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M 1
INTRODUCTION
This chapter introduces the kinds of industrial processes that can be PLC controlled. SCADA is
such a process. Different types of control systems are used for complex processes. These
control systems may be PLCs, but other controllers include robots, data terminals, and
computers. For these controllers to work together, they must communicate. This chapter will
discuss the different kinds of industrial processes and the
means by which they communicate.

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INTRODUCTION
Common terms in control
Microprocessors:
Is a general purpose digital computer central processing unit (CPU). Although popularly
known as a “ computer on a chip,”. Note that it is no sense to be a completer digital computer.
the design contains : Arithmetic and logic Unit (ALU), a Program Counter (PC), a Stack
Pointer (SP), registers, clock timing circuit, interrupt circuits.
Microcontrollers:
Is a true computer on A chip. The design incorporates all of the features found in
microprocessor and added the other features needed to make a complete computer.
Added features: Read-Only-Program Memory (ROM), Random-Access data Memory (RAM),
memory decoders, input/output (I/O) devices, counters.

A programmable logic controller (PLC) :

is an industrial grade computer that is capable of being programmed to perform control
functions.
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INTRODUCTION
Types of Processes

Process control is the automated control of a process. Such systems typically deal with
analog signals from sensors. The ability of a PLC to perform math functions and utilize
analog signals makes it ideally suited for this type of control

1. A CONTINUOUS PROCESS

2. BATCH P ROCESSING

3. DISCRETE MANUFACTURING

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INTRODUCTION
1. A continuous process

A continuous process is one in which raw materials enter one end of the system and the
finished product comes out the other end of the system; the process itself runs continuously

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INTRODUCTION
2. Batch processing

In batch processing, there is no flow of product

material from one section of the process to another.

Instead, a set amount of each of the inputs to the

process is received in a batch, and then some

operation is performed on the batch to produce a

product
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INTRODUCTION
3. Discrete manufacturing

Discrete manufacturing is characterized

by individual or separate unit production.
With this manufacturing process, a series
of operations produces a useful output
product. Discrete manufacturing systems
typically deal with digital inputs to PLCs
that cause motors and robotic
devices to be activated

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INTRODUCTION
Types of Processes control: INDIVIDUAL CONTROL
Possible control configurations include individual, centralized, and distributed.

Individual control is used to control a

single machine. This type of control
does not normally require
communication with other controllers.

shows an individual control application for a cut to length operation

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INTRODUCTION
Types of Processes control : CENTRALIZED CONTROL

Centralized control is used when several machines or processes are controlled by one central
controller.

• All individual steps in the manufacturing

process are handled by a central control
system controller.
• No exchange of controller status or data is
sent to other controllers.
• If the main controller fails, the whole
process stops.
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INTRODUCTION
Types of Processes control : DISTRIBUTIVE CONTROL SYSTEM (DCS)
A distributive control system (DCS) is a network based system. Distributive control involves
two or more PLCs communicating with each other to accomplish the complete control task

• Distributive control permits the distribution of the processing tasks among several controllers.
• Each PLC controls its associated machine or process.
• High-speed communication among the computers is done through CAT-5 or CAT-6 twisted
pair wires, single coaxial cables, fiber optics, or the Ethernet

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INTRODUCTION
Types of Processes control

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INTRODUCTION
Structure of Control Systems

The major components of a process control system include the following:

1. Sensors

• Provide inputs from the process and from the external environment

• Convert physical information such as pressure, temperature, flow rate, and position into
electrical signals

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INTRODUCTION
Structure of Control Systems

2. Human Machine Interface (HMI)

Allows human inputs through various types of
programmed switches, controls, and keypads to set up
the starting conditions or alter the control of a process

3. Signal Conditioning
Involves converting input and output signals to a
usable form and may include amplification,
attenuation, filtering, scaling, A/D and D/A converters
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INTRODUCTION
Structure of Control Systems

4. Actuators
Convert system output electrical signals into physical action such as flow control valves,
pumps, positioning drives, variable speed drives, clutches, brakes, solenoids, stepping
motors, and power relays

5. Controller
• Makes the system’s decisions based on the input signals
• Generates output signals that operate actuators to carry out the decisions

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INTRODUCTION
Structure of Control Systems
6. Graphic HMI terminals offer electronic interfacing in a wide variety.

Operational Summary Manual Control Diagnostics Trend Values

Configuration/Setup Alarm Summary Event History

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INTRODUCTION
Types of control system: Open/ close loop Control Systems

The control system can be classified as open loop control system , closed loop control systems

Closed loop Open loop

Contain sensor Dose not Contain sensor

There is relation between input There is not relation between input

and output. and output.

More stable Less stable

More complex Less complex.

More performance Less performance.

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INTRODUCTION
Types of control system : fill box containers

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INTRODUCTION
Types of control systems: On/Off Control

With on/off controllers the final control element is either on or off. one for the occasion
when the value of the measured variable is above the set-point and the other for the occasion
when the value is below the set-point

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INTRODUCTION
Types of control systems: On/Off Control

• A deadband is usually established around the set-point. The deadband of the controller
is usually a selectable value that determines the error range above and below the set-
point that will not produce an output as long as the process variable is within the set
limits.

• The deadband eliminates any hunting by the control device around the set-point.

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INTRODUCTION
Types of control systems: PID Control

Proportional controllers are designed to eliminate the hunting or cycling associated with
on/off control. They allow the final control element to take intermediate positions between on
and off.

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INTRODUCTION
Types of control systems: PID Control

The integral action, sometimes termed reset action, responds to the size and time duration
of the error signal. An error signal exists when there is a difference between the process
variable and the set point, so the integral action will cause the output to change and
continue to change until the error no longer exists

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INTRODUCTION
Types of control systems: PID Control
The derivative action responds to the speed at which the error signal is changing that is, the
greater the error change, the greater the correcting output. The derivative action is measured
in terms of time.

Rate action (derivative control) acts on the error signal just like reset does, but rate action
is a function of the rate of change rather than the magnitude of error

Proportional plus integral (PI) control combines the characteristics of both types of control.

Proportional plus derivative (PD) control is used in process control systems with errors that
change very rapidly

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INTRODUCTION
Types of control systems: PID Control

PID control is a feedback control that

combines proportional, integral, and
derivative actions.

The proportional action provides smooth control without hunting.

The integral action automatically corrects offset.
The derivative action responds quickly to large external disturbances.
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INTRODUCTION
Types of control systems: another classification

Manual
• The operator estimates the tuning parameters required to give the desired controller response.
• The proportional, integral, and derivative terms must be adjusted, or tuned, individually to a
particular system using a trial-and-error method

Semiautomatic
• The controller takes care of calculating and setting PID parameters

Fully Automatic or Intelligent

• This method is also known in the industry as fuzzy logic control.
• The controller uses artificial intelligence to readjust PID tuning parameters continually
as necessary

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INTRODUCTION
Types of control systems: PID Control

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INTRODUCTION
Data Communications

the different ways that PLC microprocessor-

based systems talk to each other and to
other devices. The two general types of
communications links that can be
established between the PLC and other
devices are point-to-point links and network
links.

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INTRODUCTION
Data Communications

As control systems become more

complex, they require more
effective communications schemes
between the system components. A
local area network or LAN is a
system that interconnects data
communications components
within a limited geographical area,
typically no more
than one or two miles

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INTRODUCTION
Data Communications: Transmission media
Transmission media are the cable through which data and control signals flow on a network

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INTRODUCTION
Data Communications: Levels of network
There are three general levels of functionality of industrial networks.

Device Level: sensors, switches, drives, motors, and

valves.
Control Level: The control level involves the
network’s industrial controllers such as PLCs and
robot controllers.
Information Level: The information level is a plant
wide network typically composed of the company’s
business networks and computers
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INTRODUCTION
Data Communications: Networks’ topology

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INTRODUCTION
Data Communications: Networks’ topology

Translating from one network-access scheme to another

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Data Communications: peer-to-peer control network channels

A peer-to-peer network has a

distributive means of control, as
opposed to a master/slave network
in which one node controls all
communications originating from
other nodes

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INTRODUCTION
Data Communications: peer-to-peer control network channels

Serial Communication

Serial data communication is

implemented using standards such as
RS-232, RS-422, and RS-485. The RS
in the standard’s name means
recommended standard that specifies
the electrical, mechanical, and
functional characteristics for serial
communications
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INTRODUCTION
Data Communications: peer-to-peer control network channels

ControlNet

ControlNet is positioned one level above

DeviceNet. It uses the Common Industrial
Protocol (CIP) to combine the
functionality of an I/O network and a peer-
to-peer network providing high-speed
performance for both functions.

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INTRODUCTION
Data Communications: peer-to-peer control network channels

EtherNet/IP

EtherNet/IP (Ethernet Industrial

Protocol) is an open
communications protocol based
on the Common Industrial
Protocol (CIP) layer used in both
DeviceNet and ControlNet.

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INTRODUCTION
Data Communications communication protocols

Modbus

Modbus is a serial communication protocol

originally developed by Modicon for use with
its PLCs. Basically, it is a method used for
transmitting information over serial lines
between electronic devices.

Omron PLC with Modbus-RTU network communication capabilities.

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INTRODUCTION
Data Communications communication protocols

Fieldbus

Fieldbus is an open, serial, two-way communications system that interconnects measurement

and control equipment such as sensors, actuators, and controllers. At the base level in the
hierarchy of plant networks, it serves as a network for Field devices used in process control
applications.

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INTRODUCTION
Data Communications communication protocols

PROFIBUS-DP

PROFIBUS-DP (where DP stands for

Decentralized Periphery) is an open,
international fieldbus communication
standard that supports both analog and
discrete signals. It is functionally
comparable to DeviceNet. The physical
media are defined via the RS-485 or
fiber optic transmission technologies.

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INTRODUCTION
Supervisory Control and Data Acquisition (SCADA)
In some applications, in addition to its normal control
functions, the PLC is responsible for collecting data,
performing the necessary processing, and structuring
the data for generating reports. As an example, you
could have a PLC count parts and automatically send
the data to a spreadsheet on your desktop computer.

a supervisory computer allows data logging, data

display, trending, downloading of recipes, setting of
selected parameters, and availability of general
production data

a SCADA system usually refers to a system that

coordinates but does not control processes in real time.
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