Industrial Automation

T Rajendran
 Industrial Automation
 Control Systems
 Process Control
 Industrial Control
 Computer Integrated Manufacturing
 Systems Modeling
 Systems Engineering
 Real Time Programming
 Software tools
 Expectation of Automation
 High Reliability
 Fast Trouble shooting
 Simple Operation
 Easily Configurable
 High Accuracy
 Optimization functions and
processing of operating data
 Flexibility
 Process Controls

PC
Integrated
Control &
Management
systems
IS

MIS

1970-80 1980…
1960-70
 History
 Pioneering period – 60 – Electronic devices
 Direct Digital control
 Microcomputer
 Computer controlled Process plants

– Centralized
– Distributed
– Process Models
– Advanced Control (AI)
Process Controls
 Water out Process Control

Set point (desired value)

Steam out
Temp sensor -

Deviation (error)

Control
Signal
generation

Water in

Steam in
 Basic principles of controller loop
 Memory - Set Point
 Comparator for set point (measured
value MV) as reported by transmitter
 Deviation = error

 Amplifier – amplifies the control

deviations – output of the controller
 Process Control
 Open Loop Control
 Closed Loop control
 Process Control
 Two position control
 Multi position control

 PID Proportional control (proportional,

integral or derivative)
 Ratio control

 Cascade control
 Controller Operation
Set point
Control element

sensor
error Control signal process
- controller

Measured value

Auto/manual
Position control

High set point

Low set point

Control
Control actions
value

No control

Proportional only

Set point
PID PI

Time
Instrumentation
 Instrumentation
 Pressure
 Flow
 liquid level
 Temperature
 Pneumatic and control valves
 Transducers
 Sensors
 high / low limits of measurand
 Transducers
 To measure / sense
 to convert measured value to a
useful output
 Transducers
 Measurement
– Type of measurand
– Number of measurements
– Sensing measurement
– Transduction element
– Range of measurement
 Conversion
– Specific format
– Amplified
– Conversion of AC to DC
 Transducers
 Conventional
 Silicon
 Fiber Optic
 Transducers
 Conventional
 Silicon
 Fiber Optic

 Displacement / motion transducers

 Temperature Transducers
 Pressure Transducers
 Liquid level Transducers
 Liquid Flow
 Intelligent Sensors
 On-chip signal processing
 MEMS (Micro Electro Mechanical
Systems) sensors
 BIOSENSORS

 NANOSENSORS
 NANOSENSORS & future trends
 1 nm = 1 millionth of a mm
Building Blocks in
Automation
 Building blocks
 The Processor
 Analog & Digital I/O modules

 interrupts, Timers/counters

 Display controls

 SCADA (Supervisory control and

data acquisition systems)
 Processing System
 The use of Microprocessors
(calculator chips & Mini computers)
 Architecture

– Input, Memory, Output, MicrpP

Address bus, Data bus, control bus
 8 , 16, 32, 64 bits
 Microprocessors & microcontrollers
 Analog & Digital I/O modules
 Basic signals

Analog inputs Control outputs

Display outputs
Digital inputs

Timer / counter inputs

Interrupt inputs
 Analog & Digital I/O modules
 Basic signals

Analog inputs Control outputs

Display outputs
Digital inputs

Timer / counter inputs

Interrupt inputs
 Inside look of a real time sysytem

Analog input module

Display outputs

Analog inputs

Control outputs

Processor
& memory
module

Interrupt
Digital inputs controller Timer /
counter

Timer / counter inputs

Interrupt inputs
 I/O modules
 Analog input
– From Sensors
– Measurand like flow, position,
temperature …
– Signal may be amplified, filtered or/and
isolated
 Digital input
– Refer to ON-OFF status of valves, linit
switches.. (1 bit )
 I/O modules
 Interrupt input
– Draw attention of real time system towards
abnormal situations
– Attends to interrupt and resumes normal
work
 Timer / Counter
– Clock input or Gate input to enable/ disable
timer/counters
– Output of timer/counter can be used as
interrupts
 I/O signals
 Display output signals
– LED, LCD, VDU, alarms
– Status of process, limits sets
– May control or operator assisted
 Control output signal
– Required to drive the control valves, motors etc
– May be simple ON/OFF or fine control of motor
speed, position, displacement, flow..
– Analog signals / digital actuators
 Analog input
 The module continuously scans the
analog input signals in the pre
defined order and frequency
 Amplifies -> converts to digital ->
processor and memory module for
processing
 EPROM or switches

 Local intelligence
 Digital Input
 Directly accepted by processor
 N bits in parallel

 Local intelligence
 Analog Output
 Digital multiplexer
 Digital to Analog converter

 Master processor executes two I/O

instructions
– Write Data byte/word in digital output
port
– Write address byte/word in address port
 Interrupt control
 Interface between no. of interrupting
devices and master processor
 Priorities allocation- static or
dynamic.
 Timer / Counter
 Number of timers and counters
which may be cascaded or used
independently
 Count in the form of data byte/word

 Clock from the processor or external

 Display Control module
 Manual entry sub module
 CRT controller sub module

 LED / LCD control sub module

 Alarm annunciator sub module

 Printer controller sub module

 SCADA
 Supervisory Control And Data
Acquisition Systems
– Channel scanning
– Conversion into engineering units
– Data processing
CAD / CAM / CIM
 CIM
cad
Robots fe simul
ation

CNC
fms
MeM

ERP
Sche
dudle cim
draf
ting
Shop
floor
data Prod
plan Process
Tool planning
design
 CAD / CAM / CIM
 CIM, Concurrent Engineering
 Product Life Cycle Management

 Engineering Modeling

 CIM databases

 Computer aided process planning

 IT & ERP

 Manufacturing automation – PLC, CNC,

Robots
 CAD/CAM/CIM
 FlexibleManufacturing
 Shop Floor Data Collection

 Simulation
 Concurrent Engineering
 DESIGN software
– Solid Modeling
– Assembly modeling
– Sheet metal design
– Drafting
– Tolerance analysis
– Mechanism Design
– Mould Design
– Thermal Analysis
– Piping Design
– Optimization
– Tool Design
 Concurrent Engineering
 Process Planning
 ERP

 Shop Floor Data Collection

 PLM

 EDM
 Concurrent Engineering
 Visualization / Simulation
– Factory simulation
– Rapid prototyping
– Plastic injection moulding
– Forming
– Forging
– Casting