INDUSTRIAL CONTROL TECHNOLOGY

DR SOPHAN WAHYUDI NAWAWI

Control and intrumentation engineering department
faculty of electrical engineering
utm

1
LECTURE 1:
FUNDAMENTAL CONCEPT IN
MANUFACTURING AND AUTOMATION

■ Definition
D fi iti off automation,
t ti reasons ffor
automating;
■ production operations and automation
strategies.
■ Building blocks of automation: sensors,
analysers, actuators and drivers.

2
 TYPES OF PRODUCTION
1. Continous-flow processes
■ Dedicated production of large amounts of
bulk pproducts e.g.
g chemical p
plants,, oil
refineries
■ It is the manufacture of a product through a
series of interconnected operations where
material moves from one stage to another
without interruption

3
TYPES OF PRODUCTION (cont
(cont’))

2. Mass production of discrete products

■ Dedicated production of large quantities
of one product (with perhaps limited
model variations) e.g. automobiles,
engine blocks
■ Here goods are produced in large
quantities
titi using
i St
Standardisation,
d di ti product
d t
wise layout and balanced production
 TYPES OF PRODUCTION (cont
(cont’))
3. Batch production
■ Production of medium sizes of the same product
or component
■ The lots may be produced once or repeated
periodically e.g. books,clothing

4. Job shop production

■ Production of low quantities, often one of a kind,
of specialized products
■ The
Th products
d t are often
ft customized
t i d and d
technologically complex e.g prototypes, aircraft,
machine tools
5
 AUTOMATION

“…technology in which a process or

procedure is accomplished by means
of programmed instruction….”
 DEFINITION OF AUTOMATION

■ A technology concerned with the application of

mechanical, electronic and computer-based
systems to operate and control production

■ The use of computers to control a particular

process in order to increase reliability and
efficiency,
e c e cy, often
o e through
oug the e replacement
ep ace e o of
employees. For a manufacturer, this could entail
using robotic assembly lines to manufacture a
product.
DEFINITION OF AUTOMATION (cont’)
■ The replacement of manual operations by computerized
methods.
h d Offi
Office automation
i refers
f to integrating
i i clerical
l i l
tasks such as typing, filing and appointment scheduling.
Factory automation refers to computer-driven assembly
lines
■ Examples:
- Automatic machine tools to process parts
- Automatic assembly machines
- Industrial robots
- Automatic material handling and storage systems
- Automated inspection systems for quality control
- Feedback control and computer process control
A hundred years ago,
the concept of the
future lacked one
major ingredient...
the computer! (Image
courtesy of
Rosemont
Engineering)

A Vision of
Automation
Artist Unknown, Circa
1895
 AUTOMATION CLASSIFICATIONS

AUTOMATION PRODUCTION SYSTEMS

FIXED PROGRAMMABLE FLEXIBLE

AUTOMATION AUTOMATION AUTOMATION
-custom-engineered, -equipment designed to -designed to
special-purpose accommodate a specific class manufacture a variety
equipment to of product changes of products or parts
automate a fixed -batch
batch production
production, medium -low
low production rates,
rates
sequence of volume varying product design
operations and demand
-High production
rates,
t iinflexible
fl ibl
product design
 FIXED AUTOMATION
“..the sequence of processing or assembly operations is fixed
by the equipment configuration and cannot be readily
changed without altering the equipment..”

Typical features :
■ High initial investment for custom-engineered equipment
■ High
Hi h production
d ti ratest
■ Application to products in which high quantities are to be
produced
p
■ Relative inflexibility in accommodating product changes
 PROGRAMMABLE AUTOMATION
“..the equipment is designed in such a way that the sequence of
production operations is controlled by a program i.e a set of coded
i t ti
instructions th
thatt can be
b read
d and
d iinterpreted
t t dbby th
the system..”
t ”

- The operation sequence can be readily changed to permit different

product configurations to be produced on the same equipment
equipment.
Typical features
■ High
g investment in g general-purpose
p p p
programmable
g equipment
q p
■ Lower production rates compared to fixed automation
■ Flexibility to deal with changes in product configuration
■ Suited to low and/or medium production of similar products or parts e.g. part
families
Examples
■ Numerically controlled (NC) machine tools
■ Industrial robots
■ Programmable logic controllers (PLC)
 FLEXIBLE AUTOMATION
“….Flexible automation is an extension of
programmable bl automation.
t ti The
Th disadvantage
di d t with
ith
programmable automation is the time required to
reprogram and change over the production
equipment for each batch of new product. This is
lost p
production time,, which is expensive.
p In flexible
automation, the variety of products is sufficiently
limited so that the changeover of the equipment
can be
b ddone very quickly…”
i kl ”
 ATTRIBUTES AND ADVANTAGES

When to
Automation consider Advantages Disadvantages

High demand volume, ■Maximum efficiency ■Large initial

long product life cycle ■Low unit cost investment
Fixed ■inflexibility

Batch production, ■Flexibility to deal with ■New product requires

product with different changes in product long set time
Programmable options ■Low unit cost for large ■High unit cost relative
batches to foxed automation
Low production rates, ■Flexibility to deal with ■Large initial
varying demand, short design variations investment
Flexible product cycles ■Customized products ■High unit cost relative
to fixed or
programmable
automation
 REASON FOR AUTOMATION
1. Increase in productivity
- automation of an operation usually increases production rate
and output per labour hour
2. Reduction of labour cost
- as labour cost increases, economics tends to force a
subtitution of automated equipment for labour
3. Labour shortage
- automation as an alternative
4. Trend of labour toward the service sector
-people tend to view factory work as demeaning and
undesireable
5. Safety
-automation of a production operation tends to remove the
h
human ffrom di
direct participation
i i i iin the
h operation.
i Thi
This iimproves
safety in potentially dangerous production situations
REASON FOR AUTOMATION( cont’)
cont )
6. High cost materials
7 Improved quality
7.
8. Reduction of manufacturing lead time
- manufacturing lead time is the time between customer order
and delivery of the finished product
9. Reduction of work-in-process
- work-in-process is product in the factory either being
processed or between processing operations
10. Increase in flexibility
11. High cost of not automating
- companies that do not automate often find themselves at a
competitive disadvantages with their customers, their
employers and the general public.
 AUTOMATION ISLANDS
■ Computer-assisted design (CAD)
■ Computer-assisted engineering (CAE)
■ Computer-assisted manufacturing (CAM)
■ Manufacturing resource planning (MRP)
■ Just-in-time (JIT)
■ Flexible manufacturing system (FMS)
■ Numerically controlled tools (NC)
■ Manufacturing automation protocol (MAP)
 BUILDING BLOCKS OF AUTOMATION

Objectives
- To identify basic devices for implementing an
automation project
- To examine and classify the basic components
off automation
t ti
- To recognizes the usefulness of the basic
automation components
 BUILDING BLOCKS OF AUTOMATION (CONT’)

CLASS OF COMPONENTS

1 SENSORS

2
ANALYZERS

3 ACTUATORS

4
DRIVES
BLOCK
OC DIAGRAM
G OF
O AUTOMATION
U O O
 SENSOR
EN OR
DEFINITION
1)The first link between typical automated
system and the conventional process
2)Convey information from the manufacturing
process equipment,
i t th
the piece
i partt being
b i
manufactured, and from the human operator,
if any.
 TYPES OF SENSOR
SENSOR

SWITCH PHOTOELECTRIC INFRARED

-a device that controls the
flow of current in an
electric circuit, esp. by
turning the current on or
off or diverting it to a
particular part of the circuit
-types of switch :
1)manual switch
)
2)limit switch
3)proximity switch
-sensitive to light radiation
-two basic approaches:
1. Uses a photocell to detect
the presence of light radiating
naturally from some object in the
process e.g. the automatic road
lighting system.
2. Employs a beam of light
emitted by an artificial light source
-respond to radiation in
the range of wavelengths
just beyond the visible
spectrum
-hot objects emit infrared
radiation, and thus
infrared sensors are
useful for locating heat
sources in a process
 TYPES OF SWITCH
SWITCH

MANUAL LIMIT SWITCHES PROXIMITY

SWITCHES SWITCHES
-An automation system -sense the presence of a
-automatic inputs from the nearbyy object
j without
is linked to the manufacturing
f t i process, the th
operator, who may touching it
material, or the automated system
desire to be turned on itself, without intervention by the -capable of performing a
or off or make operator task that can not be done by
adjustments to the human except they use the
automated cycle -actuated by levers, plungers, supernatural power
push buttons, rollers, toggles, and
-e.g electric lamp just about anything else the -as such, it can be used on
switch = link between inventor can devise to make an robots to g
give the robot
the person who desires automation application feasible certain advantages over
the lamp to be turned human operators
on or off
 Examples of Sensor
Fiber Optics
-The typical automation application
is to use one fiber to transmit a
light beam that is sensed by the
system as either present or absent
-Very
Very efficient
Lasers
-Light Amplification by Stimulated
Emission of Radiation
-capable of delivering over a
distance a large amount of energy
into a tiny spot and thus have
obvious industrial application.
-useful in providing very long,
precise light beam that can be
used to detect the presence of tiny
objects
j as well as g
good tool for
dimensional peasurement
 WHAT IS VISION?
Camera

Monitor and Keyboard Lighting

CONTROLLER IMAGE
PROCESSING

Other Devices
HOW CAN VISION HELP YOU?

Uneven

Overlook Fatigue

Vision

Non Reliable Low Productivity

D
Dangerous
 Guide to your sensor Application
The following address important issues that will help you to
id tif the
identify th right
i ht sensor for
f your application
li ti

1) Sensing Distance
2) Supply Voltage
3) Output Type/Switching Requirements
4) Load Requirements
5) Target Material
6) Target Dimensions
7) Target Finish
8)) Target
g Movement
 Guide to your sensor Application (cont
(cont’))

9) Mounting Requirements
10)Response Time
11)Electrical Connections
12)Mutual Interference
13)Ambient Operating Temperature
14)Environment
15)Waterproof
16)Color Detection
 ANALYZERS
Definition

Once information is sensed by an

automated
t t d system,
t it mustt be
b registered
i t d
and analyzed for content, and then a
d i i mustt b
decision be maded bby th
the system
t as tto
what action should be taken
 TYPES OF ANALYZERS
COMPUTERS
-digital computers are the
primary means of analyzing
automation system inputs
-extremely versatile
-the continuing miniaturization
of the computer components
along with decreasing costs
has created the continuing
increase in the number of
feasible application of
manufacturing automation
ANALYZERS
COUNTERS TIMERS
-useful to determine how -very useful devices in
many of various items are industrial logic control
present or pass through an systems
automated system
-available as separate units,
-can be mechanical, but most but can be internal to PLC
automatic systems employ and on-line process control
solid-state electronic counters computers
-the quantity counted is
usually a series of voltage
pulses that have been
generated by a sensor
detecting some physical
quantity
 BAR CODE READERS
-incorporates a conventional photoelectric or laser
scanner along
l with
i h timers
i andd counters
-successive bars of varying width are scanned and
counted
-the scan is orthogonal to the bars, and thus voltage
pulses from the p
p photoelectric sensor can be compared
p to
determine individual bar widths
-the sequence and width of bars is then analyzed to
d
decode
d ththe b
bars andd ttranslate
l t th
them tto an alphanumeric
l h i
data string
 Types of Barcode Reader
consist of a light source and a
photodiode
h t di d thatth t are placed
l d nextt to
t
Pen type each other in the tip of a pen or
readers wand. To read a bar code, the tip of
the pen moves across the bars in a
steady
t d motion.
ti
work the same way as pen type
readers except that they use a
Laser scanner laser beam as the light
g source

use an array of hundreds of tiny

light sensors lined up in a row in
CCD Readers the head of the reader

Camera-Based he fourth and newest type of bar

code reader currently
y available.
R d
Readers They use a small video camera to
capture an image of a bar code.
FIRST, SECOND AND THIRD GENERATION
BARCODES
First
Generation

Second
Generation

Third
Generation
 OPTICAL ENCODERS

- Useful for automatically detecting shaft rotation

- The shaft rotation information can be fed back into
a computer
t or control
t l mechanism
h i ffor controlling
t lli
velocity or position of the shaft
- Wide application for robots and NC machine tools
- Type of optical encoders ; incremental and
absolute
 T
Types off Optical
O ti l Encoders
E d

OPTICAL ENCODER

INCREMENTAL
Transmit a series of voltage
pulses proportional to the
angle rotation of the shaft
ABSOLUTE
Transmit a pattern of
voltage that describes the
position of the shaft at any
given time
 T
Types off Optical
O ti l Encoders
E d (cont’)
( t’)

Ab l t O
Absolute Optical
ti l EEncoder
d Incremental Optical Encoder
 ACTUATORS

Once a real-world condition is

sensed and analyzed
analyzed, something
may need to be done about it.
 TYPES OF ACTUATORS

ACTUATORS

CYLINDERS RELAY SOLENOIDS

 TYPES OF ACTUATORS (cont
(cont’))

CYLINDERS
- usually
ll chosen
h to
t accomplish
li h a linear
li
movement
- the most popular are the pneumatic types
- the control of air cylinders is accomplished by
valves that may be driven by electrical
impulses or by air logic devices
 TYPES OF ACTUATORS (cont
(cont’))

RELAYS
-an
an electrically controlled device that opens and closes electric
contacts affecting other devices in the same or another circuit
-can control a large load current at high voltage by means of a
smallll relay-energizing
l i i currentt att a low
l voltage
lt
-relay : power circuit of less than 10A
-power
power relay : the amperage range between 10-30A 10 30A
-contactor : higher amperage
-motor starters : contactors/relays used in tripping of power
circuits for electric motor ( also provides the overload protection)
 TYPES OF ACTUATORS (cont
(cont’))

SOLENOIDS
OLENOID
-suitable
suitable when a small,
small lights
lights, quick linear
motion is desired
-its
its working principle is based on the creation of
a magnetic field set up by passing an electric
current.
 TYPES OF ACTUATORS (cont
(cont’))

Cylinder Actuator (Series CG1

precision air cylinder )
Relays (ARM Series Automotive
40 AMP)
Solenoids ( 1E Rotary
Solenoids )
 DRIVES
-Like actuators,, drives take some action upon p the
process at the command of a computer or other
analyzer
-The
Th distinction
di ti ti between
b t actuators
t t andd drives
di is
i
that actuators are used to effect a short,
complete,
p , discrete motion ( usuallyy linear ) and
drives execute more continuous movements
typified by, but not limited to, rotation.
-Actuators
A t t may turn
t drives
di on and d off,
ff and
d drives
di
may provide the energy for the movement of
actuators.
 TYPES OF DRIVES

Motors

Drives

Stepper DC Serve
Motor Motors
 TYPES OF DRIVES (cont
(cont’))

MOTORS
■ Internal combustion engine,
g , also called motors,, are
relatively insignificant in automated manufacturing.
■ The automation engineer must have a broad
perspective of the term motor to include not only
electric motors but hydraulic and pneumatic motors
as well
■ Hydraulic motors are capable of delivering a large
amount of power in confined space
space.
 TYPES OF DRIVES (cont
(cont’))

STEPPER MOTORS
■ driven by discrete dc voltage pulses, which are
very convenient outputs from digital computers
and other automation control systems
■ -ideal
ideal for executing a precise angular advance
■ -also ideal for open-loop operations where the
control system gives a specific output command
and expects the system to react properly without
monitoring results in a feedback loop.
 TYPES OF DRIVES (cont
(cont’))

DC SERVO MOTORS
■ Useful in numerically controlled machine tools and industrial
robots for the control of motion
■ By using a feedback loop, the controller can deliver to the
motor dc voltage that is proportional to the observed error
■ when the error is reduced to zero,
zero the voltage goes to zero
and the motors stops
■ One important characteristics of the dc servo motor that is
also true of the stepper motor is that both hold their torque
when they come to rest under power
■ Therefore, the power is useful not only for rotating the shaft
but also for holding it motionless when no movement is
desired