Automation is a broad term that covers many areas of technology where human intervention is minimized. It includes various domains such as business process automation, IT automation, marketing automation, and industrial process automation.
Our main focus is OT (Operational Technology) automation. Since it is not possible to cover all aspects of OT automation here, we have selected a small subset that includes OT automation and IT automation.
In this context, we will describe the key electrical and technological components required for both process automation and IT automation.
Operational Technology (OT) refers to hardware and software used to monitor and control physical processes, equipment, and industrial operations. It includes systems such as sensors, controllers, and automated machines that ensure safe and efficient performance.
Common OT components:
-PLC (Programmable Logic Controllers)
-SCADA control systems
-Industrial robots
-Sensors & actuators
-Power grid systems
Examples:
-Factory automation machines
-Traffic control systems
-Power plant controls
-Water treatment plant monitoring
IT (Information Technology) is the use of computers, software, networks, and digital systems to create, process, store, and share information. It supports communication, data management, and business operations through technologies such as cloud computing, cybersecurity, and networking. IT helps organizations improve efficiency, decision-making, collaboration, and overall productivity.
Common IT components:
-Computers & laptops
-Servers & cloud platforms
-Business software (ERP, CRM)
-Networks (Wi-Fi, internet)
-Cybersecurity systems
Examples:
-Email systems
-Websites & apps
-Company databases
-Microsoft 365 or Google Workspace
-Financial software
Though each section is a tiny technical area, we need to know many technical details to understand the development completely. We keep in mind that this knowledge can be used for industrial automation development, we have divided each technical area separately. If you want to understand go through each module.
What is process variable
Automation systems are used to monitor and control a process to keep the process within a specified limit. The parameters that we wish to control at the correct limit are called Process Variables. A variable is something that can be changed over time. Because process variables can and do change, automation systems measure the variable and then control the variable to keep it within the given limits.
For example, we want to have an air pressure value of 10 Bar for a typical pneumatic system. If the pressure drops below 10, then we need to start the compressor. This 10 is a process variable which we control. Pressure, Temperature, and flow are the three process variables in industries.
Generic Software development (such as by C#, Visual Studio Code, Using log4net)
Whatever the automation system is, it is mostly based on electrical, electronic, and mechanical systems. We need a switch to run a motor. The switch can be an electronic switch that can be put ON by executing software. Software is the brain of the system. We need to have good knowledge of developing an automation system. We shall explain or review the most important software system on these pages.
How to read electrical drawing
Understanding electrical drawing is essential for automation engineers. Sometimes, a typical automation engineer can draw the electrical drawing, or at least read the drawing to understand how the component works and the sequence he needs to implement in the PLC program. We have a collection of these from the internet; consider reading it.
Solenoid, contactor, relay and sensor
How different kinds of valves are controlled by using pressure is discussed, consider reading it.
Control panel design
OPC UA technology and Software development
OPC client is software that uses the service provided by the OPC UA server. OPC UA server can be any device where we are running the server. The Server is a standard program and the interface is managed by the OPC foundation. Continue reading the technology with a working sample.
OPC UA technology and Software development
OPC UA provides secure transport of data via diverse and expandable protocols. There is no Industry 4.0 without OPC UA. In our fictitious home automation system, we use OPC UA to collect data and to communicate with the devices we are controlling. Click on the OPC UA icon to know how to develop the OPC UA application.
OPC UA technology and Software development
OPC UA provides secure transport of data via diverse and expandable protocols. There is no Industry 4.0 without OPC UA. In our fictitious home automation system, we use OPC UA to collect data and to communicate with the devices we are controlling. Click on the OPC UA icon to know how to develop the OPC UA application.
USB to RS485 (PC to Pi) Data Transfer
How can we transfer data from a PC to a device over an RS485 device? We shall describe by using putty and a C# Windows application. Later we shall expand the application by using TwinCAT HMI. There will be a sample code that you can download and test or integrate into your application. Continue reading the article.
Modbus Protocol
Modbus TCP/IP (also Modbus TCP) is simply the Modbus RTU protocol with a TCP interface that runs on Ethernet. The Modbus messaging structure is the application protocol that defines the rules for organizing and interpreting the data independent of the data transmission medium. Continue reading.
Communication over ADS with C#
ADS stands for automation device specification. This is a library written by Beckhoff and developers can use it without thinking about what is happening at a lower level. We shall explain how the ADS works and how to use it in our client program (C# client and TwinCAT HMI client). Continue reading with a complete sample code.
Inside MQTT, explained with C# and ST example
What are MQTT and IoT? In this section, we explained the technology with fully functional source code. Continue here
MQTT, Node-RED and MS SQL
How to store data from MQTT to MSSQL, this is explained here. In this sample, we are getting data from the PLC and storing to SQL Database and displaying to Node-RED dash board.
MQTT, Node-RED, MS-SQL and reporting
How to generate a report from our automation system and send the report to an email is explained here. Here in this sample, we shall use MQTT, and Node-RED as we learned in the previous three chapters, and continue reading the article.
Sending email by JavaScript and CSharp
We need to send reports or any other events to our users by email or SMS. In this article, we shall describe how to send email by using JavaScript or by using C#. C# is an extension module. This is fully functional and integrated with TwinCAT HMI. This sample can be used also with any web application. Please take a look at it to read the sample and implementation details.
Cloud Computing
Cloud computing is the on-demand delivery of IT resources over the Internet with pay-as-you-go pricing. Instead of buying, owning, and maintaining physical data centers and servers, you can access technology services, such as computing power, storage, and databases. Take a look to get an insight into cloud computing.
What you need to know about EtherCAT
EtherCAT (Ethernet for Control Automation Technology) is an Ethernet-based Fieldbus system, invented by Beckhoff Automation. The protocol is standardized in IEC 61158 and is suitable for both hard and soft real-time computing requirements in automation technology. Continue reading.
Different hardware used in Beckhoff world
There are lots of different devices and hardware in automation. If you are not an expert then those names can be confusing, misleading, this article will clarify these hopefully, Continue reading..
Usages of IO Cards
Higher-level automation devices read and write the field devices in a continuous cycle. So PLC developers must have good knowledge about these IO Cards. This section will describe a few cards for reading different data types such as analog inputs, digital inputs, etc. Get more information with a sample program.
Structured Text Programming. Learn from start to end
Structured text, abbreviated as ST or STX, is one of the five languages supported by the IEC 61131-3 standard, designed for programmable logic controllers. It is a high-level language that is block-structured and syntactically resembles Pascal. Structured Text is a PLC programming language defined by PLCOpen in IEC 61131-3. Click on the PLC ST (IEC 61131-3) Programming icon to learn how to develop an application by using ST.
Industrial communication protocol
There are varieties of protocol which are commonly used in industrial automation. Here in this section we briefly explain mostly used protocol. Continue reading the protocols.
Know about PLC hardware
Beckhoff is a leading PLC provider in the world. We shall provide hardware/environment-related tips on this page. For example, how to remove your boot project, what to do when the PLC does not boot.
Draw icon and symbol for automation system for free
Inkscape Tutorial, Tips, and Tricks that are necessary for an HMI designer. This is a collection of tips and tricks. Inkscape is a Free and open-source vector graphics editor for GNU/Linux, Windows, and macOS X. It offers a rich set of features and is widely used for both artistic and technical illustrations such as valves, motors, etc.
Motor Control Software to Hardware
How information is passed from a graphical user interface (GUI application) to the hardware device (such as a motor). There are many ways to control hardware by using the software. In this example, we shall explain how to control a typical motor (stop and start). We are not considering the safety issue here but just explain the concept. Continue reading.
VFD and Soft Starter
A variable-frequency drive (VFD) or adjustable-frequency drive (AFD), variable-voltage/variable-frequency drive, variable speed drive (VSD), AC drive, microdrive, or inverter drive is a type of adjustable-speed drive used in electro-mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage. The basic principle is that it changes the frequency gradually to full load, more.
Sensors One and Two Point calibration
A sensor is a device that changes the physical properties of a process into an electrical signal. That electrical signal is only useful if it accurately represents the physical properties applied to the sensor. Calibration is the process by which the sensor’s electrical signal is adjusted so that it has a known relationship to the applied pressure. After calibration, the electrical signal can be measured and that can be used to determine the properties at the sensor, know more.
Industrial network (video collection)
Collections of video which explain the industrial communications
Building Automation
Building automation is relatively new technology
Sample Projects
Sample projects are going to be implemented and designed. All these steps are explained in detail. Continue reading how to build the project
References
=> 1. https://forumautomation.com/t/what-is-process-variable-and-types-of-process-variables/2818