basics of industrial automation Module 01 - introduction

1. INTRODUCTION TO
AUTOMATION
Ameya p. Nijasure
napradeep@mes.ac.in

2. Definition and fundamentals• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel
■ Definition
Automation is a set of technologies that results in operation of
machines and systems without significant human intervention & achive
performance superior to manual operations.
■ Key areas of industrial automation
– Controls & signal processing
– Communication & networking
– Simulation, design & analysis
– Optimization
– Real time computing
– Database & storage

3. Reasons for automation
■ To increase labour productivity
■ To reduce labour cost
■ To manage effect of labour shortage
■ To reduce/eliminate routine manual & clerical tasks
■ To improve worker safety
■ To reduce manufacturing lead time
■ To improve product quality
■ To accomplish process that can not be done manually
■ To avoid the high cost of not automating
• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel

4. Basic elements of automation system• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel
Program of
Instruction
Control Systems Process
Power
Set of instruction
• Work cycles
• Decision making
in programmed
cycle
• Open loop
control system
• Closed loop
control system
• Energy conversion
• requirements of
complete systems
• Mainly electrical
1. Power
2. Program of instructions
3. Control systems
4. Process

5. Advanced automation functions• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel
– To enhance performance and safety
■ Safety monitoring
■ Maintenance and repair diagnostics
■ Error detection and recovery
– It can be list of actions to be done by worker / maintenance or
can be set of instruction that performs automatically safety
measure, error detection and recovery tasks.

6. Safety, maintenance & repair
diagnosis
• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel
■ Safety
– To protect human workers in the vicinity of the system
– To protect equipment associated with the system
■ Maintenance and repair diagnostics
– Capabilities of an automated system to assist in the
identification of the source of potential or actual
malfunctioning & failures of systems.
■ Status monitoring
■ Failure diagnostics
■ Recommend repair procedure
■ sd

7. Error detection and recovery• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel
■ Detection
– Random errors
– Systematic errors
– aberrations
■ Problems in error detection
– To automate all of the possible errors that can generated in a
process
– To setup/specify appropriate sensor system & software so
that system is capable of recognizing each error
■ Recovery
– Make adjustment at the end of the current work cycle
– Make adjustments during current cycle
– Stop the process to invoke corrective action
– Stop the process & call for help

8. USA principle
■ U – understand the existing process
■ S – simplify the process
■ A – automate the process
• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
Understand Simplify automate
• Input-output
relationship
• Process charts, flow
charts
• Mathematical
modelling
• Simplification/
elimination
• Integration
• Purpose of each
step
• Automation
strategies
• Migration strategies
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel

9. Tens strategies of automation and
production systems
■ Specialization of operation
■ Combined operation
■ Integration of operation
■ Simultaneous operation
■ Increased flexibility
■ Improved material handling & storage
■ Online inspection
■ Process control & optimization
■ Plant operation control
■ CIM – computer integrated manufacturing
• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and
production systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel

10. Automation migration strategy• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
• Phase 1
manual production
• Phase II
automated production
• Phase III
automation integrated
production
• Advantages
• Introduction of new product in shortest possible time
• Avoids risk commitment at initial stage of product development
• Allows automation to introduce gradually as product gets final design
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel

11. Automation Manufacturing systems• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
MODULE NO - 01
■ Fixed automation is used
when the volume of production
is very high and therefore it is
appropriate to design
specialized equipment to
process the product effectively
and at high production rate.
■ Programmable automation is
used when the volume of
production is relatively low and
there are variety of products to
be made. The production
equipment is designed to be
adaptable to variations in
product configuration. Unique
products are made in small
batches.
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel
■ Flexible automation is used for
mid volume production size. It
possesses some of the features of
both fixed automation and
programmable automation.

12. 08-02-2019 By Prof. Ameya Nijasure - PCE New panvel
MODULE NO - 01
• Introduction to automation
• Definition
• Reason for automation
• Basic elements of
automation system
• Advanced automation
functions
• Safety, maintenance &
repair diagnosis
• Error detection and
recovery
• Automation principles &
Strategies
• USA principle
• Tens strategies of
automation and production
systems
• Automation migration
strategy
• Automation manufacturing
systems
• Levels of Automation
Levels of Automation
Enterprise Level
• Corporate information systems
Plant Level
• Production systems
Cell/system Level
• Manufacturing system – group of machines
Machine Level
• Individual machines
Device Level
• Sensors, actuators and Hardware elements
Level 01
Level 02
Level 03
Level 04
Level 05

13. Thank You….!!!
Ameya P. Nijasure
7093062719
napradee@mes.ac.in
08-02-2019 By Prof. Ameya Nijasure - PCE New panvel