Tuesday 20 December 2016

Simulation Softwares and their Application Areas

All fresh engineers and those are still pursuing his engineering degree in Electrical and electronics engineering should focus on the following skills to be employable in this demanding, challenging corporate world:

They are Communication Skills, Soft Skills, and Technical Skills. In this blog, I like to stress upon the technical skills which can be further classified to (i) Fundamental Knowledge (ii) Practical Knowledge or Hands-on Knowledge (iii) Engineering Software Skills

An electrical and electronics engineer can’t skip the following list of softwares.

· MATLAB with Simulink:

· Labview: It is particularly useful in simulation and testing the control and processing part of a system.

· Pspice: is a circuit simulation application

· ETAP: Popular design software used across the industry for power system application

· Orcad: software for electronic circuit design and pcb design

· Auto CAD: Popular Software for Design and used by Electrical, Mechanical and Civil engineering applications

· Programming: C++, Python etc At least one programming language is necessary for any engineer. Soft computing are the domains where these basic programming skills can be utilized. 
 
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Friday 16 December 2016

Programmable logic controller PLC and its functioning

PLC History

PLC (Programmable logic controller) came into existence in late 60s. PLC was designed because use of PLC was eliminating higher cost involved in replacing relay based control systems. Changes in Industrial automation Control system are dependent on production requirements. When there are frequent changes in production requirements, it is a costly affair. Relays being mechanical devices have a limited lifespan. Relay based control involves many relays into operation, troubleshooting becomes quite difficult when so many relays are involved.

What is a PLC (programmable logic controller)?

A PLC is an microprocessor based electronic industrial computer which is used various machines and process control systems. It reads various conditions of input devices such as limit switches, push buttons, proximity / photoelectric sensors, float switches, pressure switches, implements the logic written in the software and updates the final control elements; relays, contactors, pilot lights, motor starters, actuators, solenoids, drives etc. which are called output devices.

Why use a PLC?

PLC is a system that is used for automation of various processes across industries. Why automation of a manufacturing unit is necessary? Industrial Automation helps process and manufacturing industry to:
have control of their manufacturing plant
Achieve consistent manufacturing
Achieve higher quality
Safety of personnel and equipments in hazardous environments
Enhance productivity level
Lower wastage of raw material, and lower time in rework
Industrial automation offers multiple product variety with ease.
Easy migration from one product to the other
Efficient inventory Control

HOW PLCS KNOW the task assigned to them?

PLC System follows the instructions stored in its memory for future use and reference. Each instruction entered is placed in PLC memory with the help of a computer and software. These set of instructions are written in certain order/guidelines called PLC Programming languages; FBD, Ladder language, SFC, IL etc. This is the language PLC Processor is made to understand. We at Sofcon India Pvt Ltd have various PLC SCADA training, PLC training, DCS Training courses. Ladder programs are developed using PLC software package with the help of a PC. The basic difference between a PC and a PLC System is PC is manufactured for office use whereas a PLC system is manufactured to be installed into industries. They can withstand harsh industrial environment; high temperature, dust, humidity. Ladder Logic program is developed by PLC Programmer, this program is them downloaded into processor’s memory. PLC Training helps in understanding how PLC programming software is to be developed in order to achieve desired process control. 
 
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Friday 9 December 2016

Comparative Analysis between Industrial Automation and Building Automation

Lets have a quick comparison of some of the important attributes concerning industrial and building automation:

Feature
Building Automation
Industrial Automation
Products/System Cost
Very price sensitive
Expensive, More difficult, more demanding in terms of speed and accuracy
Product Fault-Immunity
Not much built-in beyond retention of controller memory
Lots of built-in features to deal with power and other controller/
system failures
Design & Installation Approach
Typically a lower priority issue in comparison to many other design/construction disciplines
Typically a top priority given that it is the “heart” of the plant
Ease of Programming and Operator Interface
Designed for ease of use vs. ultimate flexibility
Designed for flexibility over ease of use
Communication Protocol
BACNET etc
EtherNet/IP, Modbus/Profibus are generally the communication protocol
Information of performance data
Integration is a must
Not so required everytime

It is not wise to go with industrial automation approach in complex building projects. It usually leads to problems which are generally due to technical and business practical gaps and this makes this approach not-feasible.
In Industrial Automation, there is a study of PLC-SCADA, HMI, Motors and Drives, Industrial Networking, Wireless Networks, DCS, Panel Design, AutoCAD and Process Instrumentation.
In Building Automation, there is a study of HVAC Control, Fire Detection and Alarm System, Access Control System and CCTV Surveillance System, Public Address System, Gas Suppression System.


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Thursday 8 December 2016

Expecting one-year ROI on industrial automation systems is short sighted

Majority of industrial Automation systems users, integrators, and manufacturers expect very early Return on Investment (ROI) when replacing or adding new industrial automation systems. This is very short term view. ROI is basically payback time based on how long it will take to earn back the cost of an investment from the savings it generates. This has been an issue for years - industrial automation controls and systems have not been treated like other production assets. The majority of industrial automation systems in plants are 20 years old or more. The typical reasons companies upgrade or replace industrial automation systems include lack of support, high repair parts cost, and obsolescence. When companies keep existing industrial automation systems for too long, they ignore the importance of industrial automation as a strategic business investment. On the other hand, short term ROI justification requirements almost guarantee mediocre results rather than striving for excellence.

Industrial Automation is now fundamental for manufacturers to improve productivity and efficiency. To remain competitive, manufacturers need to change their thought process. Automation professionals should educate management about the value of industrial automation investments. The knowledge will assist them in budget planning and also elevate the understanding of automation’s value contribution.

Business Lifecycle Process

A decision to invest in new industrial automation components or systems should be based on fact and provide answer to savings in production cost, production volume increase, less machine downtime & savings in maintenance cost. These improvements all equate to more profits. In many cases new technology investments simplify operations, application configuration, and programming changes.

Because industrial automation systems must run in difficult environments they can have a long lifespan. Technology is advancing very fast, even though industrial automation systems may not have reached near to its lifespan end, sometimes it may be beneficial to upgrade. New technology can improve productivity and quality while reducing operations and maintenance costs.

Suggestions to industrial Automation Professionals It is important to focus on business and operating value or the financial decision makers will view you as those technology people that just want to play with new toys. Update your plan every year and you will create awareness of industrial automation system issues. As a result, automation investments can be included in the budgeting process. The capital budgeting process enables managing staff to keep some money separately for large investments so that old & inefficient systems are replaced with new industrial automation systems based on business strategy. Industrial Automation needs to be a core part of the business and it is up to industrial automation professionals to make it happen.


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or

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