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Introduction To Factory Automation: IE337 Automatic Control Systems KSU - College of Engineering - IE Department

This document introduces factory automation and control systems. It discusses four levels of factory automation from the machine to the plant level. Control systems can be continuous, dealing with smoothly changing values, or discrete, dealing with on/off states. Control systems can also be linear, nonlinear, or sequential depending on how the system is modeled. The document provides examples of elevator control to illustrate discrete and continuous systems and discusses open and closed loop control systems. It also covers classification based on time and resolution and stability in continuous closed loop systems.

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sudhir rai
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75 views

Introduction To Factory Automation: IE337 Automatic Control Systems KSU - College of Engineering - IE Department

This document introduces factory automation and control systems. It discusses four levels of factory automation from the machine to the plant level. Control systems can be continuous, dealing with smoothly changing values, or discrete, dealing with on/off states. Control systems can also be linear, nonlinear, or sequential depending on how the system is modeled. The document provides examples of elevator control to illustrate discrete and continuous systems and discusses open and closed loop control systems. It also covers classification based on time and resolution and stability in continuous closed loop systems.

Uploaded by

sudhir rai
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Chapter 1:

Introduction to Factory
Automation

IE337 Automatic Control KSU - College of Engineering - IE 1


Systems Department
1.1 A hierarchical model of factory automation;

There are four levels of factory automation namely:


1. Machine level automation
2. Production line or work cell automation
3. Shop floor automation
4. Plant level automation .

Course objectives focus on 1st level.

IE337 Automatic Control KSU - College of Engineering - IE 2


Systems Department
1.2 Control system requirements and automatic control

technologies

Control system
Continuous control system Discrete control system

Linear : e.g PID controller. Conditional: (Boolean – Expert system)


Nonlinear : e.g. MARC, Fuzzy. Sequential : (Temporal – Event)

Continuous: In this case the values to be controlled changes smoothly.


Discrete: The value to be controlled can be described as on or off, e.g. room light is switched on or off.
Linear systems: Linear systems can be represented using linear differential equations.
Non-linear systems: This is how the real world behaves, that will complicate the mathematical modeling of a
system behavior.
Sequential systems: The logic controller depends not only on time but also on the previous logic condition

Fig. 1.1 Main types of control systems

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Illustrated Example: Simple Elevator Problem

Discrete/sequential:
+ The elevator must move towards a floor when push button is used.
+ The elevator must open a door when it is at the floor level.
+ The elevator door must be closed before elevator travel.
+ The elevator door must suddenly open when the elevator door is jammed or
interrupted by the users.
+….etc.
Linear or continuous:
+ If desired level or position is updated, accelerate quickly towards the required
position
+ The elevator will slow-down or decelerate when approaching the new position.
+ …etc.

IE337 Automatic Control KSU - College of Engineering - IE 4


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Open loop systems
There is no link (feedback) between inputs and outputs
Controller has no feedback information on the evolution of
outputs

Input Control Mechanical

Instruction Action Action


Controller Actuator Controlled Process

Input material Output

Figure 1.2: Block diagram of open loop control system.

IE337 Automatic Control KSU - College of Engineering - IE 5


Systems Department
Closed loop systems

Inputs and outputs are connected with feedback loop


Controller has a feedback information on the evolution of
outputs
Input

Instruction.
controller Actuator Controlled
Output Process e.g.
e.g. Required heating element
power
Furnace output

temperature input material

Sensor, e.g.
thermocouple

Feed back loop

Figure 1.3 Block diagram of closed loop control system.

IE337 Automatic Control KSU - College of Engineering - IE 6


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Classification of systems and
control systems

Controlled system

Linear Non Linear

Continuous/Analog Discrete

Controller

IE337 Automatic KSU - College of Engineering - IE 7


Control Systems Department
Classification of control systems based on time and resolution

Time refers to how quickly it is necessary to update the information on the system state in order to affect
adequate control. Furthermore, continuous updating of information is required when system states change
rapidly.
 
Resolution refers to the precision with which it is necessary to measure the state of the system. For
example, maintain the room temp +/- 1 deg, requires high resolution. Switching a lamp in room ON/OFF
does not require high resolution because it is just binary information (on or off).

•Continuous control systems.


This type of system monitors the system constantly and adjusts the parameters of the control system.
The control system has closed loop plus short time response plus high resolution, e.g. Temp. control in
heat treatment furnace problem
Also possible: open loop (low resolution) plus short time response time. Bench mounted room heater
problem.
•Discrete event control systems.
In this control systems, the system often does not require time-critical control specifications or high-
resolution measurement, but just the existence of closed loop control or even open loop control.
e.g. Hooper filling problem can be open loop or closed loop system.

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Continuous and closed loop control system response system and its stability

Over-shot Steady state error

Time
Under-shot

Steering time
(a) Stable response system

Temperature error Er = (Tr-T)

Time
(b) Unstable system (oscillatory)

Temperature error Er = (Tr-T)

Time

(c)Unstable system with divergence

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Systems Department
Discrete open and closed loop control systems – Illustrated Applications
Flow control valve

Sensor 1

Hopper
Sensor 2

Figure 1.5 Hopper control through discrete event system.


Front position sensor Back position sensor

Permanent Magnet

rod cylinder

Pneumatic actuator

Figure 1. 6 Pneumatic cylinder position control problem.

IE337 Automatic Control KSU - College of Engineering - IE 10


Systems Department

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