Introduction to Automation

CHAPTER 8
INTRODUCTION TO AUTOMATION IN
HYDRAULIC AND PNEUMATIC SYSTEM
13 August 2020 @RT 1
Prepared by : Prof. Rahul Thaker
Department of Mechanical Engineering
Alpha College of Engineering & Technology

What is Automation Control System?
 Automation Control System - system that is able to control a
process with minimal human assistance or without manual and
have the ability to initiate, adjust, action show or measures the
variables in the process and stop the process in order to obtain the
desired output.
 The main objective of Automation Control System used in the
industry are:
1. To increase productivity
2. To improve quality of the product
3. Control production cost

 The overall production time for a product is affected by various
factors. Automation affects all of these factors. Firstly, automated
machines have significantly lower production times.
 For example, in machine tools, manufacturing a variety of parts,
significant setup times are needed for setting the operational
configuration and parameters whenever a new part is loaded into
the machine.
 This can lead to significant unproductive for expensive machines
when a variety of products is manufactured. In Computer
Numerically Controlled (CNC) Machining Centers set up time is
reduced significantly with the help of Automated Tool Changers,
Automatic Control of Machines from a Part Program loaded in the
machine computer

 Automation also reduces the overall product life cycle i.e.,
the time required to complete
 (i) Product conception and design
 (ii) Process planning and installation
 (iii) Various stages of the product life cycle

Types of Automation Systems
Permanent / Fixed Automation:
 This control system is designed to perform a
specific task
 Functions of control circuit is fixed and
permanent.
 It will be complicated if we want to do other
task apart from the existing task

Types of Automation Systems
Fixed Automation:
It is used in high volume production with dedicated
equipment, which has a fixed set of operation and
designed to be efficient for this set. Continuous flow
and Discrete Mass Production systems use this
automation. e.g. Distillation Process, Conveyors,
Paint Shops, Transfer lines etc.
A process using mechanized machinery to perform
fixed and repetitive operations in order to produce a
high volume of similar parts.

Programmable Automation:
 It is used for a changeable sequence of operation and
configuration of the machines using electronic controls.
However, non-trivial programming effort may be needed to
reprogram the machine or sequence of operations. Investment
on programmable equipment is less, as production process is
not changed frequently.
 It is typically used in Batch process where job variety is low
and product volume is medium to high, and sometimes in
mass production also. e.g. in Steel Rolling Mills, Paper Mills
etc.

Flexible Automation:
 It is used in Flexible Manufacturing Systems (FMS) which is
invariably computer controlled. Human operators give high-
level commands in the form of codes entered into computer
identifying product and its location in the sequence and the
lower level changes are done automatically. Each production
machine receives settings/instructions from computer. These
automatically loads/unloads required tools and carries out
their processing instructions.
 After processing, products are automatically transferred to
next machine. It is typically used in job shops and batch
processes where product varieties are high and job volumes
are medium to low. Such systems typically use Multi purpose
CNC machines, Automated Guided Vehicles (AGV) etc.13 August 2020 @RT 9

Integrated Automation:
 It denotes complete automation of a manufacturing plant,
with all processes functioning under computer control and
under coordination through digital information processing.
 It includes technologies such as computer-aided design and
manufacturing, computer-aided process planning, computer
numerical control machine tools, flexible machining
systems, automated storage and retrieval systems, automated
material handling systems such as robots and automated
cranes and conveyors, computerized scheduling and
production control
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 It may also integrate a business system through a
common database. In other words, it symbolizes full
integration of process and management operations
using information and communication technologies.
 Typical examples of such technologies are seen in
Advanced Process Automation Systems and Computer
Integrated Manufacturing (CIM)
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Comparison between fixed and
flexible automation system
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Hydraulics Applications:
Industrial:
Electrohydraulic is the mechanism used for controlling the
industrial applications of hydraulics. Precise and fast
response is an advantage of this. Plastic processing
machinery, steel making and primary metal extraction
applications, automated production lines, machine tool
industry, paper industries, loaders, crushers, presses, textile
industry machinery, etc. are some of the examples of
industrial hydraulics.
13 August 2020 @RT 13

Mobile Hydraulics:
 In mobile hydraulics, the hydraulic system is controlled
manually. Building and construction equipment like
cranes, excavators, backhoe, earth moving equipment,
etc., tractors, irrigation system, material handling
equipment, tunnel boring equipment, rail equipment, etc.
are some examples of mobile hydraulics.
13 August 2020 @RT 14

Marine Applications:
 Hydraulics plays an important role in maintaining the
stability and control of ships. Steering gears, bow and stern
thrusters, engine room maintenance systems including pumps
and jacks, deck machineries like cranes, winches, hatch
covers, mooring drums and others are examples of hydraulics
in the marine industry.
13 August 2020 @RT 15
Mining:
 Hydraulic fracturing is one of the advanced mining
technology used for extracting unused gases/oils beneath the
earth surface. In this approach, a high-pressure mixture of
water, sand and other chemical additives are passed into the
cracks.

Aerospace Applications:
 Airplanes, rockets, spaceships, etc.. use hydraulic systems
for various applications. Aerospace industry uses
hydraulics for adjusting wings, retraction and extension of
landing gears, opening/closing of doors, brakes, steering,
etc.
13 August 2020 @RT 16

Pneumatics Applications:
Automobile:
 Automobile industry use pneumatic systems for dismantling
vehicle tire, filling compressed air in the tire, vehicle
painting, opening and closing of doors, air brakes on heavy
vehicles, etc.
Transporting Goods:
 Pneumatics is used to transport goods from shelf to other
location inside the company. The cylinder will push the item
on the shelf into the moving belt if the button is pushed.
13 August 2020 @RT 17

Industrial Applications:
 Material handling, drilling, sawing, filling, packaging,
clamping, shifting, etc. are some of the general
applications of the pneumatic system.
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ADVANTAGES AND DISADVANTAGES
OF AUTOMATION CONTROL IN
INDUSTRY
The main advantages of automation are:
 Replacing human operators in tasks that involve hard physical work.
 Replacing humans in tasks done in dangerous environments (i.e. fire,
space, volcanoes, nuclear facilities, underwater, etc.)
 Performing tasks that are beyond human capabilities of size, weight,
speed, endurance, etc.
 Economy improvement: Automation may improve in economy of
enterprises, society or most of humanity. For example, when an enterprise
invests in automation, technology recovers its investment; or when a state
or country increases its income due to automation like Germany or Japan
in the 20th Century.
 Reduces operation time and work handling time significantly.
13 August 2020 @RT 19

ADVANTAGES AND DISADVANTAGES
OF AUTOMATION CONTROL IN
INDUSTRY
The main disadvantages of automation are:
 Unemployment rate increases due to machines replacing humans and
putting those humans out of their jobs.
 Technical Limitation: Current technology is unable to automate all the
desired tasks.
 Security Threats/Vulnerability: An automated system may have limited
level of intelligence, hence it is most likely susceptible to commit error.
 Unpredictable development costs: The research and development cost of
automating a process may exceed the cost saved by the automation itself.
 High initial cost: The automation of a new product or plant requires a
huge initial investment in comparison with the unit cost of the product,
although the cost of automation is spread in many product batches of
things13 August 2020 @RT 20

ADVANTAGES AND
DISADVANTAGES Advantages:
very flexible , free-format syntax.
Supported by every product.
It can express arithmetic operations as well
as operations to aggregate data and sort data for
output.
 Disadvantages:
It is not a general-purpose programming
language and thus the development of an
application requires the use of a SQL with a
programming language.

Introduction to Automation

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