Professional Documents
Culture Documents
Manufacturing Automation Lecture 2
Manufacturing Automation Lecture 2
2 Credits – 2 Lectures
Lecture 2
• What is Automation?
• Automation:
• Use of Control Systems to
reduce Human Intervention
• A Step beyond Mechanization
(Pure Mechanical Systems)
• Key Ingredients:
– Sensors
– Controller
– Actuator
• Applications:
– Production Plants, Manipulation, Manufacturing parts
(Textile, Petroleum, Paper & Automotive
Industries )
Introduction to Manufacturing Automation
• Applications of Manipulators:
– Mainly used for Pick & Drop Applications in Production lines
– Painting, Welding in Automotive Industry
Types of Automation
• Fixed Automation:
• Production facility where the sequence of operations is fixed
by process configuration
– Examples:
• Production Plants (Paper etc), Automotive Industry with fixed
equipment
– Features:
• High Initial Investment
• High Production Rates
• Relative Inflexibility
Types of Automation
• Programmable Automation:
• The production equipment is made to change the sequence
of operations
• The sequence of operation is generally modified by a
program
– Examples:
• Automation using Numerically Controlled Machine Tools,
Industrial Robots & PLC’s
– Features:
• High Initial Investment
• Flexibility to deal with Variation & Changes in Production
• Low Production rate then Fixed Automation
• Loss of time during change over
Types of Automation
• Flexible Automation:
• An Extension of Programmable Automation
• Virtually no loss in time during change over (Tools, Machine
settings)
• Difference between parts is not significant
– Examples:
• Automotive production using Flexible Manufacturing
systems
– Features:
• High Initial Investment
• Flexibility to deal with Variation & Changes in Production
• Medium Production rate
• Continuous Production of Mixtures of Products
• Minimal Loss of time during change over
Classification of Industries
Industries
Amount Quantity
Process Variables
Typical Sensors:
– Thermocouples, RTD (resistance temperature detectors), Flow meters,
Pressure sensors
Typical Actuators:
– Valves, Heaters
Discrete Variables
• Definition:
– Can take up a finite set of values within a range
– Further distinguished as Discrete Binary Variables
Typical Sensors:
– Limit Switches, Proximity Sensors
Typical Actuators:
– Switches, Motors, Solenoid Valves
Example:
– Counting Parts moving on a conveyer
Basic Analog Control Loop
Process
Sensors
Actuator
Comparator Set Point
Continuous Control:
– A control sequence characterized by analog inputs & outputs
– Examples:
Feed forward Control
Feed back Control
Discrete Control
Discrete Control
– Examples:
• Operation of a time driven agitator in mixing liquids
• Heating for a specific period of time
Requirements of Control Systems
• Basic Requirements:
– Deal with Discrete & Continuous Control.
– Real time controller capable of responding to changing inputs
from the process
– Multi tasking
• Deals with Multiple task concurrently
– Provides tools for Event & Time driven control.
– Dealing with System initiated events
• Communication with Peripherals and other Elements on the Network.
– Dealing with Operator Based Events
• Changing Existing Logic
• Emergency Stoppage of Control Process
Capabilities of Control Systems
• Polling:
– Sampling of Process variables.
– Important Characteristics:
• Polling Frequency Time rate at which all the variables of the process
are sampled (variable or fixed frequency)
Interlocks:
– Safe guarding Mechanisms to coordinate activities of different
devices
– All controllers should be capable of providing interlock capabilities
– Classified as Input & Output Interlocks
– Examples:
Pump and Valve connected in a pipe (should have interlocks).
Robot putting work piece in CNC should provide interlocks
Capabilities of Control Systems
• Interrupts:
– Certain conditions where controller should interrupt regular control
program to deal with other important matters
– Suspension of current program to deal with other matters
– Types of Interrupts:
• Internal Polling of sensor data or Sending Commands to process.
• External Process Initiated interrupts or Operator inputs
– Level Or Edge Triggered Process Interrupts
– Controllers should provide tools to effectively deal with sudden interrupts.
– An interrupt is a program with highest priority
– All programs are assigned priorities based on which decisions are taken.
Capabilities of Control Systems
Controllers
Differences?
Priority Assignment
1 Operator Inputs
2 System & Program Interrupts
3 Timer Interrupts
4 Process Interrupts
5 Emergency Stop
Capabilities of Control Systems
• Exception Handling:
– An event outside the norms of process control.
– Dealing with exceptions is essential in Industrial Process Control.
– Termed as a process of Error Detection & Recovery.
• Error Detection:
– Random Errors Due to stochastic nature of process
(difference in raw materials for process)
– Systematic Errors can be assigned reason’s (such as
drift in Equipment settings)
– Aberrations Due to equipment failure
– Examples:
• Controller Failure
• Process Variables outside normal range
Process Description Tools
Process Description Tools
Process Description Tools
Start Block
Operation Block
Decision Block
Data Block
Flow Charts
No
S2=1
Yes
No
S3=1
Yes
Valve= ‘ON’
Flow Charts
• A Tank which starts filling (Inlet Valve) when the start button is
pressed and flows out (Outlet valve) when either stop button is
pressed or the level (binary) switch specifies the tank as full
Start
Yes No Yes
Stop=1 Start=1
No
State Diagrams
• Another Effective method to represent Process flow Conditions &
Control.
• Example:
– State diagram for light switch?
On_Push Button
Light Off Light On
Off_Push Button
State Diagrams
• State Diagram of a Vending Machine
Coins Returned
Make Coffee User’s Choice
Push Button
Pressed
State Diagrams
• A Tank which starts filling (Inlet Valve) when the start button is
pressed and flows out (Outlet valve) when either stop button is
pressed or the level (binary) switch specifies the tank as full
Stop or Full
Flow In Flow Out
Start
Sequence Bits
• Quite commonly used and represents the scenario as a sequence of
steps
• Example:
– Consider a tank with level switches which trigger at 20% and 80% of
tanks capacity, when level goes below 20% inlet valves opens and at 80%
outlet valve opens
• Sequence Bits:
– When Level < 20% inlet valve opens
– When Level >80% outlet valve opens
Sequence Bits
• A Tank which starts filling (Inlet Valve) when the start button is
pressed and flows out (Outlet valve) when either stop button is
pressed or the level (binary) switch specifies the tank as full
• Sequence Bits:
•When start button is pressed inlet valve opens
•When tank is full or stop button is pressed outlet valve
opens