Industrial Automation Viva Preparation — Complete Guide
1. What is Industrial Automation?
Industrial automation is the use of control systems such as Programmable Logic Controllers (PLC),
Supervisory Control and Data Acquisition (SCADA), and Distributed Control Systems (DCS) to handle
different industrial processes and machinery with minimal human intervention. Benefits: Increases
productivity, reduces human error, enhances safety. Examples: Automated manufacturing lines,
chemical plants.
2. What is a Programmable Logic Controller (PLC)?
A PLC is a digital computer used for automation of industrial processes.
• Purpose: Controls machinery and processes.
• Working Principle: Receives input from sensors, processes logic, and gives output to actuators.
• Common Programming Languages: Ladder Logic, Function Block Diagram (FBD), Structured
Text.
• Common Brands: Siemens, Allen Bradley, Mitsubishi.
3. What is Supervisory Control and Data Acquisition (SCADA)?
SCADA is a system used for monitoring and controlling industrial processes remotely.
• Purpose: Supervises and controls systems across wide networks.
• Main Components: Human-Machine Interface (HMI), Remote Terminal Units (RTU), PLCs.
• Difference from PLC: PLC handles local process control; SCADA focuses on remote monitoring,
data acquisition, and control.
4. What is Distributed Control System (DCS)?
DCS is an industrial automation system where control elements are distributed throughout the plant.
• Purpose: Manages complex, large-scale industrial processes such as chemical plants, power
stations.
• How It Works: Uses multiple controllers connected to a central control station.
• Difference from PLC/SCADA: DCS integrates process control and monitoring in a more
centralized way than SCADA and is suited for continuous processes.
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5. What is Human-Machine Interface (HMI)?
HMI is the interface that allows human operators to interact with the machine/system.
• Purpose: Displays process data, allows input commands.
• Examples: Touchscreens, computer-based interfaces.
6. Difference Between Sensor and Actuator:
• Sensor: Detects physical conditions (temperature, pressure, flow, proximity) and sends signals to
controllers.
• Actuator: Converts control signals into physical action (e.g., pneumatic cylinders, electric
motors).
7. Control System Types:
• Open Loop System: Operates without feedback (e.g., basic timer-based control).
• Closed Loop System: Uses feedback to adjust inputs (e.g., with Proportional–Integral–Derivative
(PID) control).
8. What is Proportional–Integral–Derivative (PID) Control?
PID control is a closed-loop control method combining three elements:
• Proportional (P): Corrects error based on current value.
• Integral (I): Corrects error based on past values.
• Derivative (D): Predicts future errors. Example: Temperature control using a heater in industrial
processes.
9. What are Relays and Contactors?
Both are types of electrically operated switches used in control circuits.
• Relays: Handle low power; used for signal switching.
• Contactors: Handle high power; used to switch motors or heavy loads.
10. Common Industrial Motors — Types, Definition, and Usage
1. Induction Motor (Asynchronous Motor)
• Definition: An AC motor where the rotor is powered by electromagnetic induction rather than
direct electrical connection.
• Usage: Pumps, fans, conveyors, compressors; widely used for general industrial applications.
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2. Synchronous Motor
• Definition: An AC motor where the rotor rotates at the same speed as the stator’s rotating
magnetic field.
• Usage: High-precision applications, constant-speed drives, power factor correction.
3. Servo Motor (Servomechanism Motor)
• Definition: A motor with built-in feedback systems for precise position, speed, and torque
control.
• Usage: Robotics, CNC machines, automated manufacturing requiring high accuracy.
4. Stepper Motor
• Definition: A motor that moves in fixed angular steps using electromagnetic pulses.
• Usage: 3D printers, CNC machines, camera platforms; where precise incremental movement is
needed.
5. Brushless Direct Current Motor (BLDC Motor)
• Definition: A DC motor that uses electronic commutation instead of brushes, providing higher
efficiency and reliability.
• Usage: Electric vehicles, drones, computer fans, and modern appliances.
6. Direct Current (DC) Motor
• Definition: A motor powered by direct current electricity, using brushes and commutators or
electronic control.
• Usage: Small appliances, toys, portable tools, and where variable speed is required.
Quick Comparison Table for Industrial Viva:
Motor Type Power Type Precision Control Common Uses
Induction AC Low Pumps, conveyors
Synchronous AC Moderate High-precision industrial tasks
Servo AC/DC High Robotics, CNC machines
Stepper DC Very High Printers, positioning systems
BLDC DC High EVs, drones, home appliances
DC Motor DC Moderate Tools, toys, variable speed needs
11. What is Ladder Logic?
Ladder Logic is a graphical programming language used in PLCs.
• Resembles relay logic diagrams with "rungs" like a ladder.
• Implements control logic through symbols representing inputs, outputs, and logic functions
(AND, OR, NOT).
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12. Explain a Simple Motor Control Circuit:
• Inputs: Start and Stop push buttons.
• Control: PLC processes logic.
• Output: Motor runs when Start is pressed; stops when Stop is pressed.
• Representation: Easily programmed using Ladder Logic.
13. Difference Between Programmable Logic Controller (PLC) and Microcontroller:
Feature PLC Microcontroller
Application Industrial control General-purpose embedded systems
Environment Rugged, industrial-grade Standard electronics
Programming Ladder Logic, FBD C, Assembly
User Friendliness High Moderate
14. What is Your Personal Introduction? (Example)
"I’m [Your Name], with a background in Electrical and Electronic Engineering. I have a strong interest in
industrial automation as it combines engineering skills with real-world industrial applications. I believe
this field has great growth potential, and I am eager to contribute to smarter, safer, and more efficient
manufacturing processes."
15. Why Do You Want to Learn Industrial Automation? (Example Answer)
"I want to learn industrial automation because it is essential in modern industry for increasing
efficiency, reducing errors, and ensuring safety. Building skills in PLC, SCADA, DCS, and related systems
will help me develop practical expertise that is in demand both locally and globally."
