Mouser Reference Guide Industrial Automation

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Reference Guide Industrial Automation

Industrial automation is the control of machinery and processes used in various industries by autonomous
systems through the use of technologies like robotics and computer software. Automation adds control loops to
machine operation. These can be open control loops that allow for human input or closed loops which are fully
automated. Industrial control systems (ICS) allow for monitoring and control locally and remotely.

Evolution of Automation
The simplest type of an automatic A relay logic circuit is an electrical With computer hardware
control loop. A controller compares network consisting of lines. The becoming affordable,
a measured value of a process with a output is controlled by a combination digital logic started to
desired set value and processes the of input or output conditions, such replace electro-magnetical
resulting error signal to change some as input switches and control relays. relays, culminating in the
input to the process, in such a way The conditions that represent the development of programmable
that the process stays at its set point inputs are connected in series, logic controllers (PLCs). PLCs
despite disturbances. parallel, or series-parallel to obtain are essentially ruggedized
the logic required to drive the output. industrial computers.

Modern Automation Structure PLCs vary in complexity

Microcontroller: Essentially, a PLC is an MCU with some


special features, e.g. fieldbus communication.

SBC: Single-board computers using semi-customized


or fully proprietary hardware for very demanding
control applications. Soft PLCs can interface with
industrial I/O hardware while executing programs
within commercial operating systems.

PLR: Programmable Logic Relays have 8 to 12 discrete


inputs, 4 to 8 discrete outputs, and up to 2 analog
inputs. Many include a tiny LC screen for viewing
simplified ladder logic.

Supervisor Level: The supervisor level usually consists


of an Industrial PC, which is usually available as a desktop
PC or a Panel PC or a Rack-mounted PC. Communication
usually runs over some form of Ethernet.
Generally, a PLC consists of;

• A CPU which interprets inputs, executes the control program stored in memory and
Control Level: All the automation related programs are sends output signals,
executed. For this purpose, PLCs are used, providing real- • A power supply unit which converts AC voltage to DC,
time computing capability. PLCs are usually implemented • A memory unit storing data from inputs and program to be executed by the processor,
using 16-bit or 32-bit microcontrollers and run on a • An I/O interface, where the controller receives and sends data from/to external
proprietary operating system to meet the real-time devices,
requirements. PLCs are also capable of being interfaced • A communications interface to receive and transmit data on communication networks
with several I/O devices and can communicate through from/to remote PLCs.
various communication protocols like CAN.
PLCs require programming device which is used to
develop and later download the created program into
the memory of the controller.
Field Level: The terminal equipment like Sensors and
Actuators are categorized into Field Level in the hierarchy.
They can be programmed in a variety of ways,
The sensors like temperature, optical, pressure etc. and
from the relay-derived ladder logic to programming
actuators like motors, valves, switches etc. are interfaced
languages such as specially adapted dialects of
to a PLC through a field bus and the communication
between a Field Level device and its corresponding PLC is BASIC and C, adhering to IEC 61131-3.
usually based on a point-to-point connection. Both wired
and wireless networks are used for communication.

Industrial Automation Reference Guide

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