Part I: Questionnaires related to Industrial Automation

1.​ What are the Five IEC1131 - Programming Languages?

​ Instruction List (IL)
-​ The most popular for relatively simple, yet frequently used,
algorithms.
Structured Text (ST)
-​ A Pascal-like language that generally permits for greater flexibility,
and less tedium, in wiring control algorithms.
​ ​ Ladder Diagram (LD)
-​ The most popular language involving situations with relay logic and
with AND and OR gates.
​ ​ Function Block Diagram (FBD)
-​ This language allows the control algorithms to be developed in a
graphical manner by inserting the program units termed Functions
and Function Blocks into a control program.
​ ​ Sequential Function Chart (SFC)
-​ This allows for complex algorithms to be executed using a series of
“steps” and “transitions”.

2.​ Explain PID Based Control System.

​ A PID (Proportional-Integral-Derivative) controller is an instrument utilized
by control engineers to regulate temperature, flow, pressure, speed, and other
process variables in industrial control systems.
 ​ A PID controller is used to force feedback to match a setpoint, they are
best used in systems that have a relatively small mass and those which react
quickly to changes in the energy added to the process.

A PID controller works on the terms of proportional, integral, and

derivative that must be individually tuned.
-​ Proportional tuning involves correcting a target proportional to the
difference. It responds to the present error, to generate an output
proportional to its magnitude.
-​ Integral tuning attempts to remedy this by cumulating the error
result from the “P” action in an effective manner to increase the
correction factor. However, “I” attempts drive the cumulative error to
zero which results in an overshoot.
-​ Derivative tuning tries to minimize an overshoot by slowing the
correction factor applied as the target is approached. It anticipates
future changes in the error by evaluating its rate of change.

3.​ Explain the difference between a PLC and DCS.

​ A Programmable Logic Controller (PLC) obtains data from linked sensors
or input devices, processes the acquired information, and activates outputs
according to predefined parameters. A PLC can oversee and log real-time data
like machine productivity or operating temperature, it can also initiate or stop
processes automatically, issue alerts when a machine malfunctions, and perform
other various functions.
 A Distributed Control System (DCS) was developed due to the growing
utilization of microcomputers. It has the advantage of being capable of
overseeing an entire plant via proprietary communications and a distributed
system. Moreover, a DCS offered integrated monitoring and control, identical to
HMI systems.

The difference between a PLC and a DCS is that modern DCSs can be
viewed as multiple PLCs operating in parallel, however, with integrated
monitoring and control capabilities. A big difference between between PLCs and
DCSs is price, the implementation of a DCS results in massive cost savings,
especially in large-scale plants, compared to creating a system using multiple
PLCs from scratch. Moreover, a DCS includes a monitoring and control system,
while a system on PLC requires a separate HMI system which adds complexity.

4.​ What is Encoder?

 Motor encoders are electronic devices that are utilized in monitoring the
position and speed of a motor. In industrial and automated systems, they have a
crucial role as they provide accurate and precise information regarding the
motion and position of a motor.
Motor encoders comprise of two primary components, namely: the sensor
and a code wheel. The sensor, usually a photodiode or an optical sensor, detects
light and generates an electrical signal. The code wheel is a disk that contains a
series of transparent and opaque sections or lines.

5.​ What are the Different Components used in Automation?

Programmable Logic Controllers Industrial Communication Networks

(PLC)

Sensors Control and programming software

Actuators Distributed Controllers (DCS)

Human Machine Interfaces (HMI) Safety systems

Supervisory Control and Data Central Processing Units (CPU)

Acquisition Systems (SCADA)

6.​ Who are the leading PLC providers?

Siemens Rockwell Automation / Allen Bradley

 Mitsubishi Electric Schneider Electric

ABB Honeywell

Omron

7.​ Who are the leading DCS providers?

Honeywell
Yokogawa

Siemens Invensys Limited

 Emerson Electric Metso

ABB General Electric Vernova

Mitsubishi Electric Rockwell Automation

8.​ Who are the leading SCADA software companies?

Siemens Inductive Automation

AVEVA Schneider Electric

 General Electric Vernova

9.​ What types of sensors are used for measuring?

-​ Temperature Sensors
Tempereature sensors gather information about temperature from the
environment and convert them into specific values.

-​ Pressure Sensors
A sensor that can sense the pressure signal and convert the
aforementioned signal into a usable output electrical signal according to a
certain rule.

-​ Level Sensors
 Used to monitor, maintain, and measure levels of liquids and solids to
some degree.

-​ Infrared Sensors
A sensor that utilizes infrared to process data. Also called as infrared light,
it contains properties such as reflection, refraction, scattering,
interference, and absorption.

-​ Proximity Sensors
A device that has the ability to perceive proximity of an object. It utilizes
sensitive character of the displacement sensor to recognize the proximity
of an object and outputs a corresponding switch signal.
-​ Smoke Sensors
Detects a large amount of smoke generated during a fire and releases an
alarm signal in time.

-​ Optical Sensors
Utilizes the principle of optics for measurement. Performs non-contact and
non-destructive measurement without interference

-​ MEMS Sensor
A sensor for microelectronics and micromachining technology. Small in
size, low power consumption, high reliability, and suitable for mass
production.
10.​What is Transmitter?
In the context of process control, a transmitter is a device that converts a
signal produced by a sensor into a standard instrumentation signal that
represents a process variable being measured and controlled.

11.​Why is 4-20mA preferred over 0-10V signal?

A voltage signal when transmitted over a long distance produces a voltage
drop in the wires, therefore it is not generally used due to error in measurement.
A current signal is preferred as it does not get affected by a voltage drop,
it produces a superior accuracy compared to a voltage signal, and it has a more
linear response than a voltage signal. The use of 4-20mA current signal is
considered safe for hazardous area due to low power consumption and it poses
no risk of electrical shock or fire.

12.​Why is 4-20mA preferred over 0-20mA signal?

4-20 mA signal is preferred over 0-20 mA for various reasons. They are
difficult and expensive, a 0 mA essentially translates to an open circuit wherein
no current will flow, therefore engineering a device capable of reaching 0 mA and
 still being accurate can be quite tedious and expensive compared to a 4-20 mA
limit. Moreover, a circuit with a 0-20 mA range would be difficult to detect in low
ranges, a 4-20 mA circuit would be more easier. The inability to detect a system
failure of a 0 mA system because it could either mean zero or a system failure. A
term “live zero” refers to a loop signal where zero value is a number higher than
zero, which is 4 mA. The term “dead zero" denotes a loop signal where the zero
value is indeed zero, 0 mA. Lastly 0 mA does not permit devices to operate with
a minum amount of current to function, a 4-20mA signal is preferred as it
supports two-wire transmission allowing a supply of power for loop-powered
devices to function.

13.​Difference between 2-wire, 3-wire, and 4-wire transmitters?

2-wire Transmitter
-​ A 4-20 mA signal transmission loop does not require an external power
source.
-​ Source is an analog input.
-​ Utilizes 2 wires for both supply and signal transmission.
-​ Simple and cost effective
-​ Relies on a constant current source to power transmitter and transmit
signal.
-​ Voltage drop along the wires are possible as they are sed for both power
and signal.

​ 3-wire Transmitter
-​ Uses three wires, two for power and one for signal transmission.
-​ Has better signal accuracy due to a dedicated wire for signal.
-​ Mitigates voltage drop issues in 2-wire configurations.
​ 4-wire Transmitter
-​ Uses four wires, two for power and two for signal transmission.
-​ Has the highest signal accuracy as there is separation between power and
signal wires.
-​ Completely eliminates voltage drop issues, ideal for precise
measurements
-​ Often utilized in laboratory settings, scientific research, and industrial
applications where accuracy is critical.

Part II: Questionnaires related to Mechatronics Servicing

1.​ What would you do if the manufacturer’s instruction manual of the

mechatronic device is not available during installation?
2.​ If the installed device failed and the available spare is a replacement, what
would you do?
3.​ What precautions must you take when installing pneumatic system
controls?
4.​ What precaution must you take before applying power to the installed
mechatronic devices?
5.​ What basic personal protective equipment would you wear when working
in a noisy environment and with the presence of overhead cranes?
 6.​ What would you do if the cylinder does not function in spite of correct
connection?
7.​ What are the possible causes of false triggering of a mechatronic device
during operation?
8.​ Is it worth saving not to connect motor starter feedback to the PLC?
9.​ Why is it necessary to ground the chassis of some mechatronic devices?
10.​How many #18 AWG wire can fit into a ½” RSC Conduit?

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