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Course Goals
Raise interest for industrial automation systems
Understand industrial control systems (purpose, structure)
Automation hierarchy
Be able to analyze a process and propose automation solutions
Course Outline
Introduction to industrial automation, architecture of industrial automation, measurement system specifications, signal conditioning circuits, error and calibration, sensors (temperature, RPM meters, position, force, flow, tilt and acceleration), actuators, ADC/DACs, Supervisory Control And Data Acquisition ( SCADA), safety instrumentation and future trends
Grading Policy
Assignments/ Quizzes: Mid Term: Labs: Term Project: Final: 10% 20% 20% 10% 40%
Lecture Plan
Week 1 Week 2 Introduction to Industrial Automation Architecture of Industrial Automation and measurement system specifications Signal conditioning Circuits, Errors and calibration Sensors (Temperature)
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
Week 9
Notes
1. This course is application of concepts studied in previous courses; students are advised to study from the reference books and develop a habit of consulting online resources.
2. Check your emails regularly as you will be provided with selected study material and assignments through this media. 3. A special feature of the course would be a Term project which will consolidate the course learning.
Ground Rules - I
Attendance in class is Mandatory You are expected to rise when instructor enters the class Time keeping Only one conversation! Keep your mobiles OFF!
Ground Rules-II
Listen for understanding Participate in class discussion Ask questions! Adhere to Air University Code of Conduct
Dress Code Ethical Behavior
I want to understand
I can make a model of my world I know how to calculate
Programming:
Initiative:
I can structure
Systematic Work: I can plan I try various strategies to make things works
Team Work
Vision/Goal
safety
Concerns for human safety and system hazards
Lesson Objectives
To define Automation and Control and explain the differences in the sense of the terms To explain the relation between Automation and Information Technology To underline the basic objectives of a manufacturing industry and explain how automation and control technologies relate to these To introduce the concept of a Product Life Cycle and explain how Automation and Control technologies relate to the various phases of the cycle
Definition of terms
Industry
In a general sense the term Industry is defined as follows. Definition: Systematic Economic Activity thatcould be related to Manufacture/Service/ Trade. In this course, we shall be concerned with Manufacturing Industries only.
Definition of Automation
Definition: Automation is a set of technologies that results in operation of machines and systems without significant human intervention and achieves performance superior to manual operation
A Definition from Encyclopaedia Britannica The application of machines to tasks once performed by human beings or, increasingly, to tasks that would otherwise be impossible. Although the term mechanization is often used to refer to the simple replacement of human labour by machines, automation generally implies the integration of machines into a self-governing system.
Controls vs Automation
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
A. Industrial information systems are generally reactive in the sense that they receive stimuli from their universe of discourse and in turn produce responses that stimulate its environment. Naturally, a crucial component of an industrial information system is its interface to the world. B. Most of industrial information systems have to be real-time. The computation not only has to be correct, but also must be produced in time. An accurate result, which is not timely may be less preferable than a less accurate result produced in time. Therefore systems have to be designed with explicit considerations of meeting computing time deadlines. C. Many industrial information systems are considered mission-critical, in the sense that the malfunctioning can bring about catastrophic consequences in terms of loss of human life or property. Therefore extraordinary care must be exercised during their design to make them flawless. Fault-tolerance to emergencies due to hardware and software faults must often be built in.
Control Tasks
Definition of Control
Definition: Control is a set of technologies that achieves desired patterns of variations of operational parameters and sequences for machines and systems by providing the input signals necessary.
Control Systems Engineering, Fourth Edition by Norman S. Nise Copyright 2004 by John Wiley & Sons. All rights reserved.
The search for extraterrestrial life is being carried out with radio antennas like the one pictured here. A radio antenna is an example of a system with position controls.
Control Systems Engineering, Fourth Edition by Norman S. Nise Copyright 2004 by John Wiley & Sons. All rights reserved.
Peter Menzel.
Control Systems Engineering, Fourth Edition by Norman S. Nise Copyright 2004 by John Wiley & Sons. All rights reserved.
Manual Control
Automatic Control
open loop:
3
2
1
4
5
closed loop:
140 180 200
120
220
+ -
higher /lower
temperature sensor
b. closedloop system
Electrical Power
"batch control": semi-continuous processes, associated with individual products, e.g. fine chemicals, pharmaceutical, brewery
"manufacturing": also called factory automation discrete processes, associated with transformation of parts, e.g. automobile industry, bottle-filling, packaging
Organization of Course
( Slide Courtesy EPA)
numbers refer to the chapter (EPA guide book)
enterprise
6
execution
8
real-time dependability
5 4
supervision
device access
9 3
2.2 2.3 2.1
communication networks
5
vertical Comm.
File Edit
Engineering
4.3 communication
Control Bus
horizontal
Control level
4.2 programmable
controllers Fieldbus direct I/O microPLCs Fieldbus
3
Field level
2.3
Sensor-Actuator Bus
4.1
2.1
transducers / actors