Basics of automation
- 1. AUTOMATION- COMPONENTS AND ARCHITECTURE Presented by Adarsh M.Kalla SEMINAR 1
- 2. CONTENTS Introduction History Mechanization vs. automation Role of automation in industry Types of production systems Types of automation Architecture of automation Automation control system Sensors and actuators 2
- 3. INTRODUCTION Automation - “auto” (self) and “matos” (moving) self acting machine. Definition Automation can generally be defined as set of technologies that results in operation of industrial machines and systems without significant human intervention and achieves performance superior to manual operation. 3
- 4. INTRODUCTION Automation is achieved through the use of a variety of devices, sensors, actuators, techniques and equipments. continuous observation making decisions controlling all aspects of it. Automation is applied in Trade, environmental protection engineering, building engineering, medicinal engineering, agriculture and food industry. 4
- 5. HISTORY Automation has been introduced very early in the history of human civilization. In the form of mechanical tools like wheel, pulley, lever etc. Later many efficient power machines like steam engines, electric motors, IC engines were introduced. Many electronic devices like triode, transistors, integrated circuits (invented in 1958), which combined tiny transistors The IC laid a path for the introduction of the microprocessor (first- Intel 4004, in 1971) which integrates all the function of CPU of a computer. Now advanced control systems, with complicated control functions have been developed. 5
- 6. AUTOMATION V/S MECHANIZATION Mechanization Automation Saves human muscle Saves use of human judgment Displaces physical labor Displaces mental labor It replaces craft work It replaces human thinking with computers and sophisticated machines Creates job for unskilled labor create jobs for skilled workers at the expense of unskilled and semi-skilled workers. affects one or two industries at a time. affects many industries at a time. moves slowly and the job displacement is short term. Moves rapidly and creates longer-term job displacement occurred during industrial revolution more characteristic since the 1950s. 6
- 7. ROLE OF AUTOMATION IN INDUSTRY Raw/unfinished material Energy, man power, infrastructure manufacturing process Finished product Basic goal of industry is to make profit hence, it is necessary to understand what affects the profit. The automation affects every aspects of profit making of an industry; hence automation is very crucial for success of any industry. Profit = (price/unit – cost/unit) x production volume cost profit volume price profit profit 7
- 8. COST/UNIT Cost/unit Material Energy Man power Infrastructure Automation 8
- 9. PRODUCTION VOLUME Total manufacturing time Production time Material handling time Idle time Quality assurance time The production volume can be increased if we can reduce the time required to produce one unit product. 9
- 10. TYPE OF PRODUCTION SYSTEMS Production system Continuous manufacturing Discrete manufacturing Continuous flow process Batch process Mass discrete manufacturing Job shops 10
- 11. QUANTITY VARIETY CHART Continuous flow process Mass manufacturing of discrete product Batch process Job shop quantity Variety Machine tools, prototypes Pharmaceuticals, food processing Appliances ( TV, Mixers) , automobiles Oil refinery, cement, fertilizer, iron and steel 11
- 12. TYPES OF AUTOMATION Automation systems flexibleprogrammableFixed integrated 12
- 13. FIXED AUTOMATION Features High volume of production Dedicated equipments Fixed efficient operation Factory types Continuous flow Discrete mass production Examples Process automation Conveyors Paint shops Transfer lines 13
- 14. PROGRAMMABLE AUTOMATION Features Changeable sequence of operation Electronic controls Factory types Batch process Mass production Examples Numerically controlled machines Assembly robots Numerically controlled lathe 14
- 15. FLEXIBLE AUTOMATION Features Computer controlled with graphically user interface, so that operator can operate it. Changes should be preprogrammed, so that operator select certain parameters and rest is done automatically. Programmable material handling Factory types Job shops Batch processes Examples CNC machining centers Automatic guided vehicles Automated guided vehicle 15
- 16. INTEGRATED AUTOMATION Features Advanced optimizing algorithms There is lot of knowledge built in them and they do lot of mathematical calculations based on sophisticated models. Computer communication : To integrate various parts you require computer communication Production/ management integration Factory types To all types of factories large Examples Chemical process automation Plant with computer integrated manufacturing 16
- 17. ARCHITECTURE OF INDUSTRIAL AUTOMATION Production control Supervisory control Enterprise Automatic control Sensors and actuators Process/ machine Level 4 Level 3 Level 2 Level 1 Level 0 Spatialscale/timescale 17
- 18. Contd…… Not all these layer are perfectly automated. Sensors and actuators and automatic controls are automated. From the supervisory control upwards they are not completely automated. E.g. in supervisory control- you will have cabinets with computers monitored by process supervisor and operators. Production control level- performed by humans with aid of tools Production manager, shift in charge engineer, T.O They are mix of manual and automated tools. 18
- 19. NATURE OF LEVEL The spatial scale and time scale increases as the level is increased. For e.g. at level 0--- one sensor will measure one process variable. At level 1---one automatic controller may be taking control action by considering several sensors. At level 2--- looks after one piece of equipment having many control loops. At level 3--- the product control is typically done at section level containing several equipments. 19
- 20. INDUSTRIAL CONTROL SYSTEM controller plantActuator Sensor Output Set point 20
- 23. ACTUATORS Signal processing element--accepts the command from the control system and processes it in various ways. Eliminates frequencies that may cause resonance Power amplification element--contains linear power amplification stages called servo-amplifiers. Variable conversion element-- alters the nature of the signal from electrical to non-electrical form, generally in the form of motion. Eg. electro hydraulic servo valve, stepper/servo motors etc 23
- 24. ACTUATORS energy conversion elements-- may be used further to transform the actuated variable in desired forms. e.g. motion-to-flow rate conversion in flow-valves, rotary to linear motion converters using mechanisms, flow-rate to heat conversion using steam or other hot fluids etc. 24
- 25. CONTROLLERS A device which accepts the inputs , measure them and depending on the predetermined conditions actuate one or more devices is called the controller. Inputs allow a controller to read temperatures, humidity, pressure, current flow, air flow, and other essential factors. The outputs allow the controller to send command and control signals to slave devices, and to other parts of the system. 25
- 26. TYPES OF CONTROLLERS 1. Parameter or physical quantity they are controlling Examples- Temperature controller, RPM controller, Pressure controller etc. 2.The manner in which they are controlling the Physical quantity Proportional controller P Proportional Integral controller PI Proportional Integral derivative Controller PID ON –OFF Controller 3.The device used for controlling – PLC , PAC, Digital circuits using comparators 26
- 27. AUTOMATION TOOLS HMI – Human machine interface DSC – Distributed control system PLC – programmable logic controller PAC – Programmable automation controller SCADA – Supervisory control and data acquisition ANN- Artificial neural network Instrumentation Motion control Robotics 27
- 28. SOCIAL ISSUES OF AUTOMATION Automation impact on employment. But automation need not bring unemployment for two reasons It is a temporary displacement which can be offset by the demands of a broadening market, as well as the creation of new industries. Automation is the necessary solution to a predicted shortage of labour. It is designed to the work of men who are not there. 28
- 29. CONCLUSION Automation has many advantages including making our lives comfortable and enable human beings to do the things which otherwise would have been impossible to do manually with same efficiency and accuracy. Automation changes the nature of jobs and demands new skills and it is a myth that it leads to unemployment… …… “It is a solution to a problem, not a cause”. 29
- 30. REFERENCES Gupta, K.A. and Arora, K.S. (2007). Industrial Automation and Robotics. 1st Edition. Pub by Laxmi publication (P) LTD, 113, Golden House, Daraganj, NewDelhi- 110002. Sharma, S.L.K. (2001). Overview of Industrial Process Automation. 1st Edition. Pub by Elsevier publication, 32 Jamestown road London. Bissell, C.C. (2009). A History of Automation control, Handbook of Automation. springer publication. P 1-18. Harrision, S.C. (2004). A review of Automation manufacturing illustrated by a case study on mixed model hot forging. Manufacturing review 1, 15. Ilyukhin, V.S., Haley, A.T. and Singh, K.R. (2001). A survey of automation practices in the food industry. Food control, vol 12(5). p 285-296. Doxanakis, E. and Kefalas,A. (2008). Automation in dairy industry. In advanced dairy science and technology Ed by britz, J.A. and Robinson, K.R. pub by blavkwell publishing ltd, 9600, Garsington Road, oxford, U.K. p. 122. 30
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