Industrial Automation from Scratch: A hands-on guide to using sensors, actuators, PLCs, HMIs, and SCADA to automate industrial processes

Cover
Title Page
Copyrights and Credits
Contributors
Table of Contents
Preface
Part 1: Learning the Concepts and Skills Required to Get Started
Chapter 1: Introduction to Industrial Automation
	Introducing industrial automation
	Exploring the types of industrial automation
		Fixed automation system
		Programmable automation system
		Flexible automation system
		Integrated automation system
	Understanding the levels of industrial automation
		Field level
		Control level
		Supervisory and production level
	Discovering the advantages and disadvantages of industrial automation
		Advantages of industrial automation
		Disadvantages of industrial automation
	Summary
	Questions
Chapter 2: Switches and Sensors – Working Principles, Applications, and Wiring
	Introducing switches and sensors
	Describing manually operated switches
		Push button
		Rocker switch
		Toggle switch
		Slide switch
		Selector switch
		Knife switch
	Describing mechanically operated switches
		Limit switches
		Level switch
		SPDT float switch
		Pressure switch
		Temperature switch
	Understanding proximity sensors (capacitive, inductive, and photoelectric)
		Inductive proximity sensor
		Capacitive proximity sensor
		Photoelectric
	Summary
	Questions
Chapter 3: Actuators and Their Applications in Industrial Automation
	Introducing actuators
	Learning about electric actuators
		Direct current motors
		Alternating current motors
		Stepper motor
		Servo motor
		Electro-mechanical relay
	Exploring pneumatic actuators
		Pneumatic linear actuator
		Pneumatic rotary actuator
	Getting to know about hydraulic actuators
	Summary
	Questions
Chapter 4: Overview of AC and DC Motors
	Understanding AC motors
		Synchronous AC motors
		Asynchronous AC motors (induction motors)
	Understanding DC motors
		Brushed DC motors
		Brushless DC motors
	Understanding stepper motors and servo motors
		Unipolar stepper motors
		Bipolar stepper motors
		Driving a stepper motor
		Servo motors
	Summary
	Questions
Chapter 5: Introduction to Variable Frequency Drive (VFD)
	An overview of a VFD
		Understanding how a VFD works
		Advantages of a VFD
		Disadvantages of a VFD
		Selecting 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
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
		Installing PCSCHEMATIC Automation
	Launching PCSCHEMATIC Automation and exploring the screen elements
		Launching the application
		Exploring the screen elements
	Creating and saving a project in PCSCHEMATIC Automation
		Saving a project
	Using the symbol, line, text, arcs/circles, and area tools
		Using symbols
		Using lines
		Using texts
		Using arcs/circles
		Using area
	Drawing a power and control schematic of a DOL starter using PCSCHEMATIC Automation
	Summary
	Questions
Part 2: Understanding PLC, HMI, and SCADA
Chapter 7: Understanding PLC Hardware and Wiring
	Technical requirements
	Introducing a PLC
		The power supply
		The CPU module
		The input module
		The output module
		Other PLC modules
	Exploring PLC types
		Compact PLC
	Understanding the PLC scan cycle
	PLC wiring (1) – Wiring of switches, lights, and actuators to a PLC
		PNP sensor
		NPN sensor
	PLC wiring (3) – Wiring of photoelectric sensors (retro-reflective)
	Wiring of the Siemens S7-1200 PLC (CPU 1211C AC/DC/Relay)
		Operation of the wiring
	Questions
Chapter 8: Understanding PLC Software and Programming with TIA Portal
	Technical requirements
	Understanding software/program in PLCs
	Introducing PLC programming languages
		Ladder Diagram (LD)
		Function Block Diagram (FBD)
		Instruction List (IL)
		Structured Text (ST)
		Sequential Function Chart (SFC)
	Introducing PLC programming devices
		Looking at the different PLC programming software
	Understanding the basics of LD
		Exploring the elements of LD (ladder logic) program
		Rules for LD programming
	Downloading and installing TIA Portal V13 Professional and PLCSIM
		Downloading TIA Portal V13 and PLCSIM
		Installing TIA Portal V13
		Installing PLCSIM
	Creating a project and writing a program with Siemens programming software (TIA Portal)
		NO contact
		NC contact
		Coil/assignment
		Empty box
		Open branch
		Close branch
	Summary
	Questions
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
		A latch and unlatch program using normally open push buttons for both starting and stopping
		A latch and unlatch program using a normally open push button for starting and a normally closed push button for stopping
	Using an output address as an input in a program
	Using the SET and RESET instructions
	Using the timer instruction
	Using the counter instruction
		Count up (CTU)
		Count down (CTD)
	Using the move instruction
	Using the compare instructions
	Level control using PLC
	Automated filling, capping, and wrapping system using PLC
	Summary
	Questions
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
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
		Downloading mySCADA
		Installing mySCADA software (myDESIGNER and myPRO)
	Interfacing SCADA with an S7-1200 PLC using mySCADA software
	Summary
	Questions
Part 3: Process Control, Industrial Network, and Smart Factory
Chapter 12: Process Control – Essentials
	Introducing process control
		Types of process control systems
	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)
		Understanding analog signals
		Reading analog values
		Normalization and scaling
		Analog input signal processing (a practical demonstration)
	Summary
	Questions
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
		Wired network protocols
		Wireless network protocols
	Common industrial network protocol – Foundation Fieldbus
	Common industrial network protocol – PROFIBUS
	Common industrial network protocol – Modbus
		Modbus Remote Terminal Unit (RTU)
		Modbus Transmission Control Protocol/Internet Protocol (TCP/IP)
	Common industrial network protocol – HART
	Common industrial network protocol – PROFINET
	Summary
	Questions
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
Assessments
Index
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