Automated Control System

Automated Control Systems:

Automated Control systems are used to control small and large Machines, electricity connections, complex industrial processes, etc. Control systems range from a remote that controls an AC in Home to a panel that controls the nuclear process in a nuclear plant. These are also used in the steering and stabilization of marine ships and Aircraft. All these applications of the automated control system save a lot of manpower. Different types of control systems are used in different industries.

Types of Industrial Control Systems:

The following are the types of control systems commonly used in industries:

1. Programmable Automation Controllers (PAC)

2. Supervisory Control and Data Acquisition (SCADA)

3. Programmable Logic Controllers (PLC)

4. Distributed Control Systems

5. Human Machine Interface (HMI)

SCADA and Plc’s are the most widely used industrial control systems.

1. Supervisory Control and Data Acquisition (SCADA) :

SCADA is used to analyze the real-time data of an ongoing industrial process. These systems are commonly used in manufacturing processes, industrial processes, energy plants, Satellites, Power transmission, and distribution, etc.

The core functions of SCADA systems :

1. Data Acquisition

2. Data Communication and Data Presentation

3. Controls

Main Components of SCADA :

1. Inputs

2. Remote Telemetry Units

3. Human Machine Interface (HMI)

4. Communications Network

How SCADA Works?

SCADA systems are used to detect problems in an ongoing process. For Example, if there is a hole present in a pipe through which a gas is leaking, SCADA will detect the error and tell this to the central site. It will also determine if the error is critical or not, and based on that it will take some necessary actions and analysis. If SCADA is unable to solve an issue then it can help workers by telling them the exact point or location where the error occurs.

2. Programmable Logical Controller (PLC) :

PlC’s are the control systems that are used to control the machinery by constantly monitoring input and output devices attached to the Automated control system. A PLC contains a CPU and embedded programs. Programs written inside a Plc system is installed from computers. “Ladder logic” and “C” programming language is the most commonly used programming languages when writing a PLC program. One feature of PLC systems is that they can work in different temperature ranges, vibrations, electrical noises, etc.

Working of a PLC :

1. Firstly, PLC analyzes the status from all the input devices (switches, Photoelectric sensors, Proximity sensors, sensing devices, Vaccum switches, etc.) connected to it.

2. Based on the analysis, it runs the pre-installed logical programs in it.

3. After running programs, it will take actions on output devices such as energize or de-energize them. For example, open the valve, turn on the alarm system, etc. Motor starters, Valves, Pumps, Printers, Stack lights, Alarms, Fans are the most common output devices controlled by PLCs.

Advantages of Automated Control Systems

1. It reduces labor costs and expenses, as machines are controlled automatically.

2. It increases the Consistency of output.

3. With the help of automated control systems, we can easily perform the tasks which include high physical and monotonous work.

4. Tasks that need a high degree of accuracy can easily be done by Automation systems.

5. With These, We can perform tasks that are beyond human capabilities. (such as to lift heavy equipment).

6. These systems replace humans in tasks performed in a dangerous environment such as near fire, volcanoes, underwater tasks, near electricity, tasks in nuclear plants, etc.

Disadvantages of Automated Control Systems

1. It increases employment as machines are replacing humans.

2. Automation systems are expensive.

3. Unpredictable Development Costs.

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