Industrial AutomationIndustrial Automation

T RajendranT Rajendran

Industrial AutomationIndustrial Automation

Control SystemsControl Systems Process ControlProcess Control Industrial ControlIndustrial Control Computer Integrated ManufacturingComputer Integrated Manufacturing Systems ModelingSystems Modeling Systems EngineeringSystems Engineering Real Time ProgrammingReal Time Programming Software toolsSoftware tools

Expectation of AutomationExpectation of Automation

High ReliabilityHigh Reliability Fast Trouble shootingFast Trouble shooting Simple OperationSimple Operation Easily ConfigurableEasily Configurable High AccuracyHigh Accuracy Optimization functions and Optimization functions and

processing of operating dataprocessing of operating data FlexibilityFlexibility

Process ControlsProcess Controls

PC

IS

IntegratedControl &

Management systems

1960-70 1970-80 1980…

MIS

HistoryHistory

Pioneering period – 60 – Electronic Pioneering period – 60 – Electronic devicesdevices

Direct Digital controlDirect Digital control MicrocomputerMicrocomputer Computer controlled Process plantsComputer controlled Process plants

– CentralizedCentralized– DistributedDistributed– Process ModelsProcess Models– Advanced Control (AI)Advanced Control (AI)

Process ControlsProcess Controls

Basic principles of controller loopBasic principles of controller loop

Memory - Set PointMemory - Set Point Comparator for set point (measured Comparator for set point (measured

value MV) as reported by transmittervalue MV) as reported by transmitter Deviation = errorDeviation = error Amplifier – amplifies the control Amplifier – amplifies the control

deviations – output of the controllerdeviations – output of the controller

Process ControlProcess Control

Open Loop ControlOpen Loop Control Closed Loop controlClosed Loop control

Process ControlProcess Control

Two position controlTwo position control Multi position controlMulti position control PID Proportional control PID Proportional control

(proportional, integral or derivative)(proportional, integral or derivative) Ratio controlRatio control Cascade control Cascade control

Controller OperationController Operation

controller-

Set point

error Control signal

Control element

sensorprocess

Measured value

Auto/manual

Position controlPosition control

High set point

Low set point

Control actionsControl actions

No control

Proportional only

PIPIDSet point

Time

Controlvalue

InstrumentationInstrumentation

InstrumentationInstrumentation

PressurePressure FlowFlow liquid levelliquid level TemperatureTemperature Pneumatic and control valvesPneumatic and control valves

TransducersTransducers

SensorsSensors high / low limits of measurandhigh / low limits of measurand

TransducersTransducers

To measure / senseTo measure / sense to convert measured value to a to convert measured value to a

useful outputuseful output

TransducersTransducers

MeasurementMeasurement– Type of measurandType of measurand– Number of measurementsNumber of measurements– Sensing measurementSensing measurement– Transduction elementTransduction element– Range of measurementRange of measurement

ConversionConversion– Specific formatSpecific format– AmplifiedAmplified– Conversion of AC to DCConversion of AC to DC

TransducersTransducers

ConventionalConventional SiliconSilicon Fiber OpticFiber Optic

TransducersTransducers

ConventionalConventional SiliconSilicon Fiber OpticFiber Optic

Displacement / motion transducersDisplacement / motion transducers Temperature TransducersTemperature Transducers Pressure TransducersPressure Transducers Liquid level TransducersLiquid level Transducers Liquid FlowLiquid Flow

Intelligent SensorsIntelligent Sensors

On-chip signal processingOn-chip signal processing MEMS (Micro Electro Mechanical MEMS (Micro Electro Mechanical

Systems) sensorsSystems) sensors BIOSENSORSBIOSENSORS NANOSENSORSNANOSENSORS

NANOSENSORS & future trendsNANOSENSORS & future trends

1 nm = 1 millionth of a mm1 nm = 1 millionth of a mm

Building Blocks in Building Blocks in AutomationAutomation

Building blocksBuilding blocks

The Processor The Processor Analog & Digital I/O modulesAnalog & Digital I/O modules interrupts, Timers/countersinterrupts, Timers/counters Display controlsDisplay controls SCADA (Supervisory control and SCADA (Supervisory control and

data acquisition systems)data acquisition systems)

Processing SystemProcessing System

The use of Microprocessors The use of Microprocessors (calculator chips & Mini computers)(calculator chips & Mini computers)

ArchitectureArchitecture– Input, Memory, Output, MicrpPInput, Memory, Output, MicrpP

Address bus, Data bus, control busAddress bus, Data bus, control bus 8 , 16, 32, 64 bits8 , 16, 32, 64 bits Microprocessors & microcontrollersMicroprocessors & microcontrollers

Analog & Digital I/O modulesAnalog & Digital I/O modules

Basic signalsBasic signals

Analog inputs

Digital inputs

Interrupt inputsTimer / counter inputs

Control outputs

Display outputs

Analog & Digital I/O modulesAnalog & Digital I/O modules

Basic signalsBasic signals

Analog inputs

Digital inputs

Interrupt inputsTimer / counter inputs

Control outputs

Display outputs

Inside look of a real time sysytemInside look of a real time sysytem

Processor & memory

module

Analog inputs

Digital inputs

Interrupt inputsTimer / counter inputs

Control outputs

Display outputs

Interruptcontroller Timer /

counter

Analo

g inpu

t m

odule

I/O modulesI/O modules

Analog input Analog input – From SensorsFrom Sensors– Measurand like flow, position, Measurand like flow, position,

temperature …temperature …– Signal may be amplified, filtered or/and Signal may be amplified, filtered or/and

isolatedisolated Digital inputDigital input

– Refer to ON-OFF status of valves, linit Refer to ON-OFF status of valves, linit switches.. (1 bit )switches.. (1 bit )

I/O modulesI/O modules

Interrupt input Interrupt input – Draw attention of real time system towards Draw attention of real time system towards

abnormal situationsabnormal situations– Attends to interrupt and resumes normal Attends to interrupt and resumes normal

workwork Timer / CounterTimer / Counter

– Clock input or Gate input to enable/ disable Clock input or Gate input to enable/ disable timer/counterstimer/counters

– Output of timer/counter can be used as Output of timer/counter can be used as interruptsinterrupts

I/O signalsI/O signals

Display output signalsDisplay output signals– LED, LCD, VDU, alarmsLED, LCD, VDU, alarms– Status of process, limits setsStatus of process, limits sets– May control or operator assistedMay control or operator assisted

Control output signalControl output signal– Required to drive the control valves, motors Required to drive the control valves, motors

etcetc– May be simple ON/OFF or fine control of May be simple ON/OFF or fine control of

motor speed, position, displacement, flow..motor speed, position, displacement, flow..– Analog signals / digital actuatorsAnalog signals / digital actuators

Analog inputAnalog input

The module continuously scans the The module continuously scans the analog input signals in the pre analog input signals in the pre defined order and frequencydefined order and frequency

Amplifies -> converts to digital -> Amplifies -> converts to digital -> processor and memory module for processor and memory module for processingprocessing

EPROM or switchesEPROM or switches Local intelligenceLocal intelligence

Digital InputDigital Input

Directly accepted by processorDirectly accepted by processor N bits in parallelN bits in parallel Local intelligenceLocal intelligence

Analog OutputAnalog Output

Digital multiplexerDigital multiplexer Digital to Analog converterDigital to Analog converter Master processor executes two I/O Master processor executes two I/O

instructionsinstructions– Write Data byte/word in digital output Write Data byte/word in digital output

portport– Write address byte/word in address port Write address byte/word in address port

Interrupt controlInterrupt control

Interface between no. of interrupting Interface between no. of interrupting devices and master processordevices and master processor

Priorities allocation- static or Priorities allocation- static or dynamic.dynamic.

Timer / CounterTimer / Counter

Number of timers and counters which Number of timers and counters which may be cascaded or used may be cascaded or used independentlyindependently

Count in the form of data byte/wordCount in the form of data byte/word Clock from the processor or externalClock from the processor or external

Display Control moduleDisplay Control module

Manual entry sub moduleManual entry sub module CRT controller sub moduleCRT controller sub module LED / LCD control sub moduleLED / LCD control sub module Alarm annunciator sub moduleAlarm annunciator sub module Printer controller sub modulePrinter controller sub module

SCADASCADA

Supervisory Control And Data Supervisory Control And Data Acquisition SystemsAcquisition Systems– Channel scanningChannel scanning– Conversion into engineering unitsConversion into engineering units– Data processingData processing

CAD / CAM / CIMCAD / CAM / CIM

CIMCIM

cim

Process planning

drafting

MeM

fe

CNC

Robots

Schedudle

Prodplan

cad

Tool design

fms

simulation

ERP

Shop floor data

CAD / CAM / CIMCAD / CAM / CIM

CIM, Concurrent EngineeringCIM, Concurrent Engineering Product Life Cycle ManagementProduct Life Cycle Management Engineering ModelingEngineering Modeling CIM databasesCIM databases Computer aided process planningComputer aided process planning IT & ERPIT & ERP Manufacturing automation – PLC, Manufacturing automation – PLC,

CNC, RobotsCNC, Robots

CAD/CAM/CIMCAD/CAM/CIM

Flexible ManufacturingFlexible Manufacturing Shop Floor Data CollectionShop Floor Data Collection SimulationSimulation

Concurrent EngineeringConcurrent Engineering

DESIGN softwareDESIGN software– Solid ModelingSolid Modeling– Assembly modelingAssembly modeling– Sheet metal designSheet metal design– DraftingDrafting– Tolerance analysisTolerance analysis– Mechanism DesignMechanism Design– Mould DesignMould Design– Thermal AnalysisThermal Analysis– Piping DesignPiping Design– OptimizationOptimization– Tool DesignTool Design

Concurrent EngineeringConcurrent Engineering

Process PlanningProcess Planning ERPERP Shop Floor Data CollectionShop Floor Data Collection PLMPLM EDMEDM

Concurrent EngineeringConcurrent Engineering

Visualization / SimulationVisualization / Simulation– Factory simulationFactory simulation– Rapid prototypingRapid prototyping– Plastic injection mouldingPlastic injection moulding– FormingForming– ForgingForging– CastingCasting