This document discusses automation components and architecture. It begins with definitions of automation and its history. It then covers types of production systems and automation, including fixed, programmable, flexible, and integrated automation. The architecture of industrial automation is described through five levels from sensors and actuators to the enterprise level. Sensors, actuators, controllers, and automation tools are also outlined. Social issues of automation and conclusions are presented.

1. AUTOMATION- COMPONENTS
AND ARCHITECTURE
Presented by
Adarsh M.Kalla
SEMINAR
1

2. CONTENTS
 Introduction
 History
 Mechanization vs. automation
 Role of automation in industry
 Types of production systems
 Types of automation
 Architecture of automation
 Automation control system
 Sensors and actuators 2

3. INTRODUCTION
 Automation - “auto” (self) and “matos” (moving) self acting
machine.
 Definition
Automation can generally be defined as set of
technologies that results in operation of industrial
machines and systems without significant human
intervention and achieves performance superior to manual
operation.
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4. INTRODUCTION
 Automation is achieved through the use of a variety of
devices, sensors, actuators, techniques and
equipments.
continuous observation
making decisions
controlling all aspects of it.
 Automation is applied in Trade, environmental
protection engineering, building engineering, medicinal
engineering, agriculture and food industry.
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5. HISTORY
 Automation has been introduced very early in the history of
human civilization. In the form of mechanical tools like wheel,
pulley, lever etc.
 Later many efficient power machines like steam engines,
electric motors, IC engines were introduced.
 Many electronic devices like triode, transistors, integrated
circuits (invented in 1958), which combined tiny transistors
 The IC laid a path for the introduction of the microprocessor
(first- Intel 4004, in 1971) which integrates all the function of
CPU of a computer.
 Now advanced control systems, with complicated control
functions have been developed. 5

6. AUTOMATION V/S MECHANIZATION
Mechanization Automation
Saves human muscle Saves use of human judgment
Displaces physical labor Displaces mental labor
It replaces craft work It replaces human thinking with
computers and sophisticated machines
Creates job for unskilled labor create jobs for skilled workers at the
expense of unskilled and semi-skilled
workers.
affects one or two industries at a time. affects many industries at a time.
moves slowly and the job
displacement is short term.
Moves rapidly and creates longer-term
job displacement
occurred during industrial revolution more characteristic since the 1950s. 6

7. ROLE OF AUTOMATION IN INDUSTRY
Raw/unfinished material
Energy, man power, infrastructure manufacturing process
Finished product
 Basic goal of industry is to make profit hence, it is necessary to understand
what affects the profit.
 The automation affects every aspects of profit making of an industry; hence
automation is very crucial for success of any industry.
 Profit = (price/unit – cost/unit) x production volume
cost profit
volume
price
profit
profit
7

8. COST/UNIT
Cost/unit
Material Energy Man power Infrastructure
Automation
8

9. PRODUCTION VOLUME
Total manufacturing time
Production time Material handling time Idle time Quality assurance time
The production volume can be increased if we can reduce the time required
to produce one unit product.
9

10. TYPE OF PRODUCTION SYSTEMS
Production system
Continuous manufacturing Discrete manufacturing
Continuous
flow process
Batch
process
Mass discrete
manufacturing
Job shops
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11. QUANTITY VARIETY CHART
Continuous
flow process
Mass
manufacturing of
discrete product
Batch process
Job shop
quantity
Variety
Machine tools,
prototypes
Pharmaceuticals, food
processing
Appliances ( TV, Mixers) ,
automobiles
Oil refinery, cement, fertilizer, iron and
steel
11

12. TYPES OF AUTOMATION
Automation systems
flexibleprogrammableFixed integrated
12

13. FIXED AUTOMATION
Features
High volume of production
Dedicated equipments
Fixed efficient operation
Factory types
Continuous flow
Discrete mass
production
Examples
Process automation
Conveyors
Paint shops
Transfer lines
13

14. PROGRAMMABLE AUTOMATION
Features
Changeable sequence of operation
Electronic controls
Factory types
Batch process
Mass production
Examples
Numerically controlled
machines
Assembly robots
Numerically controlled lathe
14

15. FLEXIBLE AUTOMATION
Features
Computer controlled with graphically user interface, so that operator can
operate it.
Changes should be preprogrammed, so that operator select certain
parameters and rest is done automatically.
Programmable material handling
Factory types
Job shops
Batch processes
Examples
CNC machining centers
Automatic guided vehicles
Automated guided vehicle
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16. INTEGRATED AUTOMATION
Features
Advanced optimizing algorithms
There is lot of knowledge built in them and they do lot of mathematical
calculations based on sophisticated models.
Computer communication : To integrate various parts you require computer
communication
Production/ management integration
Factory types
To all types of factories
large
Examples
Chemical process automation
Plant with computer integrated
manufacturing
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17. ARCHITECTURE OF INDUSTRIAL AUTOMATION
Production control
Supervisory control
Enterprise
Automatic control
Sensors and actuators
Process/ machine
Level 4
Level 3
Level 2
Level 1
Level 0
Spatialscale/timescale
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18. Contd……
 Not all these layer are perfectly automated.
 Sensors and actuators and automatic controls are
automated.
 From the supervisory control upwards they are not
completely automated.
 E.g. in supervisory control- you will have cabinets with
computers monitored by process supervisor and
operators.
 Production control level- performed by humans with aid
of tools
 Production manager, shift in charge engineer, T.O
 They are mix of manual and automated tools.
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19. NATURE OF LEVEL
 The spatial scale and time scale increases as the level is
increased.
 For e.g. at level 0--- one sensor will measure one process
variable.
 At level 1---one automatic controller may be taking control
action by considering several sensors.
 At level 2--- looks after one piece of equipment having
many control loops.
 At level 3--- the product control is typically done at section
level containing several equipments. 19

20. INDUSTRIAL CONTROL SYSTEM
controller plantActuator
Sensor
Output
Set point
20

21. SENSORS
Physical
medium
Sensing
element
Signal
conditioning
Signal
processing
Target
signal
handling
element
21

22. ACTUATORS
Signal
processing
element
Power
amplifying
element
Variable
conversion
element
Energy
conversion
element
process
22

23. ACTUATORS
 Signal processing element--accepts the command from
the control system and processes it in various ways.
 Eliminates frequencies that may cause resonance
 Power amplification element--contains linear power
amplification stages called servo-amplifiers.
 Variable conversion element-- alters the nature of the
signal from electrical to non-electrical form, generally in
the form of motion.
 Eg. electro hydraulic servo valve, stepper/servo motors
etc
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24. ACTUATORS
 energy conversion elements-- may be used further to transform
the actuated variable in desired forms.
e.g. motion-to-flow rate conversion in flow-valves, rotary to
linear motion converters using mechanisms, flow-rate to heat
conversion using steam or other hot fluids etc.
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25. CONTROLLERS
 A device which accepts the inputs , measure them and
depending on the predetermined conditions actuate one or more
devices is called the controller.
 Inputs allow a controller to read temperatures, humidity,
pressure, current flow, air flow, and other essential factors.
 The outputs allow the controller to send command and control
signals to slave devices, and to other parts of the system. 25

26. TYPES OF CONTROLLERS
1. Parameter or physical quantity they are controlling
Examples- Temperature controller, RPM controller, Pressure
controller etc.
2.The manner in which they are controlling the Physical quantity
Proportional controller P
Proportional Integral controller PI
Proportional Integral derivative Controller PID
ON –OFF Controller
3.The device used for controlling –
PLC , PAC, Digital circuits using comparators
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27. AUTOMATION TOOLS
 HMI – Human machine interface
 DSC – Distributed control system
 PLC – programmable logic controller
 PAC – Programmable automation controller
 SCADA – Supervisory control and data acquisition
 ANN- Artificial neural network
 Instrumentation
 Motion control
 Robotics
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28. SOCIAL ISSUES OF AUTOMATION
 Automation impact on employment.
 But automation need not bring unemployment for two
reasons
 It is a temporary displacement which can be offset by the
demands of a broadening market, as well as the creation
of new industries.
 Automation is the necessary solution to a predicted
shortage of labour. It is designed to the work of men who
are not there.
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29. CONCLUSION
 Automation has many advantages including making our
lives comfortable and enable human beings to do the
things which otherwise would have been impossible to
do manually with same efficiency and accuracy.
 Automation changes the nature of jobs and demands new
skills and it is a myth that it leads to unemployment…
…… “It is a solution to a problem, not a cause”.
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30. REFERENCES
 Gupta, K.A. and Arora, K.S. (2007). Industrial Automation and
Robotics. 1st Edition. Pub by Laxmi publication (P) LTD, 113,
Golden House, Daraganj, NewDelhi- 110002.
 Sharma, S.L.K. (2001). Overview of Industrial Process Automation.
1st Edition. Pub by Elsevier publication, 32 Jamestown road
London.
 Bissell, C.C. (2009). A History of Automation control, Handbook of
Automation. springer publication. P 1-18.
 Harrision, S.C. (2004). A review of Automation manufacturing
illustrated by a case study on mixed model hot forging.
Manufacturing review 1, 15.
 Ilyukhin, V.S., Haley, A.T. and Singh, K.R. (2001). A survey of
automation practices in the food industry. Food control, vol 12(5). p
285-296.
 Doxanakis, E. and Kefalas,A. (2008). Automation in dairy industry.
In advanced dairy science and technology Ed by britz, J.A. and
Robinson, K.R. pub by blavkwell publishing ltd, 9600, Garsington
Road, oxford, U.K. p. 122. 30

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