Industrial Automation Slides, DR Khalil All Lectures Optimized 1

Automation Comparison
Automation When to consider Advantages Disadvantages

Fixed - High demand - Maximum - Large initial
volume, efficiency investment
- Long product life - Low unit cost - Inflexibility
cycles
Programmable - Batch - Flexibility to deal -New products
production, with changes in requires long setup
- Product with product. time.
different options. - Low unit cost for - High unit cost
large batches. relative to fixed
automation.
Flexible - Low production - Flexibility to deal - Large initial
rates. with designs investment .
- Varying demand. variations. - High unit cost or
- Short product life - Customized programmable
cycles. products. automation.
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 40
Product Variety and Production
Quantity for Three Automation Types
Fig. 1.5
Elements of an Automated System
Basic Elements of An Automated System
1) Power to accomplish the automated process
2) Program Instruction
3) Control System
1) Power to accomplish the automated process
• An automated system is used to operate some process and power
is required to drive the process as well as the controls.
• The principal source of power is electricity:
❑ Available at moderate cost.
❑ Can be readily converted to alternative energy forms (mechanical,
thermal, light, acoustic, hydraulic and pneumatic).
❑ Low level power can be used to accomplish functions such as signal
transmission, information processing and data storage and
communication.
❑ Can be stored in long-life batteries for use in remote locations
a) Power for the Process
 The term ‘process’ refers to the manufacturing operation that is
performed on work unit as follows:
 Material handling functions:
→Loading and unloading the work unit
→Material transport between operations
Manufacturing process and their power requirements

b) Power for Automation
• Controller unit:→Need electrical power to read the program

of instructions, calculations and execute the instructions by
transmitting the proper commands to actuating devices.
• Power to actuate the control signals:→Controller sent the

commands by means of low-voltage control signal to provide
the proper power level for actuating device (motor).
• Data acquisition and information processing:→ Keeping the

records of process performance or product quality.
2) Program of instructions
The action performed by an automated process are defined by a program of
instructions. Whether the manufacturing operation involves low, medium or high
production, each part require one or more processing steps performed during the
work cycle.
Program is a set of commands that specify the sequence of steps in the work
cycle and the details of each step. The set point is the value of the process
parameter or desired value of the controlled variable in the process.
❑ Work cycle programs
• The simplest automated processes, the work cycle consists of 1 step (set
point control). The more complicated systems consist of multiple steps.
• The process parameter changes in each step. A process parameter is an input
to the process, whereas a process variable is the corresponding output of the
process.
❑ Decision making in the Programmed Work Cycle
• Each work cycle consists of the same steps and associated process changes
with no variation from one cycle to the next.
• →Operator interaction →Different part or product styles are processed by the
system → Variations in the starting work unit.
Work Cycle programs
▪ In the simplest automated processes, the work cycle consists of essentially one
step, which is to maintain a single process parameter at a defined level. It is
assumed that loading and unloading of the work units into and from the furnace
is performed manually and is therefore not part of the automatic cycle.
▪ Process parameter : is an input to the process, such as the temperature dial
setting.
▪ Process variable: is the corresponding output of the process, which is the actual
temperature of the furnace
▪ During each step, there are one or more activities involving changes in one or
more process parameters
▪ Examples of process parameters include: desired coordinate axis value in a
positioning system, valve open or closed in a fluid flow system, and motor on
or off.
▪ Examples of corresponding process variables include the actual position of the
coordinate axis, flow rate of fluid in the pipe, and rotational speed of the
motor. 47
Five Categories Of Work
Cycle Programs
▪ Set-point control, in which the process parameter value is constant during the work
cycle (as in the furnace example).
▪ Logic control, in which the process parameter value depends on the values of other
variables in the process.
▪ Sequence control, in which the value of the process parameter changes as a function of
time. The process parameter values can be either discrete (a sequence of step values) or
continuously variable.
▪ Interactive program, in which interaction occurs between a human operator and the
control system during the work cycle.
▪ Intelligent program, in which the control system exhibits aspects of human intelligence
(e.g., logic, decision making, cognition, learning) as a result of the work cycle program.
▪ A work cycle consisting of multiple steps that are repeated with no deviation from one
cycle to the next. Most discrete part manufacturing operations are in this category. A
typical sequence of steps (simplified) is the following: (1) load the part into the
production machine, (2) perform the process, and (3) unload the part. During each step,
there are one or more activities that involve changes in one or more process parameters.
48
Example 4.1 An Automated
Turning Operation
Consider an automated turning operation that generates a cone-shaped product The system
is automated and a robot loads and unloads the work units. The work cycle consists of the
following steps: (1) load starting workpiece, (2) position cutting tool prior to turning, (3)
turn, (4) reposition tool to a safe location at end of turning, and (5) unload finished
workpiece. Identify the activities and process parameters for each step of the operation.
Solution:
step # Activities Process parameters
(1) Robot reaching, lifting and positioning the raw work axis values, gripper value (open or closed),
manipulator part, then retreating to safe position. chuck jaw value (open or closed).
(2) cutting tool movement to a “ready” position. x- and z-axis position of the tool.
(3) turning workpiece rotation, cutting tool feed & speed (rev/min), (mm/rev), radial distance
operation position, cut the conical shape, finishing (changed continuously at a constant rate
operation (multiple turning passes). /revolution) For a consistent finish on the
surface, the rotational speed must be
continuously adjusted to maintain a constant
surface speed (m/min)
4 are the reverse of steps (2) and (1), respectively process parameters are the same.
5
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 49/20
Decision-Making in a
Programmed Work Cycle
▪ The two features of the work cycle were:
(1) The number and sequence of processing steps and
(2) The process parameter changes in each step.
▪ The following are examples of automated work cycles in which
decision making is required:
▪ Operator interaction (input data)
▪ 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
The following summarizes the features of work cycle programs (part programs)
used to direct the operations of an automated system:
1. Number of steps in the work cycle: A general sequence in discrete
production operations is (1) load, (2), process, (3) unload, but the process
may include multiple steps.
2. Manual participation in the work cycle (e.g., loading and unloading
workparts)
3. Process parameters - How many process parameters must be controlled
during each step? Are the process parameters continuous or discrete? Do
they change during the step?
4. Operator interaction - does the operator enter processing data?
5. Variations in part or product styles
6. Variations in starting work units - some adjustments in process
parameters may be required to compensate for differences in starting units
51
Control System – Two Types
▪ The control system causes the process to accomplish its defined
function, which is to perform some manufacturing operation.
▪ The control element of the automated system executes the program
of instructions.
1. Closed-loop (feedback) control system – a system in which the
output variable is compared with an input parameter, and any
difference between the two is used to drive the output into
agreement with the input
2. Open-loop control system – operates without the feedback loop, so
no comparison is made between the actual value of the output and the
desired input parameter.
▪ Simpler and less expensive
▪ Risk that the actuator will not have the intended effect
Closed-loop (Feedback)
Control System
1. The input parameter (i.e., set point) represents the desired value of the output.
2. The process is the operation or function being controlled.
3. The output variable (process variable) that is being controlled in the loop, perhaps a critical performance
measure in the process, such as temperature or force or flow rate.
4. A sensor is used to measure the output variable and close the loop between input and output. Sensors perform
the feedback function in a closed-loop control system.
5. The controller compares the output with the input and makes the required adjustment in the process to reduce
the difference between them.
6. The adjustment is accomplished using one or more actuators, which are the hardware devices that physically
carry out the control actions, such as electric motors or flow valves.
Figure 4.3 shows only one loop. Most industrial processes require multiple
loops, one for each process variable that must be controlled 53/75
Open-Loop Control System
▪ In this case, the controls operate without measuring the
output variable.
▪ The controller relies on an accurate model of the effect of
its actuator on the process variable.
▪ With an open-loop system, there is always the risk that the
actuator will not have the intended effect on the process,
and that is the disadvantage of an open-loop system. Its
advantage is that it is generally simpler and less expensive
than a closed-loop system.
Positioning System Using
Feedback Control
A one-axis position control system consisting of a leadscrew driven by
a servomotor and using an optical encoder as the feedback sensor.
For the open-loop case, the diagram for the positioning system would be similar to the preceding, except
that no feedback loop is present and a stepper motor would be used in place of the dc servomotor. A
stepper motor is designed to rotate a precise fraction of a turn for each pulse received from the controller.
Since the motor shaft is connected to the leadscrew, and the leadscrew drives the worktable, each pulse
converts into a small constant linear movement of the table. To move the table a desired distance, the
number of pulses corresponding to that distance is sent to the motor. Given the proper application, whose
characteristics match the preceding list of operating conditions, an open-loop positioning system works
with high reliability.
When to Use an
Open-Loop Control System
Open-loop systems are usually appropriate when the following

conditions apply:
▪ 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
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
Advanced Automated Function
Safety monitoring
• An automated system is often installed to perform a potentially dangerous
operation that would otherwise be accomplished manually by human
workers.
• To protect human workers in the vicinity of the system
• To protect the equipment associated with the system
Example: Emergency stop buttons, Limit switches, photoelectric sensors,

temperature sensors, heat or smoke detectors, pressure-sensitive floor pads
and machine vision systems.
Maintenance and repair diagnostics
• Status monitoring: To monitor and record the status of key sensors and
parameter of the system during normal operation.
• Failure diagnostics: The failure diagnostics mode is invoked when a
malfunction or failure occurs.
• Recommendation of repair procedure: The subsystem provides a
recommendation procedure to the repair crew as to the steps that should be
taken to effects repairs.
Error Detection
❑ Error detection – in analyzing a given production operation, the possible errors can be
classified into one of three general categories:
1. Random errors, occur when the process is in statistical control. Large variations in part
dimensions, even when the production process is in statistical control, can cause problems
in downstream operations.
2. Systematic errors, are those that result from some assignable cause such as a change in raw
material or drift in an equipment setting.
3. Aberrations errors that results from either an equipment failure or a human mistake
❑ Functions:
▪ Use the system’s available sensors to determine when a deviation or malfunction has
occurred
▪ Correctly interpret the sensor signal
▪ Classify the error
❑ The two main design problems in error detection are (1) anticipating all of the possible
errors that can occur in a given process, and (2) specifying the appropriate sensor systems
and associated interpretive software so that the system is capable of recognizing each error
Error Recovery
❑ Error recovery – is concerned with applying the
necessary corrective action to overcome the error
and bring the system back to normal operation.
▪ 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
Reasons for Automating
Companies undertake projects in automation and computer-integrated
manufacturing for good reasons, some of which are the following:
1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating
Reason for Automated and Not Automated
REASON FOR AUTOMATED
• Improved product quality: Automation performs the manufacturing
process with greater uniformity and conformity to quality
specifications. Reduction of fraction defect rate is one of the chief
benefits of automation.
• To accomplish processes that cannot be done manually: Certain
operation cannot be accomplished without the aid of a machine.
These processes have requirements for precision, miniaturization or
complexity of geometry that cannot be achieved manually. Example:
manufacturing process based on CAD models and rapid prototyping.
• Increased labor productivity:

✓ Value of output per person per hour increases-automating a
manufacturing operation usually increases production rate and
labor productivity.
• Reduce labor cost:
✓ Higher investment in automation has become economically
justifiable to replace manual operation. Machines are increasingly
being substituted for human labor to reduce unit product cost.
• To reduce or eliminate routine manual and clerical tasks:

✓ An argument can be put forth that there is social value in automating
operations that routine, boring, fatiguing and possibly irksome.
Automating such tasks serves a purpose of improving the general
level of working conditions.
• Lower costs: Reduce scrap, lower in-process inventory, superior
quality, shorter lines.
• Reducing manufacturing lead time and reduces work-in-
progress: Respond quickly to the customers’ needs and rapid
response to changes in design.
• Improve worker safety: By automating a given operation and
transferring the worker from activate participation in the process to a
supervisory role, the work is made safer.
• To avoid the high cost of not automating:
• The advantage of automating cannot easily be demonstrated on a
company’s authorized from. The benefits of automation often show
up in unexpected and intangible ways, such as improved quality,
higher sales, better labor relationship and better company image.
• Companies that do not automate are likely to find themselves at a
competitive disadvantage with their customers, their employees
and the general public.
• Competition: Lower prices, better product, better image, better labor
relation.
• New process technologies require automation: Example; Robot
controlled thermal spray torch for coating engine blocks with steel
with atomized steel particles.
• Potential for mass customization and reduced inventory.
• High cost of raw materials
Reason for not automated
• Labor resistance
• Cost of upgraded labor :
Example : Chrysler Detroit plant spend 1 million hours of
retraining
• Initial investment
• Management of process improvement
• Intellectual assets versus technological assets
• Appropriate use of technology
• A system approach to automation is important
• Equipment incompatibilities
Automation Principles and Strategies
1. The USA Principle

2. Ten Strategies for Automation and Process
Improvement
3. Automation Migration Strategy
U.S.A Principle
1. Understand the existing process:
▪ Input/output analysis: What are the inputs? What are the outputs? What
exactly happens to the work unit between input and output? What is the
function of the process?
▪ Value chain analysis: How does it add value to the product? What are the
upstream and downstream operations in the production sequence, and can
they be combined with the process under consideration?
▪ Charting techniques(such as the operation chart and the flow process
chart) and mathematical modeling
2. Simplify the process: Reduce unnecessary steps and moves
3. Automate the process:
▪ Ten strategies for automation and production systems
▪ Automation migration strategy
Ten Strategies for Automation and
Process Improvement
If automation seems a feasible solution to improving productivity, quality, or other
measure of performance, then the following ten strategies provide a road map to
search for these improvements
1. Specialization of operations: use of special-purpose equipment
2. Combined operations: performing more than one operation at a given machine,
thereby reducing the number of separate machines needed.
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing
Automation Migration Strategy
For Introduction of New Products
1. Phase 1 – Manual production
▪ Single-station manned cells working independently
▪ Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
▪ Single-station automated cells operating independently
▪ As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
▪ Multi-station system with serial operations and
automated transfer of work units between stations
Automation
Migration
Strategy
Levels of Automation
Enterprise level
Plant level
Cell or system level
Machine level
Device level
1) Device
• The lowest level and it includes the actuators, sensors and other hardware
components that comprise machine level.
• The devices are combined into the individual control loops of the machine.
Example: the feedback control loop for one axis of a CNC machine.
2) Machine
• Hardware at the device level is assembled into individual machines.
Example: CNC machine tools and similar production equipment, industrial
robot and AGV.
• Control function at this level includes performing the sequence of steps in
the program of instructions in correct order and making sure that each step
is properly executed.
3) Cell or system
• Manufacturing cell or system level, this cell operates under instructions
from the plant level. It is a group of machines or workstations connected
and supported by a material handling system, computers, and other
equipment appropriate to the manufacturing process.
4) Plant level
• This is the factory or production systems level. It received
instructions from the corporate information system and
translates them into operational plans for production.
• The functions include: order processing, process planning,
inventory control, purchasing, material requirement planning,
shop floor control and quality control.
5) Enterprise level
• This is the highest level, consisting of the corporate information
system. It concerned with all of the function necessary to
manage the company: marketing and sales, accounting, design,
research, aggregate planning and master production scheduling.
Levels of Automation
Fig. 4.6
Introduction to Automation Technology
▪ A beverages plant plan to mass produce orange flavor

drink for 4 different brands. All 4 brands using the
same aluminium can size but different in printing label
on the can. In your opinion what types of automated
manufacturing system is most suitable to produce
10,000 can/day and each brand is different in quantity?
▪ Identify the situations in which manual labor is
preferred over automation?
Ch 5 Industrial Control
Systems
Sections:
1. Industrial Automation vs.
Industrial Information Technology
2. Process Industries vs. Discrete
Manufacturing Industries
3. Continuous vs. Discrete Control
4. Computer Process Control
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Automation Systems vs.
Control Systems
▪ It is important at this stage to understand some of the differences
in the senses that these two terms are generally interpreted in
technical contexts and specifically in this course. These are
given below.
1. Automation Systems may include Control Systems but the
reverse is not true. Control Systems may be parts of
Automation Systems.
2. The main function of control systems is to ensure that outputs
follow the set points. However, Automation Systems may have
much more functionality, such as computing set points for
control systems, monitoring system performance, plant
startup or shutdown, job and equipment scheduling etc.
▪ Automation Systems are essential for most modern industries.
Industrial Automation vs.
Industrial Information Technology
▪ Industrial Automation makes extensive use of Information Technology. Some of the major IT
areas that are used in the context of Industrial Automation are:
1. Control and Signal Processing
2. Simulation, Design, Analysis, Optimization
3. Communication and Networking
4. Real-time Computing
5. Database
▪ However, Industrial Automation is distinct from IT in the following senses:
➢ Industrial Automation also involves significant amount of hardware technologies, related to
Instrumentation and Sensing, Actuation and Drives, Electronics for Signal Conditioning,
Communication and Display, Embedded as well as Stand-alone Computing Systems etc.
➢ As Industrial Automation systems grow more sophisticated in terms of the knowledge and
algorithms they use, as they encompass larger areas of operation comprising several units or
the whole of a factory, or even several of them, and as they integrate manufacturing with other
areas of business, such as, sales and customer care, finance and the entire supply chain of the
business, the usage of IT increases dramatically. However, the lower level Automation
Systems that only deal with individual or , at best, a group of machines, make less use of IT
and more of hardware, electronics and embedded computing.

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Automation Comparison

Automation When to consider Advantages Disadvantages

Manufacturing process and their power requirements

• Controller unit:→Need electrical power to read the program

• Power to actuate the control signals:→Controller sent the

• Data acquisition and information processing:→ Keeping the

Open-loop systems are usually appropriate when the following

Example: Emergency stop buttons, Limit switches, photoelectric sensors,

• Increased labor productivity:

• To reduce or eliminate routine manual and clerical tasks:

1. The USA Principle

Cell or system level

▪ A beverages plant plan to mass produce orange flavor

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