NextGen Automation
NextGen Automation
Welcome to NextGen Automation! π
This channel is dedicated to Industrial Automation, Electrical, and PLC/SCADA systems.
Here you will find:
β‘ Step-by-step explanations of automation concepts
β‘ Tutorials on PLC, VFD, HMI, SCADA, and wiring
β‘ Practical demonstrations with diagrams
β‘ Study + Revision content for engineers & students
My goal is to make automation easy to learn and share knowledge that helps in both study and job preparation.
π Subscribe and join me in this learning journey of NextGen Automation!
NextGen Automation
π€οΈ Good Afternoon β Day 314/365
β‘ INDUSTRIAL ELECTRICAL β INVERTER
π How Does an Inverter Convert DC into AC?
An inverter is an electrical device that converts DC (Direct Current) into AC (Alternating Current).
βοΈ HOW IT WORKS
π DC Supply
β¬οΈ
β‘ Switching Circuit (IGBT/MOSFET)
β¬οΈ
γ°οΈ AC Output
β¬οΈ
π Motor / Electrical Load
π§ TYPES OF INVERTERS
πΉ Single-Phase Inverter β Used in single-phase AC applications.
πΉ Three-Phase Inverter β Commonly used for industrial motor control.
πΉ PWM Inverter β Uses Pulse Width Modulation to control the output waveform.
π PRACTICAL APPLICATIONS
β Variable Frequency Drives (VFDs)
β Solar Power Systems
β UPS Systems
β Battery Energy Storage
β Industrial AC Motor Control
π‘ VFD WORKING CONCEPT
AC Supply β Rectifier β DC Bus β Inverter β AC Motor
The inverter controls the output frequency and voltage according to the drive's control strategy, allowing motor speed control.
π DAY 314 CHALLENGE
What does an inverter convert?
A) AC to DC
B) DC to AC
C) AC to AC
π Comment your answer!
LEARN β’ UNDERSTAND β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day314 #365DaysAutomation #Inverter #VFD #PowerElectronics #ElectricalEngineering #IndustrialMaintenance #ElectricalMaintenance #AutomationEngineer #NextGenAutomation
12 hours ago | [YT] | 2
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NextGen Automation
π Good Morning β Day 313/365
β‘ INDUSTRIAL ELECTRICAL β RECTIFIER
π What is a Rectifier and How Does It Work?
A Rectifier is an electrical device that converts AC (Alternating Current) into DC (Direct Current).
βοΈ How It Works
π AC Supply
β¬οΈ
β‘ Rectifier Circuit
β¬οΈ
β‘οΈ DC Output
π§ Types of Rectifiers
πΉ Half-Wave Rectifier β Uses one diode to rectify one half-cycle of AC.
πΉ Full-Wave Rectifier β Uses both half-cycles of AC.
πΉ Bridge Rectifier β Commonly uses four diodes in a bridge configuration.
π Industrial Applications
β Battery Chargers
β DC Power Supplies
β Variable Frequency Drives (VFDs)
β Electroplating Systems
β Industrial DC Drives
β Solar and Power Electronics Systems
π‘ Practical Example
In many VFDs:
AC Supply β Rectifier β DC Bus β Inverter β AC Motor
The rectifier converts incoming AC into DC, and the inverter section generates the required AC output for motor control.
π DAY 313 CHALLENGE
What does a rectifier convert?
A) DC to AC
B) AC to DC
C) AC to AC
π Comment your answer!
LEARN β’ UNDERSTAND β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day313 #365DaysLearning #Rectifier #ElectricalEngineering #PowerElectronics #IndustrialMaintenance #VFD #ElectricalMaintenance #AutomationEngineer #NextGenAutomation
2 days ago | [YT] | 1
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NextGen Automation
π Good Morning β Day 311 / 365
π§ PLC PROGRAMMING β RETENTIVE MEMORY
βPLC Power OFF Hone Ke Baad Bhi Data Kaise Preserve Rakhein?β
Aaj ek important industrial PLC concept β Retentive Memory βοΈ
Normally PLC restart/power cycle ke baad kuch values reset ho sakti hain. Retentive memory ka purpose selected data ko preserve karna hota hai.
π BASIC FLOW
β‘ PLC RUNNING
β¬οΈ
π Production Count = 1250
β¬οΈ
π Power OFF
β¬οΈ
π PLC Restart
β¬οΈ
π Count = 1250 (if configured as retentive)
π WHERE USED?
πΉ Production counters
πΉ Totalizer values
πΉ Machine operating hours
πΉ Recipe parameters
πΉ Important machine settings
πΉ Production data
β οΈ IMPORTANT
Har variable ko retentive banana zaroori nahi hota.
β Temporary variables ko unnecessarily retain karna memory management aur startup behavior ko complicated kar sakta hai.
π Only required data β Retentive
π§ TROUBLESHOOTING
Power restart ke baad value change ho rahi hai?
1οΈβ£ Variable retentive hai ya nahi
2οΈβ£ PLC memory configuration
3οΈβ£ Startup/initialization logic
4οΈβ£ Program download ke effects
5οΈβ£ Battery/backup requirements, if applicable
π‘ GOLDEN RULE
βRetain only what the process needs to remember.β βοΈ
π DAY 311 CHALLENGE
Production counter = 5000
PLC power OFF β ON.
Agar counter variable properly configured as retentive hai, expected value kya hogi?
A) 0
B) 5000
C) 1
π Comment your answer!
LEARN β’ PROGRAM β’ TEST β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day311 #365DaysAutomation #PLC #PLCProgramming #RetentiveMemory #LadderLogic #IndustrialAutomation #AutomationEngineer #ElectricalEngineering #ControlSystems #AutomationLearning #NextGenAutomation πβοΈ
4 days ago | [YT] | 1
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NextGen Automation
π Good Night β Day 310 / 365
βοΈ PLC PROGRAMMING β MOVE INSTRUCTION
βPLC Me Ek Value Ko Dusre Memory Location Par Kaise Transfer Karte Hain?β
Aaj ek simple but very useful PLC programming concept β MOVE (MOV) instruction.
π§ MOVE KYA KARTA HAI?
MOVE instruction ka use ek value ko Source se Destination me copy karne ke liye kiya jata hai.
π BASIC FLOW
SOURCE VALUE
β¬οΈ
π¦ MOVE / MOV
β¬οΈ
DESTINATION
Example:
Temperature_Setpoint = 80
β¬οΈ MOVE
Active_Setpoint = 80
π PRACTICAL EXAMPLE
HMI se operator recipe select karta hai:
Recipe Setpoint = 75Β°C
PLC:
MOVE 75 β Active_Setpoint
β¬οΈ
π‘οΈ Process Setpoint = 75Β°C
π§ WHERE USED?
πΉ Recipe Management
πΉ Setpoint Transfer
πΉ Machine Modes
πΉ Parameter Initialization
πΉ Batch Processing
πΉ HMI Data Handling
πΉ Sequence Control
β οΈ IMPORTANT
MOVE instruction value copy karta hai; source value automatically delete nahi hoti.
PLC platform ke according instruction ka naam/syntax MOV, MOVE etc. ho sakta hai.
π‘ GOLDEN RULE
SOURCE β MOVE β DESTINATION
π DAY 310 CHALLENGE
Agar:
Source = 100
MOVE instruction se Destination me value copy ki.
β Destination kya hoga?
A) 0
B) 100
C) 200
π Comment your answer!
LEARN β’ PROGRAM β’ TEST β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day310 #365DaysAutomation #PLC #PLCProgramming #MOVE #MOV #LadderLogic #IndustrialAutomation #AutomationEngineer #ElectricalEngineering #ControlSystems #AutomationLearning #NextGenAutomation πβοΈ
5 days ago | [YT] | 1
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NextGen Automation
π€οΈ Good Afternoon β Day 309 / 365
π₯ PLC PROGRAMMING β HYSTERESIS
βTemperature Control Me Output Baar-Baar ON/OFF Hone Se Kaise Roka Jata Hai?β
Aaj ek important process-control concept β Hysteresis βοΈ
Agar temperature setpoint ke around continuously fluctuate kare, to output baar-baar ON/OFF ho sakta hai.
π Hysteresis ek deadband provide karta hai.
π‘οΈ EXAMPLE
Setpoint = 80Β°C
Hysteresis = Β±2Β°C
π₯ Heater:
Below 78Β°C β ON
Above 82Β°C β OFF
78β82Β°C ke beech output ko unnecessarily switch nahi karna padta.
π BASIC LOGIC
π‘οΈ Temperature < 78Β°C
β¬οΈ
π₯ Heater ON
π‘οΈ Temperature > 82Β°C
β¬οΈ
βοΈ Heater OFF
π WHERE USED?
πΉ Temperature Control
πΉ Pressure Control
πΉ Level Control
πΉ HVAC
πΉ Compressor Control
πΉ Pump Control
β οΈ WITHOUT HYSTERESIS
80.0Β°C β OFF
79.9Β°C β ON
80.0Β°C β OFF
79.9Β°C β ON
β Rapid switching / Chattering
π‘ GOLDEN RULE
Hysteresis = Stable Control + Less Chattering + Better Equipment Life
π DAY 309 CHALLENGE
Setpoint = 80Β°C
Hysteresis = Β±2Β°C
β Heater OFF kab hoga?
A) 78Β°C
B) 80Β°C
C) 82Β°C
π Comment your answer!
LEARN β’ PROGRAM β’ TEST β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day309 #365DaysAutomation #PLC #PLCProgramming #Hysteresis #ProcessControl #TemperatureControl #IndustrialAutomation #AutomationEngineer #ElectricalEngineering #ControlSystems #AutomationLearning #NextGenAutomation π
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NextGen Automation
π€οΈ Good Afternoon β Day 308 / 365
π§ PLC PROGRAMMING β COMPARISON INSTRUCTIONS
βPLC Me Do Values Equal, Greater Ya Smaller Kaise Check Karte Hain?β
Aaj ek important PLC logic concept πβοΈ
PLC program me conditions check karne ke liye comparison instructions use hoti hain.
π§ COMMON COMPARISONS
EQU = Equal
π Temperature = 80Β°C
NEQ = Not Equal
π Temperature β 80Β°C
GT = Greater Than
π Pressure > 8 bar
LT = Less Than
π Level < 20%
GE = Greater Than or Equal
π Count β₯ 100
LE = Less Than or Equal
π Speed β€ 1500 RPM
π REAL EXAMPLE
π‘οΈ Temperature = 85Β°C
Condition:
Temperature > 80Β°C
β¬οΈ
π¨ High Temperature Alarm ON
π BASIC LOGIC
PROCESS VALUE
β¬οΈ
π§ COMPARE WITH SETPOINT
β¬οΈ
β Condition TRUE β Action
β Condition FALSE β No Action
π WHERE USED?
πΉ High/Low Alarms
πΉ Temperature Control
πΉ Level Monitoring
πΉ Production Count
πΉ Pressure Limits
πΉ Speed Monitoring
πΉ Machine Interlocks
π‘ GOLDEN RULE
VALUE β COMPARE β CONDITION β ACTION
π DAY 308 CHALLENGE
Temperature = 85Β°C
Condition:
Temperature > 80Β°C
β Result?
A) TRUE β
B) FALSE
C) ERROR
π Comment your answer!
LEARN β’ PROGRAM β’ TEST β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day308 #365DaysAutomation #PLC #PLCProgramming #ComparisonInstructions #LadderLogic #IndustrialAutomation #AutomationEngineer #ElectricalEngineering #ControlSystems #AutomationLearning #NextGenAutomation πβοΈ
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NextGen Automation
π Good Morning β Day 307 / 365
π₯ PLC PROGRAMMING β CTUD COUNTER
βPLC Me Count UP Aur Count DOWN Dono Kaise Karte Hain?β
Aaj ek useful PLC concept β CTUD (Count Up/Down) βοΈ
CTUD counter me count increase (+1) bhi ho sakta hai aur decrease (-1) bhi.
π BASIC WORKING
π¦ Product IN
β¬οΈ
π’ Count UP
β¬οΈ
10 β 11
π¦ Product OUT
β¬οΈ
π΄ Count DOWN
β¬οΈ
11 β 10
π REAL EXAMPLE β PARKING
π Vehicle Entry β Count +1
π Vehicle Exit β Count β1
π HMI par:
Vehicles Inside = 25
π§ COMMON PARAMETERS
πΉ CU β Count Up
πΉ CD β Count Down
πΉ CV β Current Value
πΉ PV β Preset Value
πΉ Reset/Load β Counter initialization
π WHERE USED?
πΉ Parking systems
πΉ Warehouse inventory
πΉ Production tracking
πΉ Conveyor systems
πΉ Pallet counting
πΉ People/vehicle counting
β οΈ IMPORTANT
UP aur DOWN inputs ke pulses reliable hone chahiye. Sensor noise ya duplicate pulses se count incorrect ho sakta hai.
π ONE EVENT = ONE VALID COUNT
π‘ GOLDEN RULE
ENTRY β +1
EXIT β β1
CURRENT VALUE = ACTUAL COUNT
π DAY 307 CHALLENGE
Current count = 50
2 products IN β +2
5 products OUT β β5
β Final count kya hoga?
A) 43
B) 47
C) 53
π Comment your answer!
LEARN β’ PROGRAM β’ TEST β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day307 #365DaysAutomation #PLC #PLCProgramming #CTUD #Counter #LadderLogic #IndustrialAutomation #AutomationEngineer #ElectricalEngineering #ControlSystems #AutomationLearning #NextGenAutomation πβοΈ
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NextGen Automation
π€οΈ Good Afternoon β Day 306 / 365
π’ PLC PROGRAMMING β CTU COUNTER
βPLC Me Products Ki Quantity Automatically Kaise Count Karte Hain?β
Aaj ek important PLC concept β CTU (Count Up) βοΈ
π§ CTU KYA KARTA HAI?
Har valid counting pulse par counter ka value +1 hota hai.
π BASIC FLOW
π¦ Product
β¬οΈ
π‘ Sensor
β¬οΈ
π§ CTU Counter
β¬οΈ
π’ Count +1
β¬οΈ
π₯οΈ HMI Display
π EXAMPLE
Target = 100 Products
Sensor detects:
1οΈβ£ Product β Count = 1
2οΈβ£ Product β Count = 2
3οΈβ£ Product β Count = 3
...
π’ Product 100 β Counter Done
π Machine next sequence start kar sakti hai.
βοΈ COMMON PARAMETERS
PV / Preset β Target count
CV / Current Value β Current count
Q / Done β Target reached status
π§ WHERE USED?
πΉ Production Counting
πΉ Packaging Machines
πΉ Bottle Filling
πΉ Conveyor Systems
πΉ Batch Counting
πΉ Part Counting
β οΈ IMPORTANT
Agar sensor continuously ON rahe, to counting logic me edge detection / one-shot ki requirement ho sakti hai, taaki ek product multiple times count na ho.
π‘ GOLDEN RULE
ONE PRODUCT β ONE VALID PULSE β ONE COUNT π’
π DAY 306 CHALLENGE
Counter ka preset 100 hai.
Current count = 99
Ek valid product detect hua.
β Current count kya hoga?
A) 98
B) 100
C) 101
π Comment your answer!
LEARN β’ PROGRAM β’ TEST β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day306 #365DaysAutomation #PLC #PLCProgramming #CTU #Counter #LadderLogic #IndustrialAutomation #AutomationEngineer #ElectricalEngineering #ControlSystems #AutomationLearning #NextGenAutomation πβοΈ
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NextGen Automation
π Good Evening β Day 305 / 365
β±οΈ PLC PROGRAMMING β TOF TIMER
βPLC Output Ko OFF Hone Ke Baad Kuch Time Tak ON Kaise Rakhein?β
Aaj TOF (Timer OFF Delay) ka practical concept πβοΈ
π§ TOF KYA KARTA HAI?
Input OFF hone ke baad timer preset time tak output ko ON maintain kar sakta hai.
π BASIC FLOW
π’ Input ON
β¬οΈ
βοΈ Output ON
π΄ Input OFF
β¬οΈ
β±οΈ TOF Timer
β¬οΈ
β Preset Time Complete
β¬οΈ
β« Output OFF
π REAL EXAMPLE
Conveyor OFF hua:
Conveyor OFF
β¬οΈ
β±οΈ TOF = 10 sec
β¬οΈ
π Cooling Fan continues running
β¬οΈ
10 sec complete
β¬οΈ
β« Fan OFF
π₯ WHERE USED?
πΉ Cooling Fan
πΉ Exhaust Fan
πΉ Conveyor Cooling
πΉ Machine Lubrication
πΉ Ventilation
πΉ Shutdown sequences
π TON vs TOF
TON: Input ON β Wait β Output ON
TOF: Input OFF β Wait β Output OFF
β οΈ IMPORTANT
Exact timer behavior aur instruction naming PLC platform/software ke according differ kar sakti hai. Programming se pehle manufacturer documentation aur timing resolution check karna important hai.
π‘ GOLDEN RULE
TOF = OFF β WAIT β OFF
π DAY 305 CHALLENGE
TOF preset = 10 seconds
Input OFF hua.
β Output approximately kab OFF hoga?
A) Immediately
B) After 10 sec
C) After 20 sec
π Comment your answer!
LEARN β’ PROGRAM β’ TEST β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day305 #365DaysAutomation #PLC #PLCProgramming #TOF #Timer #LadderLogic #IndustrialAutomation #AutomationEngineer #ElectricalEngineering #ControlSystems #AutomationLearning #NextGenAutomation πβοΈ
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NextGen Automation
π Good Morning β Day 304 / 365
β±οΈ PLC PROGRAMMING β TON TIMER
βPLC Me Kisi Action Ko Delay Ke Baad Kaise ON Karte Hain?β
Aaj ek very useful PLC concept β TON (Timer ON Delay) βοΈ
π§ TON KYA KARTA HAI?
Input ON hone ke baad PLC preset time wait karta hai, phir timer output DONE hota hai.
π BASIC FLOW
START / CONDITION ON
β¬οΈ
β±οΈ TON Timer
β¬οΈ
β Preset Time Complete
β¬οΈ
β Timer Done
β¬οΈ
βοΈ Output ON
π REAL EXAMPLE
Conveyor start hua:
π’ Conveyor ON
β¬οΈ
β±οΈ TON = 5 sec
β¬οΈ
5 seconds complete
β¬οΈ
π’ Cooling Fan ON
π EXAMPLE
Preset = 10 sec
Input ON β 0 sec
Input remains ON β 5 sec
Input remains ON β 10 sec
β Timer Done = ON
Agar input timer complete hone se pehle OFF ho jaye, typical non-retentive TON timer reset ho jata hai; exact behavior PLC configuration par depend karta hai.
π§ WHERE USED?
πΉ Motor start delay
πΉ Conveyor sequencing
πΉ Cooling fan delay
πΉ Pump delay
πΉ Machine sequence
πΉ Alarm delay
π‘ GOLDEN RULE
TON = Input ON β Wait β Timer Done
π DAY 304 CHALLENGE
TON ka preset 5 seconds hai.
Input continuously ON raha 7 seconds.
β Timer Done kab ON hoga?
A) 2 sec
B) 5 sec
C) 7 sec
π Comment your answer!
LEARN β’ PROGRAM β’ TEST β’ TROUBLESHOOT β’ AUTOMATE βοΈ
#Day304 #365DaysAutomation #PLC #PLCProgramming #TON #Timer #LadderLogic #IndustrialAutomation #AutomationEngineer #ElectricalEngineering #ControlSystems #PLCLogic #AutomationLearning πβοΈ
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