Application of PLC SCADA in industries

Application of PLCs in process and manufacturing industries

PLC SCADA systems are used for automating process and manufacturing /assembly lines. Process means step-by-step procedure sequence, whereby a particular product is manufactured and assembled. Product engineering department is responsible for manufacturing plan of new or modified products. Some other PLC SCADA systems may be controlling sequences/ processes, which might involve filling/ capping/labeling/packaging of bottles, the printing of newspapers, or the automobile assembly lines etc. In many such manufacturing situations, PLC SCADA play very important role in carrying out the process.

Advantages of PLC systems

• PLC systems have highest Reliability in operation
• Control systems have flexibility in modifying PLC logics
• Flexibility in PLC programming and reprogramming
• large contacts in small package
• PLC systems are very cost effective for complex control systems
• Small size but speedy operation
• PLC systems can communicate with other control systems & computer systems in the plant.
• PLC controlled systems have ease of maintenance troubleshooting
• Proper documentation & high level of Security

The PLC system is so designed that it can operate in the industrial environment having robust ambient temperature, vibration, and humidity. PLC systems are immune to electrical noise. PLC systems have fault indicators, fuse status indicators, input/output status lights, and written fault information displayed on the programmer. Therefore PLC systems are easy control systems for troubleshooting. Personal computers/Laptops are used for programming/monitoring PLC systems.

Number System in PLC

PLC is just like a computer, it therefore stores information in the form of On or Off conditions referred to as binary digits (bits).

Difference between PLC systems and PCs

PCs are generally data processing computers. Such computer systems process and analyze a large data, store this database, generate report and display the data/information to operators.

PLC system is generally a process control computer; small, manufactured to work in harsh environment and it is also easy to program, maintain and repair. PLC System can handle real time data and input output tasks whereas computers can handle non-real time tasks. PLC systems are generally installed near to the machine or process they control, and are generally considered as an extension part of a industrial equipment.

PLC Architecture

PLC system consists of various sections, each designed for certain functions: like CPU, Input module, output module, communication bus, memory, power supply.

CPU
There are two types of PLC systems used in industry: fixed and modular. CPU unit of PLC system is built into a single-piece unit in fixed PLC. While in modular PLC’s, the CPU is a plug-in module. CPU functions same as brain functions in human body. CPU has a microprocessor integrated chip which is placed on a PCB with associated interface chips.

Microprocessor which is the brain of a PLC system supervises all functions in a PLC System. CPU reads position/ information of input devices and stores this information in the memory for later use. Then it executes the user program and then updates the output devices / field hardware devices.

PLC Memory System
This is as storage for the user program. The input status file consists of memory location and stores the status of each field input device. The output status file consists of memory locations and stores the status of field hardware devices after the user program is executed. The output module is a kind of switching device for each output point. The data storage area of memory is used to store numerical/math calculation related data.

PLC I/O Module
There are two types of real world input and output devices: Discrete and analog. Discrete devices are either ON or OFF type. Limit switches, push button, pilot lamps, solenoids etc. are the examples of discrete input devices. Analog devices cater to a continuously varying quantity between minimum to maximum such as temperature, Pressure, level, flow etc.

PLC INPUT MODULES
Input modules in a PLC system serve as the link between field devices and the PLC CPU. Input modules have a terminal blocks for attaching input wiring from each individual field input device. The function of an input module is to read input signals, convert it to a signal level CPU can understand and send the signal, back to the CPU. Each input terminal on each input module has one memory location in the input status file. Which stores the binary equivalent of the ON or OFF status either 0 or 1.

PLC OUTPUT MODULES
Output Modules in PLC system serve as the link between the PLC¢s microprocessor and field devices. PLC output module has a terminals for attaching output devices. Generally output modules have 8, 16, 32, 64 output terminals.

Remote PLC I/O Racks
Generally PLC input and output modules are installed closer to the actual operating equipment. Which saves lot of cable and other associated wiring/ labor cost. PLC output modules have status lights which shortens troubleshooting time and increases production, eases maintenance and efficiency of the system.

PLC Training, PLC SCADA Training courses by Sofcon India Pvt Ltd greatly help budding engineers understand practical application of automation system.

FIXED AND MODULAR PLC HARDWARE

PLC hardware falls into two physical configurations

Fixed PLC: A fixed PLC system has all of its components positioned in single unit.. This style of PLC system is also called a packaged controller.

Modular PLC:-The modular PLC system comes as modular pieces. 

For more inquiries, Kindly contact:
For More, visit at http://www.sofcontraining.com

or

Call Now Our TOLL FREE No. 1800 - 200 – 4051
Noida +91-9873630785
Delhi +91-9711861537
Gurgaon +91-9873588305
Lucknow +91-9838834288
Allahabad +91-7704003025
Jaipur +91-8058033551
Mohali +91-9873349806
Bhopal +91-9755559168
Vadodara +91-9898666980
Ahmedabad +91-9227185900
Pune +91-7387700416

Skill India: Myriads of Job Opportunity

B.Tech fresher’s who passed out their engineering in Electrical & Electronics, Electronics and Communication, Instrumentation and Control, Mechanical & Automation Engineering should convert this golden opportunity to make their career in the core field of Industrial Automation, Building Automation, Embedded System and VLSI, HVAC Control & HVAC Design and Draughting.

Migration of Non CS/IT students into IT or ITES field should be an alternative choice of the fresher because of his passion and love for computer science and IT and not because of unavailability of opportunities and lack of employment.

Sofcon Group is bridging the gap between academics and industry since 2006 and successfully placing the students since its inception. After the affiliation of Sofcon, with NSDC and other sector skill councils, our pledge to provide employment to the students irrespective of their academic, social or financial status has become strengthened.

Courses with 100% placement assurance for B.Tech EE/EC/EI are:

Industrial Automation: PLC/SCADA, Motion Control (Motors and Drives), Panel Designing, Auto CAD, Process Instrumentation, HMI, DCS, Industrial Network & Wireless Network.

Building Automation: HVAC Control, Fire Detection and Alarm System, Access Control System and CCTV Surveillance System, Public Address System, Gas Suppression System

CAD/CAM Courses: Auto CAD 2D, 3D, Catia, Solidwork

Industrial Mechanical Engineer: Hydraulic, Pneumatic, PLC, Hydraulic/Pneumatic Control with PLC, HVAC Design & Drafting, Auto CAD 2D 

 

Call Now Our TOLL FREE No. 1800 - 200 – 4051

Noida +91-9873630785
Delhi +91-9711861537
Gurgaon +91-9873588305
Lucknow +91-9838834288
Allahabad +91-7704003025
Jaipur +91-8058033551
Mohali +91-9873349806
Bhopal +91-9755559168
Vadodara +91-9898666980
Ahmedabad +91-9227185900
Pune +91-7387700416

Protecting Industrial automation control systems from Hacking

In the last few years activities of hackers have intensified, they have infiltrated information of credit cards, health care providers, retailers and other consumer industries. Cashless transactions/e-payments are basically for making the life easier, but hackers use the very technology in contrary. They gain access to our private information and financial accounts. As a result, innovative cyber security providers are constantly improving their defence technologies to keep up with the ever-changing threat.

Companies are also increasing their investments in Industrial automation control technologies in protecting vital information from the cyber threats. These systems control our power supply & distribution, water management, process & manufacturing plants, oil refineries, transportation etc. These systems have faced less of a threat simply because they were often isolated from business networks and utilized proprietary technologies. But today more and more companies are looking to gain the efficiency of remote access or utilize the Internet of Things (IoT) to improve performance. Furthermore, newer ICS Industrial automation control systems are employing open standard communication protocols. As a result, these systems have become major targets for cyber attacks.

Industrial automation control system (ICS) cyber security: The purpose of this paper is to present a cyber security framework. Readers of this document should be familiar with general ICS Industrial automation control systems components and design, cyber security concepts and communication protocols. Critical infrastructure providers are under attack, with 36% of firms experiencing at least one operational disruption in the past two years. The cyber threat to the world’s critical infrastructure is real.

First, the potential impact of cyber infiltration is serious and damaging issue and hackers know this. Cyber attack can cause significant economic harm, but can also threaten health, safety and lives.

Third: Sixty-eight percent industries claimed that they faced several cyber security breaches. 35% said cyber security incidents led to a disruption of operations. DCS is a control system that is developed to replace PID controllers and are used primarily to control production systems whereas PLC systems are generally used to control specific applications and/or standalone equipment and can be used in both SCADA and DCS systems. Leading companies such as McAfee, HP, Tripwire, Symantec and IBM, as well as thousands of start-ups are investing billions in R&D to stop the next innovative hacker. 

 

Call Now Our TOLL FREE No. 1800 - 200 – 4051

Noida +91-9873630785
Delhi +91-9711861537
Gurgaon +91-9873588305
Lucknow +91-9838834288
Allahabad +91-7704003025
Jaipur +91-8058033551
Mohali +91-9873349806
Bhopal +91-9755559168
Vadodara +91-9898666980
Ahmedabad +91-9227185900
Pune +91-7387700416

Correlation between ISO 50001 and Building Automation System

Building Automation is an integrated technology whose main purpose is not only to improve the building/ facility energy efficiency but also to ensure the safety and security of the occupants of the building and integration of electrical and mechanical devices/systems present in the building.
 

On the other hand, ISO 50001:2011 specifies requirements for establishing, implementing, maintaining and improving an Energy Management System.

Integrated Building Automation System encompasses HVAC Control, Fire Detection and Alarm System, Access Control System and CCTV Surveillance System, Public Address System, Gas Suppression System. All these technologies and the related products results in higher energy efficiency, lower operating and maintenance costs, better indoor air quality, greater occupant comfort, safety, security and productivity.

Heating, Ventilation and Air Conditioning System needs to be designed first with the help of HVAC Design and Drafting Engineer when it is commissioned in to the system then it needs to be controlled. Several Automation companies working in this HVAC Control domain has developed dedicated hardware and software like Beckhoff Automation, Siemens, Johnson control, Honeywell etc.

Fire Detection and Alarm System, Access Control System and CCTV Surveillance System, Public Address System, Gas Suppression System are parts of Building Automation Training to address safety and security concerns of the occupants of the building.

Both BAS and ISO 50001 lead to energy saving, lower operating and maintenance costs but still they should be considered separately because of the following reasons:

1.     BAS are not designed for metering and monitoring in mind and are not capable of storing large amounts of real time and historic data

 2.     There are always chances of data loss in using BAS for energy management
Building management system also deals with energy demand system.

For More, visit at www.sofcontraining.com/builiding-management.htm

or

Call Now Our TOLL FREE No. 1800 - 200 – 4051

Noida +91-9873630785
Delhi +91-9711861537
Gurgaon +91-9873588305
Lucknow +91-9838834288
Allahabad +91-7704003025
Jaipur +91-8058033551
Mohali +91-9873349806
Bhopal +91-9755559168
Vadodara +91-9898666980
Ahmedabad +91-9227185900
Pune +91-7387700416

AVR Microcontroller (MCU) based programmable object counter

Object counters are used for applications like counting the number of visitors at super markets and other public places, the number of objects passing through a particular area or into a tray or container in manufacturing industries, the number of tablets filled in a bottle or a wrapper in the pharmaceutical industry and counting and limiting the number of people entering elevators or halls, among others.

The project presented here demonstrates the working on an object counter suitable for industrial applications for counting up to 9999 objects. It is an AVR Microcontroller (MCU) based counter. 

In manufacturing industries, before the final product is ready, the product passes through a number of different stages of manufacturing process. Normally the operator enters the number of objects to be counted from the monitoring console, followed by pressing start. The products moving on a conveyor belt are counted by programmable counter. The conveyor belt automatically stops when the number of counts entered by the operator is reached. 

Main features of this are simple user interface using only 4 pushbuttons, an LCD display for UI, LEDs for simple visual indications, a buzzer for audio indication, user selectable counting up or counting down options.

ATmega16 AVR Microcontroller (MCU) is the heart of the programmable object counter. A voltage regulator is used to provide 5v regulated voltage to drive circuit including MCU and LDC Display. 

Software program

Circuit operation is done using software program loaded in to the internal memory of AVR microcontroller. The program implements all required functionalities including handling user inputs through pushbuttons, displaying messages on the LCD, switching on the switching off the load connected through relay and visual/audio indications. Program is written in C language, AVR Studio software tool is used to compile the program.

For More, visit at www.sofcontraining.com

or

Call Now Our TOLL FREE No. 1800 - 200 – 4051
Noida +91-9873630785
Delhi +91-9711861537
Gurgaon +91-9873588305
Lucknow +91-9838834288
Allahabad +91-7704003025
Jaipur +91-8058033551
Mohali +91-9873349806
Bhopal +91-9755559168
Vadodara +91-9898666980
Ahmedabad +91-9227185900
Pune +91-7387700416

Vocational training by Sofcon

Current era is of knowledge economy. Talents and skills of employees form the most critical competitive advantage for any company. 15 million job seekers enter into job market each year. On the other side companies do not get sufficiently skilled manpower. Hiring, training the right talent and retaining them with the company is huge cost. So its not possible for every employers to skill & build their talent continuously. 

Now the question arises how would the companies get trained skilled manpower for their jobs?  The answer is skill training providers.

We at Sofcon India Pvt LTD has aligned our training programs on Industrial automation, PLC SCADA, Embedded systems AVR Microcontrollers HVAC control, HVAC Design and drafting, VLSI, Building automation, Electronics surveillance, Hydraulics & Pneumatics trainings with industry requirements. Our training programs are also aligned with QPNOS (Qualification pack National occupation standards). QPNOS are set of standards set by NSDC for variety of job roles for different industries.

Where there is high attrition rate, employers are unwilling to pay for training for the candidates. Although they are willing to re-train and pay for already trained candidates. Now it becomes necessary for fresher entering into job-market to acquire the necessary skills mandatory for entry into a job role.
Engineers trained on PLC SCADA systems are given practical experience on hardware & software design. They know about different types of sensors and final control elements. These engineers are suitable for project engineer, design engineer & commissioning engineers job. A week time on job is enough for them to do justice to their assigned job role. Consumption of electronics tabs, mobile, pcs have increased many-fold which has pushed  promising technology job opportunities for embedded system engineers, AVR/ARM Microcontroller training, VLSI, System verilog, VHDL trained engineers.

Industry is showing signs of recovery. India is going to be world leader in automotives. Hydraulics training, pneumatics training plays very important role in filling skill gaps of automotive and other industries. We are fastest developing country in the world. Our infrastructure sector is going to have huge growth potential. HVAC control & HVAC Design & drafting are key skills needed for mechanical engineers wanting to enter this segment.
Be it designing of air conditioning system, ducting, load calculation, HVAC control system, Building automation system. Learning of engineers undergone practical training is much faster and they can be assigned independent project design, project execution jobs.

For More, visit at www.sofcontraining.com

or

Call Now Our TOLL FREE No. 1800 - 200 – 4051
Noida +91-9873630785
Delhi +91-9711861537
Gurgaon +91-9873588305
Lucknow +91-9838834288
Allahabad +91-7704003025
Jaipur +91-8058033551
Mohali +91-9873349806
Bhopal +91-9755559168
Vadodara +91-9898666980
Ahmedabad +91-9227185900
Pune +91-7387700416