2015 - MPAU - Lecture 2

Automation Systems of Manufacturing Processes, C2: Basic concepts
Basic concepts and main principles

in automation systems
© 2015 Quoc Chi Nguyen, Head of Control & Automation Laboratory, HCMUT, nqchi@hcmut.edu.vn 0-1
MANUFACTURING INDUSTRIES AND PRODUCTS

Manufacturing Industries
§ Primary industries: Agriculture, forestry, fishing, livestock, mining,
petroleum
§ Secondary: Aerospace, apparel, automotive, basic metal, beverage,
building materials, chemical, construction, consumer appliances,
electronics, equipment, fabricated metals, food processing, heavy
machinery, paper, petroleum refining, pharmaceuticals, plastics
§ Tertiary: Banking, communications, education, education, entertainment,
financial services, government, health and medical, hotel, information,
insurance, legal, real estate, repair, maintenance, restaurant, retail trade,
tourism, transportation, wholesale trade.
Processing and Assembly Operations

Manufacturing processes can be divided into two basic types:
(1) processing operations and (2) assembly operations.
• A processing operation transforms a work material from one state of
completion to a more advanced state that is closer to the final
desired part or product.
• An assembly operation joins two or more components to create a
new entity. which is called an assembly. subassembly, or some other
term that refers to the specific joining process.
Think pair share, what are the processing and

assembly operations?
Basic Elements of an Automated System

- Automation is the technology by which a process or procedure is
accomplished without human assistance.
- It is implemented using a program of instructions combined with a
control system that executes the instructions.
- To automate a process, power is required, both to drive the
process itself and to operate the program and control system.
Basic Elements of an Automated System
All systems that qualify as being automated

include these three basic elements in one form
or another
Power to Accomplish the Automated Process

Power for the process
• To drive the process itself
• To load and unload the work unit
• Transport between operation
Power for automation
• Controller unit
• Power to actuate the control signals
• Data acquisition and information processing
Electricity - The Principal Power Source

• Widely available at moderate cost
• Can be readily converted to alternative forms,
e.g., mechanical, thermal, light, etc.
• Low level power can be used for signal
transmission, data processing, and
communication
• Can be stored in long-life batteries
Program of Instructions
Set of commands that specify the sequence of steps in the
work cycle and the details of each step
• Example: CNC part program
• During each step, there are one or more activities
involving changes in one or more process parameters
§ Examples:
§ Temperature setting of a furnace
§ Axis position in a positioning system
§ Motor on or off
Decision-Making in a Programmed Work Cycle
The following are examples of automated work cycles in

which decision making is required:
• Operator interaction
§ Automated teller machine
• Different part or product styles processed by the system
§ Robot welding cycle for two-door vs. four door car models
• Variations in the starting work units
§ Additional machining pass for oversized sand casting
Features of a Work Cycle Program

§ Number of steps in the work cycle
§ Manual participation in the work cycle (e.g., loading and
unloading workparts)
§ Process parameters - how many must be controlled?
§ Operator interaction - does the operator enter processing
data?
§ Variations in part or product styles
§ Variations in starting work units - some adjustments in
process parameters may be required to compensate for
differences in starting units
(a) Feedback Control System and

(b) Open-Loop Control System
(a)
(b)
Brief history of control

Two of the early examples
Water clock (270 BC)
Self-leveling wine vessel (100BC)
© Prof. Bin Jiang & Dr. Ruiyun QI, Nanjing University of Aeronautics and Astronautics
Block diagram & transfer function

Block diagram: Every element of a control system receives
input signals from other elements and provide output signals.
Block diagram of a control system

n Disturbance
r e u y
Controller Actuator Plant
Controlled
Expected - Error variable
value
Sensor
Lead-out point:
Comparison component Here, the signal is
(comparison point) : transferred along two
its output equals the separate routes.
algebraic sum of all input The block represents
signals. the function and name of its
“+”: plus; “-”: minus corresponding mode, we don’t
need to draw detailed structure,
and the line guides for the transfer route.
Open-loop vs. closed-loop controls

- Open-Loop Control Systems utilize a controller or control actuator to
obtain the desired response.
- Closed-Loop Control Systems utilizes feedback to compare the actual

output to the desired output response.
Open-loop control systems
• Open-loop control systems: those systems in which the

output has no effect on the control action.
System Control System
input signal output
CONTROLLER PLANT
• The output is neither measured nor feedback for comparison

with the input.
• For each reference input, there corresponds a fixed operating
conditions; the accuracy of the system depends on calibration.
• In the presence of disturbances, an open-loop system will not
perform the desired task.
Examples of open-loop control systems

- Washing machine
- Speed control system of a motor

Some comments on open-loop control systems
– Simple construction and ease of maintenance
– Less expensive than a closed-loop system Good
– No stability problem
– Recalibration is necessary from time to time
Bad
– Sensitive to disturbances, so less accurate
When should we apply open-loop control?

– The relationship between the input and output is
exactly known.
– There are neither internal nor external
disturbances.
– Measuring the output precisely is very hard or
economically infeasible.
Closed-loop control systems

- Closed-loop control systems are often referred to as
feedback control systems.
- The idea of feedback: (i) Compare the actual output
with the expected value; (ii) Take actions based on the
difference (error).
- This seemingly simple idea is tremendously powerful.
- Feedback is a key idea in the discipline of control.
Control System
Expected Error
+ signal output
value CONTROLLER PLANT
-
Closed-loop control systems

• In practice, feedback control system and
closed-loop control system are used
interchangeably
• Closed-loop control always implies the use

of feedback control action in order to
reduce system error
Closed-loop control system: Flush toilet

Plant: water tank water q1( t )
Input: water flow piston
Output: water level h(t)
Expected value: h0 float lever
Sensor: float h0
Controller: lever
h(t)
Actuator: piston
Controller Actuator Plant

h0 q1 (t ) h(t ) threshold
Lever Piston Water
Tank q2( t )
Float
Open-loop vs. closed-loop

Open-loop control Closed-loop control
- Simple structure, low - Ability to correct error
cost - High accuracy and
- Easy to regulate resistance of disturbance
- Low accuracy and - Complex structure, high
resistance to cost
disturbance - Selecting parameter is
critical (may cause
stability problem)
Open-loop＋Closed-loop＝Composition control system

Satellite-tracking antennas
1-28
Positioning System Using Feedback Control

A one-axis position control system consisting of a leadscrew
driven by a dc servomotor and using an optical encoder as
the feedback sensor
When to Use an Open-Loop Control System
§ Actions performed by the control system are

simple
§ Actuating function is very reliable
§ Any reaction forces opposing the actuation are
small enough as to have no effect on the
actuation
§ If these conditions do not apply, then a closed-
loop control system should be used
Advanced Automation Functions

• Safety monitoring
• Maintenance and repair diagnostics
• Error detection and recovery
Safety Monitoring
Use of sensors to track the system's operation and
identify conditions that are unsafe or potentially unsafe
§ Reasons for safety monitoring
• To protect workers and equipment
§ Possible responses to hazards:
• Complete stoppage of the system
• Sounding an alarm
• Reducing operating speed of process
• Taking corrective action to recover from the safety
violation
Maintenance and Repair Diagnostics
§ Status monitoring
• Monitors and records status of key sensors and
parameters during system operation
§ Failure diagnostics
• Invoked when a malfunction occurs
• Purpose: analyze recorded values so the cause of the
malfunction can be identified
§ Recommendation of repair procedure
• Provides recommended procedure for the repair crew to
effect repairs
Error Detection and Recovery
• Error detection – functions:

§ Use the system’s available sensors to determine when a
deviation or malfunction has occurred
§ Correctly interpret the sensor signal
§ Classify the error
• Error recovery – possible strategies:
§ Make adjustments at end of work cycle
§ Make adjustments during current work cycle
§ Stop the process to invoke corrective action
§ Stop the process and call for help
Levels of Automation
• Device level – actuators, sensors, and other hardware
components to form individual control loops for the next
level
• Machine level – CNC machine tools and similar production
equipment, industrial robots, material handling equipment
• Cell or system level – manufacturing cell or system
• Plant level – factory or production systems level
• Enterprise level – corporate information system
Levels of Automation

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Automation Systems of Manufacturing Processes, C2: Basic concepts

Basic concepts and main principles

MANUFACTURING INDUSTRIES AND PRODUCTS

Processing and Assembly Operations

Think pair share, what are the processing and

Basic Elements of an Automated System

Basic Elements of an Automated System

All systems that qualify as being automated

Power to Accomplish the Automated Process

Electricity - The Principal Power Source

Decision-Making in a Programmed Work Cycle

The following are examples of automated work cycles in

Features of a Work Cycle Program

(a) Feedback Control System and

Brief history of control

Block diagram & transfer function

Block diagram of a control system

Open-loop vs. closed-loop controls

- Closed-Loop Control Systems utilizes feedback to compare the actual

Open-loop control systems

• Open-loop control systems: those systems in which the

• The output is neither measured nor feedback for comparison

Examples of open-loop control systems

- Speed control system of a motor

Open-loop control systems

Open-loop control systems

When should we apply open-loop control?

Closed-loop control systems

Closed-loop control systems

• Closed-loop control always implies the use

Closed-loop control system: Flush toilet

Controller Actuator Plant

Open-loop vs. closed-loop

Open-loop＋Closed-loop＝Composition control system

Positioning System Using Feedback Control

When to Use an Open-Loop Control System

§ Actions performed by the control system are

Advanced Automation Functions

Maintenance and Repair Diagnostics

Error Detection and Recovery

• Error detection – functions:

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