Automation

The word ‘Automation’ is derived from greek words “Auto”(self)

and “Matos” (moving). Automation therefore is the mechanism for
systems that “move by itself”. However, apart from this original
sense of the word, automated systems also achieve significantly
superior performance than what is possible with manual systems, in
terms of power, precision and speed of operation.

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
Control

• It is perhaps correct to expect that the learner for this

course has already been exposed toa course on Control
Systems, which is typically introduced in the final or
pre-final year of an undergraduate course in
Engineering in India. The word control is therefore
expected to be familiar and defined as under.

• 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.
Industrial Automation
Role of automation in industry

• Manufacturing processes, basically, produce finished

product from raw/unfinished material using energy,
manpower and equipment and infrastructure.
• Since an industry is essentially a “systematic economic
activity”, the fundamental objective of any industry is
to make profit.
• Roughly speaking,
Profit = (Price/unit – Cost/unit) x Production Volume
So profit can be maximised by producing good quality
products, which may sell at higher price, in larger
volumes with less production cost and time.
Types of Automation Systems

• Fixed Automation: It is used in high volume

production with dedicated equipment, which has
a fixed set of operation and designed to be
efficient for this set. Continuous flow and Discrete
Mass Production systems use this automation.
e.g. Distillation Process, Conveyors, Paint Shops,
Transfer lines etc. A process using mechanized
machinery to perform fixed and repetitive
operations in order to produce a high volume of
similar parts.
• Programmable Automation: It is used for a
changeable sequence of operation and
configuration of the machines using electronic
controls. However, non-trivial programming effort
may be needed to reprogram the machine or
sequence of operations. Investment on
programmable equipment is less, as production
process is not changed frequently. It is typically
used in Batch process where job variety is low
and product volume is medium to high, and
sometimes in mass production also. e.g. in Steel
Rolling Mills, Paper Mills etc.
• Flexible Automation: It is used in Flexible
Manufacturing Systems (FMS) which is invariably
computer controlled. Human operators give high-level
commands in the form of codes entered into computer
identifying product and its location in the sequence and
the lower level changes are done automatically. Each
production machine receives settings/instructions from
computer. These automatically loads/unloads required
tools and carries out their processing instructions. After
processing, products are automatically transferred to
next machine.
• Integrated Automation: It denotes complete automation
of a manufacturing plant, with all processes functioning
under computer control and under coordination
through digital information processing. It includes
technologies such as computer-aided design and
manufacturing, computer-aided process planning,
computer numerical control machine tools, flexible
machining systems, automated storage and retrieval
systems, automated material handling systems such as
robots and automated cranes and conveyors,
computerized scheduling and production control.
The Functional Elements of
Industrial Automation

• An Industrial Automation System consists of numerous

elements that perform a variety of functions related to
Instrumentation, Control, Supervision and Operations
Management related to the industrial process. These
elements may also communicate with one another to
exchange information necessary for overall
coordination and optimized operation of the
plant/factory/process. Below, we classify the major
functional elements typically found in IA systems and
also describe the nature of technologies that are
employed to realize the functions.
Sensing and Actuation Elements

• These elements interface directly and physically to the

process equipment and machines. The sensing elements
translate the physical process signals such as temperature,
pressure or displacement to convenient electrical or
pneumatic forms of information, so that these signals can
be used for analysis, decisions and finally, computation of
control inputs. These computed control inputs, which again
are in convenient electrical or pneumatic forms of
information, need to be converted to physical process
inputs such as, heat, force or flow‐rate, before they can be
applied to effect the desired changes in the process
outputs. Such physical control inputs are provided by the
actuation elements.
Industrial Sensors and Instrument
Systems
Industrial Actuator Systems
Industrial Control Systems

• By industrial control systems, we denote the

sensors systems, actuator systems as a
controller. Controllers are essentially
(predominantly electronic, at times
pneumatic/hydraulic) elements that accept
command signals from human operators or
Supervisory Systems, as well as feedback from
the process sensors and produce or compute
signals that are fed to the actuators.
Sequence / Logic Control

• Many control applications do not involve analog

process variables, that is, the ones which can assume a
continuous range of values, but instead variables that
are set valued, that is they only assume values
belonging to a finite set. The simplest examples of such
variables are binary variables, that can have either of
two possible values, (such as 1 or 0, on or off, open or
closed etc.). These control systems operate by turning
on and off switches, motors, valves, and other devices
in response to operating conditions and as a function of
time. Such systems are referred to as sequence/logic
control systems.
Supervisory Control

• Supervisory control performs at a hierarchically higher level over

the automatic controllers, which controls smaller subsystems.
• Supervisory control systems perform, typically the following
functions:
♦ Set point computation: Set points for important process variables
are computed depending on factors such as nature of the product,
production volume, mode of processing. This function has a lot of
impact on production volume, energy and quality and efficiency.
♦ Performance Monitoring / Diagnostics: Process variables are
monitored to check for possible system component failure, control
loop detuning, actuator saturation, process parameter change etc.
The results are displayed and possibly archived for subsequent
analysis.
• Start up / Shut down / Emergency Operations : Special discrete
and continuous control modes are initiated to carry out the
intended operation, either in response to operator commands or in
response to diagnostic events such as detected failure modes.
♦ Control Reconfiguration / Tuning: Structural or Parametric redesign
of control loops are carried out, either in response to operator
commands or in response to diagnostic events such as detected
failure modes. Control reconfigurations may also be necessary to
accommodate variation of feedback or energy input e.g. gas fired to
oil fired.
♦ Operator Interface: Graphical interfaces for supervisory operators
are provided, for manual supervision and intervention.
Over View
Architecture
• Size
• Application
• Memory
• Sinking
• Sourcing
Networking

• Computer network A collection of computing

devices that are connected in various ways in
order to communicate and share resources
Usually, the connections between computers
in a network are made using physical wires or
cables
However, some connections are wireless, using
radio waves or infrared signals

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Networking

• The generic term node or host refers to any

device on a network
• Data transfer rate The speed with which data
is moved from one place on a network to
another
• Data transfer rate is a key issue in computer
networks

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Networking

• Computer networks have opened up an entire

frontier in the world of computing called the
client/server model

Client/Server interaction 15-28

Networking

• File server A computer that stores and

manages files for multiple users on a network
• Web server A computer dedicated to
responding to requests (from the browser
client) for web pages

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Types of Networks

• Local‐area network (LAN) A network that

connects a relatively small number of
machines in a relatively close geographical
area

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Types of Networks

• Various configurations, called topologies, have been

used to administer LANs
– Ring topology A configuration that connects all nodes in a
closed loop on which messages travel in one direction
– Star topology A configuration that centers around one
node to which all others are connected and through which
all messages are sent
– Bus topology All nodes are connected to a single
communication line that carries messages in both
directions

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 Types of Networks

Various network topologies

• A bus technology called Ethernet has become the industry

standard for local‐area networks
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Types of Networks

• Wide‐area network (WAN) A network that

connects two or more local‐area networks over a
potentially large geographic distance
Often one particular node on a LAN is set up to serve as a
gateway to handle all communication going between that
LAN and other networks
Communication between networks is called
internetworking
The Internet, as we know it today, is essentially the
ultimate wide‐area network, spanning the entire globe

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Types of Networks

• Metropolitan‐area network (MAN) The

communication infrastructures that have been
developed in and around large cities

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So, who owns the Internet?

Well, nobody does. No single person or

company owns the Internet or even controls it
entirely. As a wide‐area network, it is made up
of many smaller networks. These smaller
networks are often owned and managed by a
person or organization. The Internet, then, is
really defined by how connections can be
made between these networks.

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Types of Networks

Local-area networks connected across a distance to create a wide-

area network 15-36
Internet Connections

• Internet backbone A set of high‐speed

networks that carry Internet traffic
These networks are provided by companies
such as AT&T, GTE, and IBM
• Internet service provider (ISP) A company
that provides other companies or individuals
with access to the Internet

15-37
Internet Connections

• There are various technologies available that you can use to

connect a home computer to the Internet
– A phone modem converts computer data into an analog audio
signal for transfer over a telephone line, and then a modem at the
destination converts it back again into data
– A digital subscriber line (DSL) uses regular copper phone lines to
transfer digital data to and from the phone company’s central
office
– A cable modem uses the same line that your cable TV signals come
in on to transfer the data back and forth

15-38
Internet Connections

• Broadband A connection in which transfer speeds

are faster than 128 bits per second
– DSL connections and cable modems are broadband
connections
– The speed for downloads (getting data from the Internet
to your home computer) may not be the same as uploads
(sending data from your home computer to the Internet)

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Packet Switching

• To improve the efficiency of transferring information over a

shared communication line, messages are divided into fixed‐
sized, numbered packets
• Network devices called routers are used to direct packets
between networks

Messages
sent by
packet
switching

15-18
Open Systems

• Proprietary system A system that uses technologies

kept private by a particular commercial vendor
One system couldn’t communicate with another, leading to
the need for
• Interoperability The ability of software and hardware
on multiple machines and from multiple commercial
vendors to communicate
Leading to
• Open systems Systems based on a common model
of network architecture and a suite of protocols used
in its implementation

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 Open Systems

• The International
Organization for
Standardization (ISO)
established the Open
Systems Interconnection
(OSI) Reference Model
• Each layer deals with a
particular aspect of
network communication
The layers of the OSI Reference Model

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15-43
2. Data Link Layer
a) Error control to compensate for
the imperfections of the physical
layer.
b) Flow control to keep a fast
sender from swamping a slow
receiver.

Main topics:
• Framing methods
• Error detection and correction
methods
• Flow control
• Frame format
• IEEE LAN standards
• Bridges
• Switches (multi-port bridges)
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 OSI REFERENCE MODEL
7 Application

6 3. Network Layer
Presentation a) Controls the operation of the subnet.
5 Session b) Routing packets from source to destination.
c) Logical addressing.
4 Transport
Main topics:

3 Network • Internetworking
• Routing algorithms
• Internet Protocol (IP) addressing
2 Data Link • Routers

1 Physical

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 OSI REFERENCE MODEL
7 Application

6 4. Transport Layer
Presentation a) Provides additional Quality of Service.
5 Session b) Heart of the OSI model.

Main topics:
4 Transport
• Connection-oriented and connectionless services
• Transmission Control Protocol (TCP)
3 Network • User Datagram Protocol (UDP)

2 Data Link

1 Physical

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 OSI REFERENCE MODEL
7 Application

6 5. Session Layer
Presentation a) Allows users on different machines to establish
sessions between them.
5 Session
b) One of the services is managing dialogue
control.
4 Transport
c) Token management.

3 Network d) Synchronization.

2 Data Link

1 Physical

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 OSI REFERENCE MODEL
7 Application

6 6. Presentation Layer
Presentation a) Concerned with the syntax and semantics of the
information.
5 Session
b) Preserves the meaning of the information.
4 Transport c) Data compression.
d) Data encryption.
3 Network

2 Data Link

1 Physical

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 OSI REFERENCE MODEL
7
Application
6 7. Application Layer
Presentation a) Provides protocols that are commonly needed.
5 Session
Main topics:
• File Transfer Protocol (FTP)
4 Transport • HyperText Transfer Protocol (HTTP)
• Simple Mail Transfer Protocol (SMTP)
3 Network • Simple Network Management Protocol (SNMP)
• Network File System (NFS)
• Telnet
2 Data Link

1 Physical

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Network Protocols

• Network protocols are layered such that each

one relies on the protocols that underlie it
• Sometimes referred to as a protocol stack

Layering of key network protocols

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Introduction

• IEEE 802 refers to a family of IEEE standards

– Dealing with local area network and metropolitan area network.
– Restricted to networks carrying variable‐size packets.
– Specified in IEEE 802 map to the lower two layers
• Data link layer
– LLC sublayer
– MAC sublayer
• Physical layer

• The most widely used standards

– The Ethernet family, Token Ring, Wireless LAN.
– Bridging and Virtual Bridged LANs.
– An individual Working Group provides the focus for each area.

51
IEEE 802 Working Groups

• a Active working groups Inactive or disbanded working groups

802.1 Higher Layer LAN Protocols Working 802.2 Logical Link Control Working Group
Group 802.4 Token Bus Working Group
802.3 Ethernet Working Group 802.5 Token Ring Working Group
802.11 Wireless LAN Working Group 802.7 Broadband Area Network Working
802.15 Wireless Personal Area Network Group
(WPAN) Working Group 802.8 Fiber Optic TAG
802.16 Broadband Wireless Access Working 802.9 Integrated Service LAN Working
Group Group
802.17 Resilient Packet Ring Working Group 802.10 Security Working Group
802.18 Radio Regulatory TAG 802.12 Demand Priority Working Group
802.19 Coexistence TAG 802.14 Cable Modem Working Group
802.20 Mobile Broadband Wireless Access
(MBWA) Working Group
802.21 Media Independent Handoff Working
Group
802.22 Wireless Regional Area Networks

52
1. The low initial cost.
2. Low maintenance costs.
3. Simple in operation.
4. Ability to operate under a wide variety of
conditions.
5. Give a smooth, continuous flow, free from
pulsation.
CENTRIFUGAL PUMPS
POSITIVE DISPLACEMENT PUMPS

• Rotary Pumps
• In Rotary pumps, movement of liquid is
achieved by mechanical displacement of liquid
produced by rotation of a sealed arrangement
of intermeshing rotating parts within the
pump casing.
Single Acting Reciprocating
Pumps
Double Acting Reciprocating
Pumps
Diaphragm pump
Rotary Pump
Rotary Pump
Advantages of Rotary Pumps

They can deliver liquid to high pressures.

Self -priming.

Give a relatively smooth output, (especially at

high speed).

Positive Acting.

Can pump viscous liquids.

Gear Pump
Lobe Pump
Vane Pump
Speed Measurement
Displacement Measurement

• Broadly speaking, displacement measurement can be of

two types: contact and noncontact types. Besides the
measurement principles can be classified into two
categories: electrical sensing and optical sensing. In
electrical sensing, passive electrical sensors are used
variation of either inductance or capacitance with
displacement is measured. On the other hand the optical
method mainly works on the principle of intensity
variation of light with distance. Interferometric
technique is also used for measurement of very small
displacement in order of nanometers. But this technique
is more suitable for laboratory purpose, not very useful
for industrial applications.
Potentiometer
Linear Variable Differential
transformer (LVDT)
Actuator
Motor