Industrial Automation

1. Industrial Automation T Rajendran

2. Industrial Automation Control Systems Process Control Industrial Control Computer Integrated Manufacturing Systems Modeling Systems Engineering Real Time Programming Software tools

3. Expectation of Automation High Reliability Fast Trouble shooting Simple Operation Easily Configurable High Accuracy Optimization functions and processing of operating data Flexibility

4. Process Controls PC Integrated Control & Management systems IS MIS 1980… 1970-80 1960-70

5. History • Pioneering period – 60 – Electronic devices • Direct Digital control • Microcomputer • Computer controlled Process plants • Centralized • Distributed • Process Models • Advanced Control (AI)

6. Process Controls

7. Basic principles of controller loop Memory - Set Point Comparator for set point (measured value MV) as reported by transmitter Deviation = error Amplifier – amplifies the control deviations – output of the controller

8. Process Control Open Loop Control Closed Loop control

9. Process Control Two position control Multi position control PID Proportional control (proportional, integral or derivative) Ratio control Cascade control

10. Controller Operation Set point Control element sensor error controller Control signal process - Measured value Auto/manual

11. Position control High set point Low set point

12. Control actions Control value No control Proportional only Set point PI PID Time

13. Instrumentation

14. Instrumentation Pressure Flow liquid level Temperature Pneumatic and control valves

15. Transducers Sensors high / low limits of measurand

16. Transducers To measure / sense to convert measured value to a useful output

17. Transducers • Measurement • Type of measurand • Number of measurements • Sensing measurement • Transduction element • Range of measurement • Conversion • Specific format • Amplified • Conversion of AC to DC

18. Transducers Conventional Silicon Fiber Optic

19. Transducers Conventional Silicon Fiber Optic Displacement / motion transducers Temperature Transducers Pressure Transducers Liquid level Transducers Liquid Flow

20. Intelligent Sensors On-chip signal processing MEMS (Micro Electro Mechanical Systems) sensors BIOSENSORS NANOSENSORS

21. NANOSENSORS & future trends 1 nm = 1 millionth of a mm

22. Building Blocks in Automation

23. Building blocks The Processor Analog & Digital I/O modules interrupts, Timers/counters Display controls SCADA (Supervisory control and data acquisition systems)

24. Processing System • The use of Microprocessors (calculator chips & Mini computers) • Architecture • Input, Memory, Output, MicrpP Address bus, Data bus, control bus • 8 , 16, 32, 64 bits • Microprocessors & microcontrollers

25. Analog & Digital I/O modules Control outputs Analog inputs Display outputs Digital inputs Timer / counter inputs Interrupt inputs Basic signals

26. Analog & Digital I/O modules Control outputs Analog inputs Display outputs Digital inputs Timer / counter inputs Interrupt inputs Basic signals

27. Inside look of a real time sysytem Display outputs Analog inputs Analog input module Control outputs Processor & memory module Interrupt controller Digital inputs Timer / counter Timer / counter inputs Interrupt inputs

28. I/O modules • Analog input • From Sensors • Measurand like flow, position, temperature … • Signal may be amplified, filtered or/and isolated • Digital input • Refer to ON-OFF status of valves, linit switches.. (1 bit )

29. I/O modules • Interrupt input • Draw attention of real time system towards abnormal situations • Attends to interrupt and resumes normal work • Timer / Counter • Clock input or Gate input to enable/ disable timer/counters • Output of timer/counter can be used as interrupts

30. I/O signals • Display output signals • LED, LCD, VDU, alarms • Status of process, limits sets • May control or operator assisted • Control output signal • Required to drive the control valves, motors etc • May be simple ON/OFF or fine control of motor speed, position, displacement, flow.. • Analog signals / digital actuators

31. Analog input The module continuously scans the analog input signals in the pre defined order and frequency Amplifies -> converts to digital -> processor and memory module for processing EPROM or switches Local intelligence

32. Digital Input Directly accepted by processor N bits in parallel Local intelligence

33. Analog Output • Digital multiplexer • Digital to Analog converter • Master processor executes two I/O instructions • Write Data byte/word in digital output port • Write address byte/word in address port

34. Interrupt control Interface between no. of interrupting devices and master processor Priorities allocation- static or dynamic.

35. Timer / Counter Number of timers and counters which may be cascaded or used independently Count in the form of data byte/word Clock from the processor or external

36. Display Control module Manual entry sub module CRT controller sub module LED / LCD control sub module Alarm annunciator sub module Printer controller sub module

37. SCADA • Supervisory Control And Data Acquisition Systems • Channel scanning • Conversion into engineering units • Data processing

39. CAD / CAM / CIM

40. CIM cad Robots fe simulation CNC fms MeM ERP Schedudle cim drafting Shop floor data Prodplan Process planning Tool design

41. CAD / CAM / CIM CIM, Concurrent Engineering Product Life Cycle Management Engineering Modeling CIM databases Computer aided process planning IT & ERP Manufacturing automation – PLC, CNC, Robots

42. CAD/CAM/CIM Flexible Manufacturing Shop Floor Data Collection Simulation

43. Concurrent Engineering • DESIGN software • Solid Modeling • Assembly modeling • Sheet metal design • Drafting • Tolerance analysis • Mechanism Design • Mould Design • Thermal Analysis • Piping Design • Optimization • Tool Design

44. Concurrent Engineering Process Planning ERP Shop Floor Data Collection PLM EDM

45. Concurrent Engineering • Visualization / Simulation • Factory simulation • Rapid prototyping • Plastic injection moulding • Forming • Forging • Casting