General Overview of Wireless Based PLC and SCADA: Senthilkumar .M

General overview of wireless
based PLC and SCADA
Senthilkumar .M
Assistant Professor - ECE
University College of Engineering Dindigul
Anna University
Programmable logic controllers
 A PLC is a solid state / industrial computer that

performs discrete or sequential logic in a factory
environment.
 It was originally developed to replace mechanical
relays, timers, counters.
 A sequence of instructions is programmed by the user
to the PLC memory. Its purpose is to monitor crucial
process parameters and adjust process operations
accordingly.
Various brands of PLCs
 AllenBradley USA
 Siemens Germany
 Modicon France
 Mitshubishi Japan
 GE Fanuc USA
 Omron Japan
Programming languages of PLC
 Ladder Diagram (LD)
 Functional block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)
 Sequential Functional Chart (SFC)
Hardware overview
 MicroLogix 1000 is a packaged controller containing a
power supply, input circuits, output circuits, and a
processor.
Data Files in Micrologix 1000
Basic Components of a PLC System
 Network Interface
 Most PLCs have the ability to communicate with other
devices. The PLC will communicate to the other devices
through a network interface.
Network
PLC
interface
module
Network connecting other devices

Typical PLC Application
Solenoid 1 Solenoid 2
Motor
Ingredient A Ingredient B
Sensor 1
Sensor 2
Solenoid 3
Human machine
interface
Sample
Automation : Typical installation . . . .
SCADA Software
Communication Cable
Control Hardware
Control Panel
Field Cabling
Junction Box
Field Cabling
Sensors Placed in the field

SUPERVISORY CONTROL AND DATA
ACQUISITION(SCADA)
SCADA refers to a system that collects data from various

sensors at a factory, plant or in other remote locations and
then sends this data to a central computer which then
manages and controls the data
Typical SCADA
SUBSYSTEMS OF SCADA SYSTEM
 Human-Machine Interface is the apparatus which
presents process data to a human operator, and through
this, the human operator monitors and controls the
process.
 Remote Terminal Units connecting to sensors in the
process, converting sensor signals to digital data and
sending digital data to the supervisory system.
 Programmable Logic Controller used as field
devices because they are more economical, versatile,
flexible, and configurable than special-purpose RTUs.
 Communication infrastructure connecting the
supervisory system to the Remote Terminal Units
Configuration of SCADA Systems
Data Server Data Server PLC’s
Field Bus
PLC Communication
Programs Processor SCADA
•Analog-Input
•Value-AI-0
Mapping •Analog-Input
•Value-AI-1
•Analog-Output •Vacuum_VALUE
•Value-AO-0 •Pressure_VALUE
Field Bus
•Value-AO-1 •Analog-Output
•Valve_1_OUT
•Heater_1_OUT
SCADA
Data Server Alarm Generation
•Analog-Input (generic) Alarm scripts:
•Vacuum_VALUE
•Pressure_VALUE IF (Pressure_VALUE > Pressure_HIHI_ALARMVAL)
{Pressure_ALARM_HIHI=TRUE
•Analog-Output
Pressure_ALARM_STATE=CRITICAL
•Valve_1_OUT Pressure_ALARM_COLOR=RED }
•Heater_1_OUT IF (Pressure_VALUE < Pressure_LOLO_ALARMVAL)
{Pressure_ALARM_LOLO=TRUE
Pressure_ALARM_STATE=ATTETION
Pressure_ALARM_COLOR=BLUE }
Today’s control room
there is no more direct wiring to the plant. …

Example of generic control
Response time and hierarchical level
Planning ERP
(Enterprise Resource
Level
Planning)
MES
Execution (Manufacturing
Level Execution System)
SCADA
(Supervisory Control
Supervisory and Data Acquisition)
Level
DCS
(Distributed
Control System)
Control
Level PLC
(Programmable Logic
Controller)
ms seconds hours days weeks month years

Data Quantity & Quality and Hierarchical Level
Higher Levels
When ascending the control hierarchy, data are reduced:

higher level data are created (e.g. summary information)
Processing and decisions becomes more complicated (requires using models).
Timing requirements are slackened. Historical data are stored
SCADA level
Presentation of complex data to the human operator,
aid to decisions (expert system) and maintenance.
Requires a knowledge database in addition to the plant's database
Lower Levels
Lowest levels (closest to the plant) are most demanding in response time.
Quantity of raw data is very large.
Processing is trivial (was formerly realized in hardware).
These levels are today under computer control,
except in emergency situations, for maintenance or commissioning.
 Consideration of human intervention breaches this hierarchy.
 Normally, the operator is only concerned by the supervisory level,
but exceptionally, operators (and engineers) want to access data of
the lowest levels.
 The operator sees the plant through a fast data base, refreshed in
background. This database is the pivot for logging and simulation.
knowledge base man-machine

communication
operator
history logging process simulation

data base
instructor
maintenance actualization
engineer
process data
plant
Sample project
 sample
Is SCADA the only Future ? ...
New Technology: Jet Web
Each node is an individual Web Server All nodes and all
I/O hooked up to the Ethernet
27

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General overview of wireless

based PLC and SCADA

 A PLC is a solid state / industrial computer that

Network connecting other devices

Sensors Placed in the field

SCADA refers to a system that collects data from various

Data Server Data Server PLC’s

there is no more direct wiring to the plant. …

ms seconds hours days weeks month years

When ascending the control hierarchy, data are reduced:

knowledge base man-machine

history logging process simulation

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