AUTOMATION

Chapter 1
MEM 365 AUTOMATION

Prepared by NOOR ANIZA NORRDIN

SCHOOL OF MECHANICAL ENGINEERING

UITM PULAU PINANG

COURSE OUTCOME
At the end of the course, students should be able to:
3. Explain a simple
2. Perform the automation control
activities related to system related to
1.Determine the pneumatic, pneumatic,
fundamentals and hydraulic, electrical- hydraulic, electrical-
basic operating pneumatic control pneumatic control
principle of systems circuit, and systems circuit, and
automatic control PLC programming as PLC programming as
systems in applicable in applicable in
manufacturing manufacturing manufacturing
industry. [PO1, LO1] automation. [PO5, automation. [PO10,
LO3) LO5]
 1. History of automation and
industrial revolution

TOPIC 2. Definitions and reasons for

automation

CONTENT 3. Introduction to automatic control

system

4. Implementation of industrial
control systems
THE HISTORY OF
AUTOMATION
In the world of manufacturing, automation is a common way to get things
done in a safe, efficient way. To stay competitive, companies from many
different industries have added automated machines to their product
creation process.
The term “automation” gained popularity beginning in 1947, when Ford
created an automation department to help assemble automobiles. It was
derived from the word “automaton,” which is a term that refers to a self-
operating machine.
1. INDUSTRIAL REVOLUTION
2. DEFINITION OF Definition 1
The technique of making an apparatus, a
AUTOMATION process, or a system operate automatically.

Definition 2
The automatic operation of an apparatus,
process or system by mechanical or electrical
devices that aid or replace human operators.

Automatic: working by itself with little or no direct human control

Automation: a technology that is concerned with the use of
mechanical, electronic and computer based system in the operation
and control of production (Groover et al., 1986)
What is
Industrial Industrial Automation is a process
Automation? of operating machines and other
industrial equipment with the help
of digital logical programming and
reducing human intervention in
decision making and manual
command process with the help of
mechanized equipment.
Eg: An operator is observing the temperature of an oven.
Assume the task is to reach a certain temperature and maintain
that temperature for about 30 minutes.
Industrial Automation
Manual Industrial Production First, there is a temperature sensor placed near
Process the oven which reports the temperature to a
computer.
The operator has to first adjust the
Now, there is motorized valve, which is also
amount of fuel to the oven by controlling a
controlled by the computer, for the fuel to be
valve to rise the temperature to the
supplied to the oven. Based on the temperature
desired amount.
readings from the sensor, the computer will open
Once the necessary temperature is
the valve to allow more fuel in the beginning.
achieved, it has to be maintained by
Once the desired temperature is achieved, the
constantly adjusting the valve i.e. either
valve is shutoff. But the computer can open or
increase or decrease the fuel depending
close the valve, even to allow a tiniest amount of
on the temperature for the next 30
fuel to flow, based on the temperature readings.
minutes.
The timer in the computer will indicate once 30
minutes is up and the computer can completely
shut off the system
Motivation for
In the beginning, the industrial production process is
Industrial based on the eyes, hands and brain of a worker, in
contrast to modern day sensors, actuators and
Automation computers.
Originally, the implementation of automation in a
production process is focused on replacing a human
worker with an independent machine. Initially, these
independent machines had to be coordinated by a human
supervisor for a smooth production process.
But with technological developments in analog and
digital control systems, microprocessors and PLCs
(Programmable Logic Controllers) and various sensors, it
has become very easy to synchronize several
independent machines and processes and achieve true
industrial automation.
Reasons for Automating
Mitigate the effects of labor
Increase labor productivity
shortages

Reduce labor cost Improve worker safety

Reduce or eliminate routine manual and

Improve product quality
clerical tasks

Reduce manufacturing lead time

Reduce high cost of not automating
Accomplish processes that
cannot be done manually
Reasons for NOT Automating
Task is too technologically difficult
to automate

Short product life cycle

Customized product – one-of-a-kind

Flexibility in coping with changing demand

Levels of Industrial Automation Process
Supervisor Level Control Level Field Level
Sitting at the top of The Control Level is the mid- The terminal equipment like
hierarchy, the supervisor level in the hierarchy and Sensors and Actuators are
level usually consists of an this is the level where all categorized into Field Level
Industrial PC, which is the automation related in the hierarchy. The sensors
usually available as a programs are executed. For like temperature, optical,
desktop PC or a Panel PC or this purpose, generally, pressure etc. and actuators
a Rack-mounted PC. These Programmable Logic like motors, valves, switches
PCs run on standard Controllers or PLCs are used, etc. are interfaced to a PLC
operating systems with a which provide real-time through a field bus and the
special software, usually computing capability. communication between a
provided by the supplier for PLCs are usually Field Level device and its
industrial process control. implemented using 16-bit or corresponding PLC is usually
32-bit microcontrollers and based on a point-to-point
run on a proprietary connection.
operating system to meet
the real-time requirements.
Considering all the above-mentioned levels and their corresponding components, a typical Industrial Automation System will
have the following structure.
 Fixed Automation
System
Types of
Programmable
Automation Automation System

Flexible Automation
System

Integrated
Automation System
Fixed In a Fixed Automation System, the production equipment is
fixed with a fixed set of operations or tasks and there are
rarely any changes to these operations.

Automation Fixed Automation System is usually used in continuous flow

processes like conveyors and mass production systems.

Used in high demand volume and long product life cycle.

Advantage: Maximum efficiency and low unit cost.

Disadvantage: Large initial investment and inflexibility

Programmable In Programmable Automation System, the sequence of
operations as well as the configuration of the machinery
can be changed using electronic controls.

Automation This system requires a significant amount of time and

effort to reprogram the machines and usually used in batch
process production.

Advantage: Flexible to deal with changes in product, low

unit cost for large batch.

Disadvantage: High unit cost relative to fixed automation,

new product required long set-up time
Flexible A Flexible Automation System is usually, always controlled by
computers and are often implemented where the product varies
frequently.

Automation CNC machines are the bet example for this system. The code
given by the operator to the computer is unique to a particular
job and based on the code, the machine acquires the necessary
tools and equipment for the production

Low or medium product rates, varying demand, short product

life cycle

Advantage: Flexible to deal with design variations, customized

products

Disadvantage: Large initial investment, high unit cost relative to

fixed or programmable automation
Integrated An Itegrated Automation System is a set of independent

Automation machines, processes and data, all working synchronously

under the command of a single control system to implement
an automation system of a production process.

CAD (Computer Aided Design), CAM (Computer Aided

Manufacturing), computer-controlled tools and machines,
robots, cranes and conveyors are all integrated using
complex scheduling and production control.
Advantages The task performed by human operators involving tedious

of physical work can be easily replaced.

Human operators can avoid working in dangerous production

Industrial environments with extreme temperatures, pollution,

intoxicating elements or radio-active substances.

Automation The tasks that are difficult for a typical human operator can be
easily done. These tasks include lifting heavy and large loads,
working with extremely tiny objects etc.
Production is always faster and the cost of the product is
significantly less (when compared to the same product that is
produced with manual operation).
Several quality control checks can be integrated into the
production process to provide consistency and uniformity.
The economy of the industry can be significantly improved,
which has a direct impact on the standard of the living.
Disadvantages
of Industrial
Loss of jobs. Since, majority of the work is done by machines,
Automation the requirement for manual labor is very less.
All the desired tasks cannot be automated using the current
technology. For example, products with irregular shapes and
sizes are best left for manual assembly. (This trend seems to
be changing with advanced computers and algorithms).
It is feasible to use automation for certain process i.e. high-
volume production, repeatable and consistent products.
The initial cost of implementing an automation system is
very high.
A set of skilled personnel is always a requirement for
maintenance and service.
Introduction to Automatic
Control System
Introduction to Automatic
Control System
Manual Control Automatic Control
Three (3) main control system
components
Implementation
of Industrial Industrial control system (ICS) is a collective term
used to describe different types of control

Control System systems and associated instrumentation, which

include the devices, systems, networks, and

(ICS) controls used to operate and/or automate

industrial processes.
Depending on the industry, each ICS functions
differently and are built to electronically manage
tasks efficiently.
Today the devices and protocols used in an ICS
are used in nearly every industrial sector and
critical infrastructure such as the manufacturing,
transportation, energy, and water treatment
industries.
 Types of Industrial
Control System (ICS)
 Types of Industrial
Control System (ICS)
END OF CHAPTER 1
Please find more information in any referances and
recommended text book