Book Image

Industrial Automation from Scratch

By : Olushola Akande
Book Image

Industrial Automation from Scratch

By: Olushola Akande

Overview of this book

Industrial automation has become a popular solution for various industries looking to reduce manual labor inputs and costs by automating processes. This book helps you discover the abilities necessary for excelling in this field. The book starts with the basics of industrial automation before progressing to the application of switches, sensors, actuators, and motors, and a direct on-line (DOL) starter and its components, such as circuit breakers, contactors, and overload relay. Next, you'll explore VFDs, their parameter settings, and how they can be wired and programmed for induction motor control. As you advance, you'll learn the wiring and programming of major industrial automation tools – PLCs, HMIs, and SCADA. You’ll also get to grips with process control and measurements (temperature, pressure, level, and flow), along with analog signal processing with hands-on experience in connecting a 4–20 mA transmitter to a PLC. The concluding chapters will help you grasp various industrial network protocols such as FOUNDATION Fieldbus, Modbus, PROFIBUS, PROFINET, and HART, as well as emerging trends in manufacturing (Industry 4.0) and its empowering technologies (such as IoT, AI, and robotics). By the end of this book, you’ll have gained a practical understanding of industrial automation concepts for machine automation and control.

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Table of Contents (21 chapters)
Preface
Preface
Who this book is for
What this book covers
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1
Part 1: Learning the Concepts and Skills Required to Get Started
Part 1: Learning the Concepts and Skills Required to Get Started
Free Chapter
2
Chapter 1: Introduction to Industrial Automation
Chapter 1: Introduction to Industrial Automation
Introducing industrial automation
Exploring the types of industrial automation
Understanding the levels of industrial automation
Discovering the advantages and disadvantages of industrial automation
Summary
Questions
3
Chapter 2: Switches and Sensors – Working Principles, Applications, and Wiring
Chapter 2: Switches and Sensors – Working Principles, Applications, and Wiring
Introducing switches and sensors
Describing manually operated switches
Describing mechanically operated switches
Understanding proximity sensors (capacitive, inductive, and photoelectric)
Summary
Questions
4
Chapter 3: Actuators and Their Applications in Industrial Automation
Chapter 3: Actuators and Their Applications in Industrial Automation
Introducing actuators
Learning about electric actuators
Exploring pneumatic actuators
Getting to know about hydraulic actuators
Summary
Questions
5
Chapter 4: Overview of AC and DC Motors
Chapter 4: Overview of AC and DC Motors
Understanding AC motors
Understanding DC motors
Understanding stepper motors and servo motors
Summary
Questions
6
Chapter 5: Introduction to Variable Frequency Drive (VFD)
Chapter 5: Introduction to Variable Frequency Drive (VFD)
An overview of a VFD
Wiring a VFD
Understanding a basic VFD parameter setting
Wiring and programming a VFD to start/stop a three-phase motor and setting the frequency (speed) using a keypad
Wiring and programming a VFD (VAT20) to use a push button or switch to run a three-phase motor in a forward/reverse direction and use a keypad to set the frequency (speed)
Wiring and programming a VFD (VAT20) to use a push button or switch to run a three-phase motor in a forward/reverse direction and to use a potentiometer to set the frequency (speed)
Summary
Questions
7
Chapter 6: Drawing Schematic/Wiring Diagrams Using CAD Software
Chapter 6: Drawing Schematic/Wiring Diagrams Using CAD Software
Technical requirements
Understanding electrical diagrams/drawings
Overview of PCSCHEMATIC Automation software
Downloading and installing PCSCHEMATIC Automation
Launching PCSCHEMATIC Automation and exploring the screen elements
Creating and saving a project in PCSCHEMATIC Automation
Using the symbol, line, text, arcs/circles, and area tools
Drawing a power and control schematic of a DOL starter using PCSCHEMATIC Automation
Summary
Questions
8
Part 2: Understanding PLC, HMI, and SCADA
Part 2: Understanding PLC, HMI, and SCADA
9
Chapter 7: Understanding PLC Hardware and Wiring
Chapter 7: Understanding PLC Hardware and Wiring
Technical requirements
Introducing a PLC
Exploring PLC types
Understanding the PLC scan cycle
PLC wiring (1) – Wiring of switches, lights, and actuators to a PLC
PLC wiring (3) – Wiring of photoelectric sensors (retro-reflective)
Wiring of the Siemens S7-1200 PLC (CPU 1211C AC/DC/Relay)
Questions
10
Chapter 8: Understanding PLC Software and Programming with TIA Portal
Chapter 8: Understanding PLC Software and Programming with TIA Portal
Technical requirements
Understanding software/program in PLCs
Introducing PLC programming languages
Introducing PLC programming devices
Understanding the basics of LD
Downloading and installing TIA Portal V13 Professional and PLCSIM
Creating a project and writing a program with Siemens programming software (TIA Portal)
Summary
Questions
11
Chapter 9: Deep Dive into PLC Programming with TIA Portal
Chapter 9: Deep Dive into PLC Programming with TIA Portal
Technical requirements
Opening a saved program
Simulating programs with Siemens TIA Portal using PLCSIM
Latching and unlatching in PLC programming
Using an output address as an input in a program
Using the SET and RESET instructions
Using the timer instruction
Using the counter instruction
Using the move instruction
Using the compare instructions
Level control using PLC
Automated filling, capping, and wrapping system using PLC
Summary
Questions
12
Chapter 10: Understanding Human Machine Interfaces (HMIs)
Chapter 10: Understanding Human Machine Interfaces (HMIs)
Technical requirements
Introducing HMIs
Exploring the applications of HMIs
Understanding HMI programming and development
Understanding HMI programming software
Exploring HMI manufacturers and their programming software
Interfacing PLCs and HMIs
Downloading programs to PLCs and HMIs
Summary
Questions
13
Chapter 11: Exploring Supervisory Control And Data Acquisition (SCADA)
Chapter 11: Exploring Supervisory Control And Data Acquisition (SCADA)
Introducing SCADA
Understanding the functions of SCADA
Exploring the applications of SCADA
Overviewing the SCADA hardware
SCADA software
Downloading and installing mySCADA software
Interfacing SCADA with an S7-1200 PLC using mySCADA software
Summary
Questions
14
Part 3: Process Control, Industrial Network, and Smart Factory
Part 3: Process Control, Industrial Network, and Smart Factory
15
Chapter 12: Process Control – Essentials
Chapter 12: Process Control – Essentials
Introducing process control
Exploring process control terms
ISA symbology
Temperature measurement and transmitters
Pressure measurement and transmitters
Level measurement and transmitters
Flow measurement and transmitters
Understanding the process control loop
A practical example of single-loop process control
Wiring and programming the analog input of a PLC (Siemens S7 1200) for process control (hands-on)
Summary
Questions
16
Chapter 13: Industrial Network and Communication Protocols Fundamentals
Chapter 13: Industrial Network and Communication Protocols Fundamentals
Understanding industrial networks
Understanding network topology
Network media – wired and wireless (Bluetooth, Wi-Fi, and cellular communication – 1G, 2G, 3G, 4G, and 5G)
Network connectors and other network components
Understanding network protocols
Common industrial network protocol – Foundation Fieldbus
Common industrial network protocol – PROFIBUS
Common industrial network protocol – Modbus
Common industrial network protocol – HART
Common industrial network protocol – PROFINET
Summary
Questions
17
Chapter 14: Exploring Smart Factory (Industry 4.0) with 5G
Chapter 14: Exploring Smart Factory (Industry 4.0) with 5G
Understanding Industry 4.0
Exploring the key technologies in Industry 4.0
The benefits of Industry 4.0
Basic steps for building a smart factory
The benefits of a 5G-enabled smart factory
Connecting your PLC or machine data to the cloud
Summary
Questions
18
Assessments
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Chapter 8
Chapter 9
Chapter 10
Chapter 11
Chapter 12
Chapter 13
Chapter 14
19
Index
Index
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To get the most out of this book

This book is written to accommodate beginners or those who are new to the field of industrial automation, just as the book title Industrial Automation from Scratch implies. However, it will be advantageous for readers to have basic electrical knowledge and computer skills to be able to follow simple steps on a computer with the Windows operating system. Also, the book requires you to have a personal computer, which can either be a desktop or a laptop with the Windows operating system installed.

The following hardware is required to get your hands dirty with some of the practical exercises but is not a must:

  • SIMATIC S7-1200 PLC (CPU 1211C AC/DC/RELAY)
  • SIMATIC HMI (KTP 400)
  • Power supply unit (220V AC - 24V DC)
  • RTD temperature transmitter for Pt100
  • RTD temperature sensor (Pt100)
  • 500 Ohm resistor
  • Heater
  • Circuit breaker
  • Ethernet cable to connect between the PLC or HMI and PC
  • Normally open (NO) and normally closed (NC) push buttons (two or more each)
  • Pilot lamps, contactors, wires, and so on

Simulation is available to enable you to get a feel of the hands-on practical exercises even if the above-stated devices and materials are not available. The software required for practicing and also for simulation can be downloaded for free (trial version) or purchase the full version with no restrictions from the manufacturer.. Links to download the trial version of the software are provided in the chapters.

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