLUTION: -
Step 1- Open TIA Portal for creating ladder logic program for the above-mentioned problem.

19
Fig. 3.1-: This is a 1st look of TIA portal when we start’s TIA portal this display popped up.

20
Fig.3.2-: This shows the window of TIA, and about all the basic things we can do in TIA.
(STEP 2)

Fig.3.3-: This is a shot of creating new project with a dialogue box. (STEP 3)

Fig.3.4-: From here we can choose any CPU and any HMI, basically any type of processor
which we had connected externally also. (STEP 4)

21
Fig.3.5-: This shows the connection building between PLC and PC i.e. PG/PC interface. (STEP 5)

22
Fig.3.6-: Connect and draw the ladder diagram for first condition of Fan Fault system. (Step 6)
(where Q0.0 is for FAN 1, Q0.1 is for FAN 2, and Q0.2 is for LED 1)

Fig.3.7-: Connect and draw the ladder diagram for second condition of Fan Fault system (Step
7)

23
Fig.3.8-: Connect and draw the ladder diagram for the third condition of the fan fault system
(Step 8) (Where Q0.0 is for FAN 1, Q0.1 is for FAN 2, Q0.2 is for FAN 3, Q0.3 is for LED 1,
and Q0.4 is for Hooter.
Step 9 – After compiling the program, with zero errors. Download the program into the PLC (s7-
1200), store it and check it on the PLC panel.

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 PROJECT UNDERTAKEN (PLC S7-1200 and HMI)

3.2 PROBLEM: - CAR PARKING

ON A PARTICULAR FLOOR OF A CAR PARKING LOT, A PLC (S7-1200) AND HMI
SCREEN HAS BEEN INSTALLED TO GUIDE THE CAR OWNERS ABOUT THE VACANT
SPACES AVAILABLE IN THE PARKING ON THAT FLOOR. NOW IN THAT PARTICULAR
PARKING LOT, ONLY 30 VACANT SPACES ARE AVAILABLE INITIALLY AT THE
BEGINNING OF DAY. CARS WILL BE PARKED AND EXIT OUT OF THE PARKING LOT
DEPENDING UPON THE VACANT SPACE AVAILABLE. CREATE A LADDER DIAGRAM AS
WELL AS IMPLEMENT HMI VIEW FOR THE ABOVE-MENTIONED PROBLEM.

STEP 1- Follow the STEPS 1-6 as done in the previous problem, in the TIA portal interface for
creating the ladder diagram for this problem.

Fig.3.9-: Connect and draw the ladder diagram to two timers, one of time 3 seconds and the other
of time 30 seconds.

25
Fig.3.10-: Connect comparators to generate a pulse of 1.5 seconds.

26
Fig.3.11-: Connect and draw the ladder diagram to a count up and down counter to count the
number of cars entering the level, and to stop when the count crosses 29.

Fig.3.12-: Connect comparators to generate a pulse 12.5 seconds.

27
Fig.3.13-: Connect and draw the ladder diagram to a count up and down counter to count the
number of cars leaving the level, and to stop when the count crosses 29

Fig.3.14-: Connect and draw the ladder diagram to a count up and down counter to count the
number of cars leaving and entering the level, and to shift to the next level when the count
crosses 29 and stop when it reaches 60.

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 RESULT ANALYSIS USING HMI PANEL
4.1 PROGRAM PERFORMED IN HMI PANEL- CAR PARKING

Fig.4.1: Basic HMI Touch Panel

Fig.4.2-: Parking Full-30 Cars at level 1

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Fig.4.3-:1st Car at level 2

4.2 PROGRAM PERFORMED IN HMI PANEL- FAN FAULT

30
Fig.4.4-: All 3 fans with Indicator, Hooter and Fault buttons on Basic HMI panel

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 CONCLUSIONS AND FUTURE SCOPE OF TRAINING

5.1 CONCLUSIONS AND OBJECTIVES ACHIEVED

Working at SIEMENS is valuables time for me and I have learned a number of things at their
plant. I had already worked on SIEMENS PLC, Drives, SCADA and HMI system but still there
is a long way to go.

5.2 FUTURE SCOPE

Since the turn of the century, the global recession has affected most businesses, including
industrial automation. After four years of the new millennium, here are my views on the
directions in which the automation industry is moving.

The rear-view mirror

Because of the relatively small production volumes and huge varieties of applications,
industrial automation typically utilizes new technologies developed in other markets.
Automation companies tend to customize products for specific applications and requirements.
So the innovation comes from targeted applications, rather than any hot, new technology.

Over the past few decades, some innovations have indeed given industrial automation new
surges of growth: The programmable logic controller (PLC) – developed by Dick Morley and
others – was designed to replace relay-logic; it generated growth in applications where custom
logic was difficult to implement and change. The PLC was a lot more reliable than relay-
contacts, and much easier to program and reprogram. Growth was rapid in automobile test-
installations, which had to be re-programmed often for new car models. The PLC has had a
long and productive life – some three decades – and (understandably) has now become a
commodity.

At about the same time that the PLC was developed, another surge of innovation came through
the use of computers for control systems. Mini-computers replaced large central mainframes
in central control rooms, and gave rise to "distributed" control systems (DCS), pioneered by

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Honeywell with its TDC 2000. But, these were not really "distributed" because they were still
relatively large clumps of computer hardware and cabinets filled with I/O connections.

Automation software has had its day, and can't go much further. No "inflection point" here.
In the future, software will embed within products and systems, with no major independent
innovation on the horizon. The plethora of manufacturing software solutions and services will
yield significant results, but all as part of other systems.

So, in general, innovation and technology can and will reestablish growth in industrial
automation. But, there won't be any technology innovations that will generate the next Cisco
or Apple or Microsoft.

We cannot Fig out future trends merely by extending past trends; it’s like trying to drive by
looking only at a rear-view mirror. The automation industry does NOT extrapolate to smaller
and cheaper PLCs, DCSs, and supervisory control and data acquisition systems; those
functions will simply be embedded in hardware and software. Instead, future growth will
come from totally new directions.

New technology directions

Industrial automation can and will generate explosive growth with technology related to new
inflection points: nanotechnology and nanoscale assembly systems; MEMS and nanotech
sensors (tiny, low-power, low-cost sensors) which can measure everything and anything; and
the pervasive Internet, machine to machine (M2M) networking.

Major new software applications will be in wireless sensors and distributed peer-to-peer
networks – tiny operating systems in wireless sensor nodes, and the software that allows nodes
to communicate with each other as a larger complex adaptive system. That is the wave of the
future.

The fully-automated factory

Automated factories and processes are too expensive to be rebuilt for every modification and
design change – so they have to be highly configurable and flexible. To successfully recon
Fig an entire production line or process requires direct access to most of its control elements
– switches, valves, motors and drives – down to a fine level of detail.

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Communications support of a very high order is now available for automated processes: lots
of sensors, very fast networks, quality diagnostic software and flexible interfaces – all with
high levels of reliability and pervasive access to hierarchical diagnosis and error-correction
advisories through centralized operations.

The large, centralized production plant is a thing of the past. The factory of the future will be
small, movable (to where the resources are, and where the customers are). For example, there
is really no need to transport raw materials long distances to a plant, for processing, and then
transport the resulting product long distances to the consumer. In the old days, this was done
because of the localized know-how and investments in equipment, technology and personnel.
Today, those things are available globally.

Hard truths about globalization

The assumption has always been that the US and other industrialized nations will keep leading
in knowledge-intensive industries while developing nations focus on lower skills and lower
labor costs. That's now changed. The impact of the wholesale entry of 2.5 billion people
(China and India) into the global economy will bring big new challenges and amazing
opportunities.

Beyond just labor, many businesses (including major automation companies) are also
outsourcing knowledge work such as design and engineering services. This trend has already
become significant, causing joblessness not only for manufacturing labor, but also for
traditionally high-paying engineering positions.

Innovation is the true source of value, and that is in danger of being dissipated – sacrificed to
a short-term search for profit, the capitalistic quarterly profits syndrome. Countries like Japan
and Germany will tend to benefit from their longer-term business perspectives. But,
significant competition is coming from many rapidly developing countries with expanding
technology prowess. So, marketing speed and business agility will be offsetting advantages.

The winning differences

In a global market, there are three keys that constitute the winning edge:

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  Proprietary products: developed quickly and inexpensively (and perhaps globally), with a
continuous stream of upgrade and adaptation to maintain leadership.
 High-value-added products: proprietary products and knowledge offered through effective
global service providers, tailored to specific customer needs.
 Global yet local services: the special needs and custom requirements of remote customers
must be handled locally, giving them the feeling of partnership and proximity.

To implementing these directions demands management and leadership abilities that are
different from old, financially-driven models. In the global economy, automation companies
have little choice – they must find more ways and means to expand globally. To do this they
.need to minimize domination of central corporate cultures, and maximize responsiveness to
local customer needs. Multi-cultural countries, like the U.S., will have significant advantages
in these important business aspects.

In the new and different business environment of the 21st century, the companies that can
adapt, innovate and utilize global resources will generate significant growth and success.

5.3 APPLICATIONS

 Food and drink

The food retail industry has started to apply automation to the ordering process; McDonald's has
introduced touch screen ordering and payment systems in many of its restaurants, reducing the
need for as many cashier employees. The University of Texas at Austin has introduced fully
automated cafe retail locations. Some Cafes and restaurants have utilized mobile and tablet "apps"
to make the ordering process more efficient by customers ordering and paying on their
device. Some restaurants have automated food delivery to customers tables using a Conveyor belt
system. The use of robots is sometimes employed to replace waiting staff.

 Stores

Many Supermarkets and even smaller stores are rapidly introducing Self checkout systems
reducing the need for employing checkout workers. Online shopping could be considered a form
of automated retail as the payment and checkout are through an automated Online transaction

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processing system. Other forms of automation can also be an integral part of online shopping, for
example the deployment of automated warehouse robotics such as that applied
by Amazon using Kiva Systems.

 Automated mining

Involves the removal of human labor from the mining process.[26] The mining industry is currently
in the transition towards Automation. Currently it can still require a large amount of human capital,
particularly in the third world where labor costs are low so there is less incentive for increasing
efficiency through automation.

 Automated video surveillance

The Defense Advanced Research Projects Agency (DARPA) started the research and development
of automated visual surveillance and monitoring (VSAM) program, between 1997 and 1999, and
airborne video surveillance (AVS) programs, from 1998 to 2002. Currently, there is a major effort
underway in the vision community to develop a fully automated tracking surveillance system.
Automated video surveillance monitors people and vehicles in real time within a busy
environment. Existing automated surveillance systems are based on the environment they are
primarily designed to observe, i.e., indoor, outdoor or airborne, the amount of sensors that the
automated system can handle and the mobility of sensor, i.e., stationary camera vs. mobile camera.
The purpose of a surveillance system is to record properties and trajectories of objects in a given
area, generate warnings or notify designated authority in case of occurrence of particular events.[27]

 Automated highway systems

As demands for safety and mobility have grown and technological possibilities have multiplied,
interest in automation has grown. Seeking to accelerate the development and introduction of fully
automated vehicles and highways, the United States Congress authorized more than $650 million
over six years for intelligent transport systems (ITS) and demonstration projects in the
1991 Intermodal Surface Transportation Efficiency Act (ISTEA). Congress legislated in ISTEA
that “the Secretary of Transportation shall develop an automated highway and vehicle prototype
from which future fully automated intelligent vehicle-highway systems can be developed. Such
development shall include research in human factors to ensure the success of the man-machine
relationship. The goal of this program is to have the first fully automated highway roadway or an

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automated test track in operation by 1997. This system shall accommodate installation of
equipment in new and existing motor vehicles." [ISTEA 1991, part B, Section 6054(b)].

Full automation commonly defined as requiring no control or very limited control by the driver;
such automation would be accomplished through a combination of sensor, computer, and
communications systems in vehicles and along the roadway. Fully automated driving would, in
theory, allow closer vehicle spacing and higher speeds, which could enhance traffic capacity in
places where additional road building is physically impossible, politically unacceptable, or
prohibitively expensive. Automated controls also might enhance road safety by reducing the
opportunity for driver error, which causes a large share of motor vehicle crashes. Other potential
benefits include improved air quality (as a result of more-efficient traffic flows), increased fuel
economy, and spin-off technologies generated during research and development related to
automated highway systems.

 Automated waste management

Automated waste collection trucks prevent the need for as many workers as well as easing the
level of Labor required to provide the service.

 Home automation

Home automation (also called domotics) designates an emerging practice of increased automation
of household appliances and features in residential dwellings, particularly through electronic
means that allow for things impracticable, overly expensive or simply not possible in recent past
decades.

 Industrial automation

Industrial automation deals primarily with the automation of manufacturing, quality control and
material handling processes. General purpose controllers for industrial processes
include Programmable logic controllers and computers. One trend is increased use of Machine
vision to provide automatic inspection and robot guidance functions, another is a continuing
increase in the use of robots. Energy efficiency in industrial processes has become a higher
priority. Semiconductor companies like Infineon Technologies are offering 8-bit micro-controller
applications for example found in motor controls, general purpose pumps, fans, and ebikes to
reduce energy consumption and thus increase efficiency.
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 Agent-assisted Automation

Agent-assisted automation refers to automation used by call center agents to handle customer
inquiries. There are two basic types: desktop automation and automated voice solutions. Desktop
automation refers to software programming that makes it easier for the call center agent to work
across multiple desktop tools. The automation would take the information entered into one tool
and populate it across the others so it did not have to be entered more than once, for example.
Automated voice solutions allow the agents to remain on the line while disclosures and other
important information is provided to customers in the form of pre-recorded audio files. Specialized
applications of these automated voice solutions enable the agents to process credit cards without
ever seeing or hearing the credit card numbers or CVV codes.

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REFERENCES

1. https://www.siemsns.com/support

2. https://www.siemens.com/industryproduct

3. https://www.iatc.com

4. https://www.siemens.com/in/en/home.html

5. https://en.wikipedia.org/wiki/siemens

6. https://www.siemens-home.bsh-group.com/in/

7. https://www.wetube.com/user/siemens

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 PROJECT DETAILS

Student Details
Student Name Aayushi Tomar
Register Number 139107338 Section / Roll ECE-A
No
Email Address aayushi7561@gmail.com Phone No (M) 7728992058
Project Details
Project Title Car Parking and Fan Fault
Project Duration 6 Months Date of 6th February,
reporting 2017
Organization Details
Organization IATC-SIEMENS
Name
Full postal address IATC-SIEMENS, TSP North
with pin code Sco-134,135,136, sector 34-a
Chandigarh-160034
Website address http://iatc.in
Supervisor Details
Supervisor Name Mr. Saurabh Bhatnagar
Designation Asst. Manager Training
Full contact IATC-SIEMENS, TSP North
address with pin Sco-134,135,136, sector 34-a
code Chandigarh-160034
Email address saurabh@iatc.in Phone No (M)
Internal Guide Details
Faculty Name Mr. Ashish Vijay
Full contact Manipal University Jaipur, VPO Dehmi Kalan, Near GVK Toll Plaza,
address with pin Ajmer Expressway, Jaipur, Rajasthan 303007
code
Email address Ashish.vijay@jaipur.manipal.edu Phone No (M) 8302306543

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