DJM5013-

CHAPTER 1.0 INDUSTRIAL

AUTOMATION
INTRODUCTION
AND BASIC DIPLOMA IN
MECHATRONIC

CONCEPT OF
ENGINEERING
MECHANICAL
ENGINEERING
AUTOMATION DEPARTMENT
POLIMAS
 DEFINITION OF INDUSTRIAL AUTOMATION
WHAT IS INDUSTRIAL AUTOMATION?

• Automation takes a step further mechanization that uses a particular

machinery mechanism aided human operators for performing a task.
Mechanization is the manual operation of a task using powered
machinery that depends on human decision making.
• On the other hand, automation replaces the human involvement with
the use of logical programming commands and powerful machineries.
 DEFINITION OF INDUSTRIAL AUTOMATION
WHAT IS INDUSTRIAL AUTOMATION?

• Industrial Automation is the replacement with computers and machines to

that of human thinking. The word Automation gives the meaning ‘self
dictating’ or ‘a mechanism move by itself’ that derived from the Greek
words Auto and Matos where auto means self while Matos means moving.
• In a brief, industrial automation can be defined as the use of
set technologies and automatic control devices that results the
automatic operation and control of industrial processes without significant
human intervention and achieving superior performance than manual
control. These automation devices include PLCs, PCs, PACs, etc. and
technologies include various industrial communication systems.
DEFINITION OF INDUSTRIAL AUTOMATION
WHAT IS INDUSTRIAL AUTOMATION?

The figure shows the power

plant automation provided by
Siemens for achieving
sustainable, safe and
economic operations. It
provides the total integrated
automation (TIA) by
automating every section of
power plant with efficient
control devices, field sensors
and actuating devices. In this
automation, SIMATIC modules
(PLCs) are used as control
devices while WinCC provides
an effective graphical
interface.
DEFINITION OF INDUSTRIAL AUTOMATION
WHAT IS INDUSTRIAL AUTOMATION?
 STATE THE ADVANTAGES OF INDUSTRIAL
AUTOMATION

To increase productivity
• Automation of factory or
manufacturing or process
plant improves production
rate through a better control
of production. It helps to
produce mass production by
drastically reducing assembly
time per product with a
greater production quality.
Therefore, for a given labor
input it produces a large
amount of output.
 STATE THE ADVANTAGES OF
INDUSTRIAL AUTOMATION

To provide optimum cost of

operation
• Integration of various
processes in industry with
automated machineries,
minimizes cycle times and
effort and hence the need of
human labor gets reduced.
Thus the investment on
employees has been saved
with automation.
 STATE THE ADVANTAGES OF
INDUSTRIAL AUTOMATION

To improve product quality

• Since the automation reduces
the human involvement, the
possibility of human errors
also gets eliminated.
Uniformity and product quality
with a greater conformity can
be maintained with
automation by adaptively
controlling and monitoring the
industrial processes in all
stages right from inception of
a product to an end product.
 STATE THE ADVANTAGES OF
INDUSTRIAL AUTOMATION

To reduce routine checks

• Automation completely
reduces the need for manual
checking of various process
parameters. By taking
advantage of automation
technologies, industrial
processes automatically
adjusts process variables to
set or desired values using
closed loop control
techniques.
 STATE THE ADVANTAGES OF
INDUSTRIAL AUTOMATION

To raise the level of safety

• Industrial automation
increases the level of safety
to personnel by substituting
them with automated
machines in hazardous
working conditions.
Traditionally, industrial robots
and robotic devices are
implemented in such risky
and hazardous places.
 STATE THE DISADVANTAGES OF
INDUSTRIAL AUTOMATION

Cannot perform complicated or

non-repetitive tasks:
• one of the main disadvantages
of automated machines is that,
since they are programmed,
they are only able to do tasks
that are programmed in them
and only can do these tasks
repeatedly. The machines do not
have a mind of its own, so they
cannot do a variety of tasks at a
time like their human
counterparts.
 STATE THE DISADVANTAGES OF
INDUSTRIAL AUTOMATION

They are costly: they have high

initial investment:
• Since, many automated
machines use the latest
hardware, software and
technology it is a given that
these are very expensive and
they require a lot of money and
high investment. As a starting
manager or a business owner,
you will have to find a way that
can allow you to produce such a
high investment.
 STATE THE DISADVANTAGES OF
INDUSTRIAL AUTOMATION

Require maintenance and training:

• another disadvantage of
automated machines is that they
require high maintenance and for
proper usage of the machines
workers are required to go
through intense training and
should learn how to properly use
the machine for high quality
results. Having a god training to
the workers assures a good
functionality for the machine.
IDENTIFY TYPES OF AUTOMATION

1. FIXED AUTOMATION
This type of automation is
employed to perform fixed and
repetitive operations in order to
achieve high production rates. It
uses special purpose or dedicated
equipment to automate the fixed
sequence assembling or processing
operations. Once it is employed, it
is relatively hard to change or vary
the product design. Therefore, it is
inflexible in providing product
variety, but increases the efficiency
with higher production rate and
reduces unit cost. Some of these
automated systems are distilled
process, paint shops and
conveyors.
IDENTIFY TYPES OF AUTOMATION

FIXED AUTOMATION
 IDENTIFY TYPES OF AUTOMATION

2. PROGRAMMABLE AUTOMATION

• In this automation, a specific class of

product changes and also assembling
or processing operations can be
changed with the modification of control
program in the automated equipment.
• This automation is best suited for batch
production process where product
volume is medium to high. But in this, it
is hard to change and reconfigure the
system for a new product or sequence
of operations. Therefore, new product
or reconfigure of sequence of
operations requires a long setup.
• Examples of this automation system
are numerically controlled machines,
paper mills, steel rolling mills, industrial
robots, etc.
 IDENTIFY TYPES OF AUTOMATION

2. PROGRAMMABLE AUTOMATION
IDENTIFY TYPES OF AUTOMATION

3. FLEXIBLE AUTOMATION
• This automation system provides the
automatic control equipment that
offers a great flexibility for making
changes in the product design. These
changes can be performed quickly
through the commands given in the
form of codes by the human
operators.
• This automation allows the
manufacturers to produce multiple
products with different ranges as a
combined combination process rather
than separate.
• Some of the examples of this
automation system are automatic
guided vehicles, automobiles, and
multipurpose CNC machines.
IDENTIFY TYPES OF AUTOMATION

3. FLEXIBLE AUTOMATION
 AUTOMATION IN PRODUCTION SYSTEM

TYPES OF PRODUCTION AUTOMATION

 DESCRIBE THE AUTOMATION
IN PRODUCTION SYSTEM

• Industrial automation systems can be very complex in

nature, having large number of devices working in
synchronization with automation technologies. The figure
describes the hierarchical arrangement of the automation
system consisting of different hierarchical levels.
 DESCRIBE THE AUTOMATION
IN PRODUCTION SYSTEM
FIELD LEVEL
• It is the lowest level of the automation
hierarchy which includes the field devices like
sensors and actuators. The main task of these
field devices is to transfer the data of
processes and machines to the next higher
level for monitoring and analysis. And also it
includes the controlling of process parameter
through actuators. For instance, we can
describe this level as eyes and arms of a
particular process.
• Sensors convert the real time parameters like
temperature, pressure, flow, level, etc into
electrical signals. This sensor data further
transferred to the controller so as to monitor
and analyze the real time parameters. Some of
the sensors include thermocouple, proximity
sensors, RTDs, flow meters, etc.
• On other hand actuators converts the electrical
signals (from the controllers) into mechanical
means to control the processes. Flow control
valves, solenoid valves, pneumatic actuators,
relays, DC motors and servo motors are the
 DESCRIBE THE AUTOMATION
IN PRODUCTION SYSTEM
CONTROL LEVEL
• This level consists of various
automation devices like
CNC machines, PLCs, etc.,
which acquires the process
parameters from various
sensors. The automatic
controllers drive the
actuators based on the
processed sensor signals
and program or control
technique.
 DESCRIBE THE AUTOMATION IN
PRODUCTION SYSTEM
PROGRAMMABLE LOGIC
CONTROLLERS (PLCS)
• most widely used robust
industrial controllers which
are capable of delivering
automatic control functions
based on input from
sensors. It consists of
various modules like CPU,
analog I/O, digital I/O and
communication modules. It
allows the operator to
program a control function or
strategy to perform certain
automatic operation on
process.
 DESCRIBE THE AUTOMATION IN
PRODUCTION SYSTEM
SUPERVISING AND
PRODUCTION CONTROL LEVEL
• In this level, automatic devices
and monitoring system facilitates
the controlling and intervening
functions like Human Machine
Interface (HMI), supervising
various parameters, setting
production targets, historical
archiving, setting machine start
and shutdown, etc.
• Mostly, either Distribution
Control System (DCS)
or Supervisory Control and
Data Acquisition
(SCADA) HMIs are popularly
used in this level.
 DESCRIBE THE AUTOMATION IN
PRODUCTION SYSTEM
SUPERVISING AND
PRODUCTION CONTROL LEVEL
• This is the top level of the industrial automation
which manages the whole automation system.
The tasks of this level include production
planning, customer and market analysis, orders
and sales, etc. So it deals more with commercial
activities and less with technical aspects.
• And also industrial communication networks are
most prominent in industrial automation systems
which transfer the information from one level to
the other. So these are present in all the levels of
automation system to provide continuous flow of
information. This communication network can be
different one level to the other. Some of these
networks include RS485, CAN, DeviceNet,
Foundation Field bus, Profibus, etc.
• From the above hierarchy we can conclude that
there is continuous information flow from high
level to low level and vice-versa. If we assume
this graphical way, it is like a pyramid in which as
we go up, the information gets aggregated and
while going down, we get detailed information
about the process.
AUTOMATION
IN
PRODUCTION
SYSTEM
BASIC
CONCEPT OF
ROBOT
TERMINOLOGY
DESCRIBE THE BASIC CONCEPT
OF INDUSTRIAL ROBOT
An industrial robot is a general-purpose, programmable machine. It possesses some
anthropomorphic characteristics, i.e. human-like characteristics that resemble the human
physical structure. The robots also respond to sensory signals in a manner that is similar to
humans. Anthropomorphic characteristics such as mechanical arms are used for various
industry tasks. Sensory perceptive devices such as sensors allow the robots to
communicate and interact with other machines and to take simple decisions. The general
commercial and technological advantages of robots are listed below:

 Robots are good substitutes to the human beings in hazardous or uncomfortable work
environments.

 A robot performs its work cycle with a consistency and repeatability which is difficult for
human beings to attain over a long period of continuous working.

 Robots can be reprogrammed. When the production run of the current task is completed,
a robot can be reprogrammed and equipped with the necessary tooling to perform an
altogether different task.

 Robots can be connected to the computer systems and other robotics systems.
Nowadays robots can be controlled with wire-less control technologies. This has
 DESCRIBE THE BASIC
CONCEPT OF:
LINK AND JOINT
• The manipulator of an industrial robot consists of a
series of joints and links. Robot anatomy deals with
the study of different joints and links and other
aspects of the manipulator's physical construction.
A robotic joint provides relative motion between
two links of the robot. Each joint, or axis, provides a
certain degree-of-freedom (dof) of motion. In most
of the cases, only one degree-of-freedom is
associated with each joint. Therefore the robot's
complexity can be classified according to the total
number of degrees-of-freedom they possess.
• Each joint is connected to two links, an input link
and an output link. Joint provides controlled relative
movement between the input link and output link. A
robotic link is the rigid component of the robot
manipulator. Most of the robots are mounted upon
a stationary base, such as the floor. From this base,
a joint-link numbering scheme may be recognized
as shown in Figure 7.5.1. The robotic base and its
connection to the first joint are termed as link-0.
The first joint in the sequence is joint-1. Link-0 is
the input link for joint-1, while the output link from
joint-1 is link-1—which leads to joint-2. Thus link 1
is, simultaneously, the output link for joint-1 and
the input link for joint-2. This joint-link-numberingJoint-link scheme for robot manipulator
scheme is further followed for all joints and links in
the robotic systems.
 DESCRIBE THE BASIC
CONCEPT OF:
LINK AND JOINT
• a) Linear joint (type L joint)
• The relative movement between the input link
and the output link is a translational sliding
motion, with the axes of the two links being
parallel.
• b) Orthogonal joint (type U joint)
• This is also a translational sliding motion, but
the input and output links are perpendicular to
each other during the move.
• c) Rotational joint (type R joint)
• This type provides rotational relative motion,
with the axis of rotation perpendicular to the
axes of the input and output links.
• d) Twisting joint (type T joint)
• This joint also involves rotary motion, but the
axis or rotation is parallel to the axes of the
two links.
• e) Revolving joint (type V-joint, V from
the “v” in revolving)
• In this type, axis of input link is parallel to the
axis of rotation of the joint. However the axis
of the output link is perpendicular to the axis Types of Joints
 DESCRIBE THE BASIC
CONCEPT OF:
LINK AND JOINT
• a) Linear joint (type L joint)
• The relative movement between the input link
and the output link is a translational sliding
motion, with the axes of the two links being
parallel.
• b) Orthogonal joint (type U joint)
• This is also a translational sliding motion, but
the input and output links are perpendicular to
each other during the move.
• c) Rotational joint (type R joint)
• This type provides rotational relative motion,
with the axis of rotation perpendicular to the
axes of the input and output links.
• d) Twisting joint (type T joint)
• This joint also involves rotary motion, but the
axis or rotation is parallel to the axes of the
two links.
• e) Revolving joint (type V-joint, V from
the “v” in revolving)
• In this type, axis of input link is parallel to the
axis of rotation of the joint. However the axis
of the output link is perpendicular to the axis Types of Joints
 DESCRIBE THE BASIC
CONCEPT OF:
LINK AND JOINT
• a) Linear joint (type L joint)
• The relative movement between the input link
and the output link is a translational sliding
motion, with the axes of the two links being
parallel.
• b) Orthogonal joint (type U joint)
• This is also a translational sliding motion, but
the input and output links are perpendicular to
each other during the move.
• c) Rotational joint (type R joint)
• This type provides rotational relative motion,
with the axis of rotation perpendicular to the
axes of the input and output links.
• d) Twisting joint (type T joint)
• This joint also involves rotary motion, but the
axis or rotation is parallel to the axes of the
two links.
• e) Revolving joint (type V-joint, V from
the “v” in revolving)
• In this type, axis of input link is parallel to the
axis of rotation of the joint. However the axis
of the output link is perpendicular to the axis Types of Joints
 DESCRIBE THE BASIC
CONCEPT OF:
DEGREE OF FREEDOM
(DOF)
• Each degree of freedom
is a joint on the arm, a
place where it can bend
or rotate or translate.
You can typically identify
the number of degrees of
freedom by the number
of actuators on the robot
arm.

The Arduino braccio is a 6 axis robot arm.

 DESCRIBE THE BASIC
CONCEPT OF:
DEGREE OF FREEDOM
(DOF)
• It is called as six degrees of freedom or six-
axis robot because it is capable of rotating
at six different axes. The following list
specifies the functions of each axis.
•
• Axis 1 – It is located at the base of a robot,
and helps it to rotate from left to right.
• Axis 2 – It helps the lower arm of a robot to
move in an up and down motion.
• Axis 3 – It allows the upper arm of a robot
to move forward and backward.
• Axis 4 – This axis is known as wrist roll, and
it rotates the upper arm of a robot in a
circular movement.
• Axis 5 – It permits the wrist of the robot’s
arm to raise and lower.
• Axis 6 – It allows the wrist of the robot’s
arm to rotate freely in a circular motion.
• All the above six axes are controlled with
the help of servo motors.
The Arduino braccio is a 6 axis robot arm.
 DESCRIBE THE BASIC
CONCEPT OF:
ORIENTATION AXES
Basically, if the tool is held at a
fixed position, the orientation
determines which direction it
can be pointed in. Roll, pitch
and yaw are the common
orientation axes used. Looking
at the figure below it will be
obvious that the tool can be
positioned at any orientation in
space. (imagine sitting in a
plane. If the plane rolls you will
turn upside down. The pitch
changes for takeoff and
landing and when flying in a
crosswind the plane will yaw.)
 DESCRIBE THE BASIC
CONCEPT OF:
POSITION AXES
The tool, regardless of
orientation, can be moved to a
number of positions in space.
Various robot geometries are
suited to different work
geometries. The definition of
an object's location in 3-D
space, usually defined by a 3-
D coordinate system using X,
Y, and Z coordinates. Part of a
robot can move to a spot
within its work envelope,
using devices that tell it
exactly where it is. Translatory
degrees of freedom.
 DESCRIBE THE BASIC
CONCEPT OF:
TOOL CENTRE POINT (TCP)
Tool Centre Point (TCP) -
The tool centre point is
located either on the robot,
or the tool. Typically the
TCP is used when referring
to the robots position, as
well as the focal point of the
tool. (e.g. the TCP could be
at the tip of a welding torch)
The TCP can be specified in
cartesian, cylindrical,
spherical, etc. coordinates
depending on the robot. As
tools are changed we will The Tool Center Point (TCP)
often reprogram the robot
for the TCP.
 DESCRIBE THE BASIC
CONCEPT OF:
WORK
ENVELOPE/WORKSPACE
• A robot's work envelope is its range
of movement. It is the shape
created when a manipulator reaches
forward, backward, up and down.
These distances are determined by
the length of a robot's arm and the
design of its axes. Each axis
contributes its own range of motion.
• A robot can only perform within the
confines of this work envelope. Still,
many of the robot are designed with
considerable flexibility. Some have
the ability to reach behind
themselves. Gantry robots defy
traditional constraints of work
envelopes. They move along track
systems to create large work
spaces.
 DESCRIBE THE BASIC
CONCEPT OF:
SPEED OF MOVEMENT
Speed with which the robot can
manipulate the end effector
Acceleration/deceleration
times are crucial for cycle time.
Determined by
– Weight of the object
– Distance moved
– Precision with which object
must be positioned
 DESCRIBE THE BASIC
CONCEPT OF:
PAYLOAD
It is very important to
consider the robot
application when
determining the maximum
payload.
Robot payload is the
weight a robot arm can
lift. It includes the weight
of the end of arm tooling
FANUC's strongest robot can handle (EOAT). Maximum payload
2300kg, Motoman's strongest robot can varies from robot to
handle 800kg, ABB's strongest robot can
handle 800kg, and KUKA's strongest robot robot.
can handle 1000kg.
 DESCRIBE THE BASIC
CONCEPT OF:
REPEATABILITY
Repeatability is the ability of a
robot to return to the same spot
with only the slightest variation.
Robotic repeatability varies by
robot, but generally ranges
between +/-0.02mm to +/-
0.4mm and is very important to
robot performance. It is achieved
when multiple robot components
- controls, motors, gears, axes -
work together. When robot
repeatability numbers are not
within the correct range, each
the repeatability of a robot might be defined as its axis is tested so the problem can
ability to achieve repetition of the same task be pinpointed and corrected.
DESCRIBE THE BASIC
CONCEPT OF:
ACCURACY
accuracy is the difference (i.e.
the error) between the
requested task and the
obtained task (i.e. the task
actually achieved by the robot).
accuracy is hitting your target each
time
“Accuracy is the ability of a
robot to move its end
effector to a desired position
and orientation that has
never been attained before.”
DESCRIBE THE BASIC
CONCEPT OF:
SETTLING TIME
During a movement, the
robot moves fast, but as the
robot approaches the final
position is slows down, and
slowly approaches. The
settling time is the time
required for the robot to be
within a given distance from
the final position. The time-
instant when the actual
output converges to the
desired output is known as
the settling time.
 DESCRIBE THE BASIC
CONCEPT OF:
CONTROL RESOLUTION

Resolution is based on a limited number of points

that the robot can be commanded to reach for,
these are shown here as black dots. These points
are typically separated by a millimeter or less,
depending on the type of robot. This is further
complicated by the fact that the user might ask for
a position such as 456.4mm, and the system can
only move to the nearest millimeter, 456mm, this
is the accuracy error of 0.4mm.
 DESCRIBE THE BASIC
CONCEPT OF:
CONTROL RESOLUTION

In a perfect mechanical situation

the accuracy and control resolution
would be determined as below,
 DESCRIBE THE BASIC
CONCEPT OF:
CONTROL RESOLUTION
Kinematic and calibration errors basically
shift the points in the workspace resulting in
an error ‘e’. Typically vendor specifications
assume that calibration and modeling errors
are zero.
DESCRIBE THE BASIC
CONCEPT OF:
COORDINATES
 For the programmer, various robot coordinate systems are
available, which can be used to determine for example the
position and orientation of the TCP much easier, to get the
geometry of a workpiece.
 Robotic systems are generally defined as Cartesian coordinate
systems:
1) Robot World Coordinate System
2) Robot origin coordinate system or ROBROOT coordinate
system
3) Workpiece and / or BASE coordinate system
4) Robot Tool coordinate system

 The ROBOOT-Koordinatensystem is a cartesian coordinate

system, which has its origin at the footprint of a robot. It
describes the position of the robot regarding the World-
coordintes.

 It is useful to set the origin of the ROBOOT coordinate system

with the origin of the WORLD coordinate system. See
the figure.