Automation describes a wide range of technologies that reduce human intervention in processes, namely by predetermining decision criteria, subprocess relationships, and related actions, as well as embodying those predeterminations in machines. In this ppt presentation, we shall learn about Automation types, process,es and development.

1. INTRODUCTION
TO
INDUSTRIAL
AUTOMATION
Presented by Raj Nayak

2. DISCUSSION
POINTS
QUICK OVERVIEW
What is Automation?
Process Automation
Impacts of Automation
Classification of Automation
Automation In Production System
Applications of Automation
Evolution of Automation
Hierarchy of Automation
Basic Components of Automation
Different Technologies used in
Industrial Automation

3. AUTOMATION
Auto Mation
Self
To Move/
Moving
Matos(Greek)

4. The word "Automation" is derived from
the greek word "Auto" and "Matos"
where Auto means 'Self' while Metos
means 'To Move' or 'Moving'.
So, The word Automation gives the
meaning 'Self dictating' or 'a mechanism
move by itself'.

5. PROCESS
AUTOMATION
Working
Process
Process
Automation
+
Control
Process
Automation
Process
Process

6. PROCESS
AUTOMATION
Boiler Automation
Home Automation
Industrial Automation
The automation Process can be applied on any
working process or Machines or devices. These
are also known as Applications of Automation.
This working process on which Automation
process is applied is called Process Automation.
Eg.-

7. DEFINITION OF
AUTOMATION
Automation refers to the collection of
personnel, hardware, and software that can
affect or influence the safe, secure and reliable
operation of an industrial process.
Automation is the use of control systems, such
as computers or robots and information
technologies for handling different processes
and machinery to replace a human being.
Hence, Automation is the technique of making
an apparatus, a process, or a system operate
automatically.

8. IMPACTS OF
AUTOMATION
ADVANTAGES
Increase Productivity
Improve the quality of
product/process
Reduce Labour Cost
Reduce Maintenance Cost
Reduce Production Cost
Improve Safety in working conditions
Increase Efficiency
Improve Consistency of process
Reduce need of manual Checking, etc.

9. IMPACTS OF
AUTOMATION
DISADVANTAGES
Increase Unemployment
Higher Initial Cost
Unpredictable Maintenance Cost,
etc.

10. CLASSIFICATION
OF AUTOMATION
Three types:
Fixed or, Hard Automation
Programmable Automation
Flexible or Soft Automation

11. FIXED OR HARD
AUTOMATION
This type of Automation performs fixed and
repeatedly operations in order to achieve high
production rates.
It uses a special or, dedicated purpose
equipment to automate the fixed processing
design.
So, It is inflexible in providing product variety.
But it increases the efficiency with high
production rate and reduce the unit cost.
For Examle, 1. Maching Transfer Lines
2. Automated assembly Machines
etc.

12. PROGRAMMABLE
AUTOMATION
This type of Automation is designed with the
capacity to change the sequence of operation to
accommodate different product configurations
This type of automation is best suitable for the
Batch production process(Many Similar items
are produced together).
For Examle, 1. Paper Mills
2. Steel Rolling Mills, etc.

13. FLEXIBLEBLE OR
SOFT AUTOMATION
This is an extension of Programmable
Automation. A flexible Automated system is one
that is capable of producing a variety of
products (Or, Parts) with virtually no time lost for
changeovers from one product to the next.
There is no production time lost while
reprogramming the system and altering the
physical setup (tooling, fixtures and machine
setting).
For Examle, 1. Automobile Industry
2. Steel Rolling Mills, etc.

14. AUTOMATION
IN PRODUCTION
SYSTEM
PRODUCTION AUTOMATION

15. APPLICATIONS
OF
AUTOMATION
Automation is present in many
forms in our everyday life and
in industry.
Some Common examples are:
Industrial/Plant/Factory
Automation
Home/Office/Building
Automation
Scientific Automation
Network Automation
Data Center Automation

16. INDUSTRIAL
AUTOMATION
Industrial Automation uses a
combination of hardware and
software technologies that enable
control and management over
industries.
eg:-
1. Power Plant
2. Oil & Gas Refinery
3. Chemical Plants
4. Manufacturing Plants
5. Production Plants
6. Water Treatment Plant
7. Product Packaging, etc.

17. HOME
AUTOMATION
It uses a combination of hardware
and software technologies that
enable control and management over
appliances and devices within a
home/office or building.
eg:-
1. Lifts
2. Escalators
3. Traffic Light
4. Street Light
5. Home Appliances
6. BMS
7. DGs, etc.

18. SCIENTIFIC
AUTOMATION
It is used for the research and
development of any technology.
eg:-
1. Medical Science
a. ECG
b. EMG
c. X-Ray
d. MRI
2. Satellite Control
3. Missile Control, etc.

19. NETWORK
AUTOMATION
It is the process of Automating the
Configuration, management, and
operation of a computer Network.

20. DATA CENTER
AUTOMATION
It enables the bulk of the data center
operations to be performed by
software programs.

21. EVOLUTION/
HISTORY/
DEVELOPMENT
OF
AUTOMATION
Pneumatic Control
Manual Control
Hardwired Control
Electronics Control using logic Gates
Microprocessor &
Microcontroller Based Control
PLC/DCS Based Control

22. MANUAL
CONTROL
Likely human errors and consequently its
effect on quality of final product
The production, safety, energy consumption
and usage of raw material are all subject to
the correctness and accuracy of human action.
All the actions related to process control are
taken by the operators
Drawbacks

23. PNEUMATIC
CONTROL
Bulky and Complex System
Involves lot of rework to implement control
logic
Longer project time
Industrial automation, with its machine and
process control, had its origin in the 1920s with the
advent of "Pneumatic Controllers".
Actions were controlled by a simple manipulation
of pneumatic valves, which in turn were controlled
by relays and switches.
Drawbacks

24. HARDWIRED
CONTROL
Bulky panels
Complex wiring
Longer project time
Difficult maintenance and troubleshooting
The contactor and Relays together with hardware
timers and counters were used in achieving the
desired level of automation
Drawbacks

25. ELECTRONICS
CONTROL
USING LOGIC
GATE
Reduced space requirements
Energy saving
Less maintenance & greater reliability
Changes in control logic not possible
More project time
In 1960s with the advent of electronics, the logic
gates started replacing the relays and auxiliary
contactors in the control circuits.
The hardware timers & counters were replaced by
electronic timers
Advantages:
Drawbacks:

26. MICROPROCESSOR
&
MICROCONTROLLER
BASED CONTROL
They contain less no of input/output pins as
required for industrial purpose.
They are expensive & require more maintenance.
It works on only +5V dc power supply.
At the end of 1960s microprocessors and
microcontrollers replace all the electronic
controllers.
They are very small and programmable, due to
which it is used widely for domestic automation
purpose.
Drawbacks:

27. PLC/DCS BASED
CONTROL
They contain Sufficient I/Os as required for
industrial Purposes.
They require less maintenance.
It works on +24V dc or 230V AC power supply
which is easy to provide in Industry.
Easy to Program
In the early 90s PLC and DCS replace all the
previous controllers due to their industrial
advantages over them.
They are programmable, due to which it is used
widely for Industrial automation purpose.
Advantages:

28. HIERARCHY/
LEVELS OF
AUTOMATION
Here we will learn about various working
levels of Industrial Automation.
It is necessary to understand various levels
of Industrial Automation.
There are so many hardware devices,
software, IT infrastructure, and networking
involved; that it is a must to co-relate things
between them and understand what the
difference between them is.

30. FIELD LEVEL
It is the lowest level of the Automation
Hierarchy, which includes the field devices
like sensors and Actuators.
It Contains AC/DC Motors, relays, Valves,
Sensors, Barcodes, etc.
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

31. CONTROL LEVEL
This level consists of various Automatic
devices, like CNC machines, PLC, Robots, etc
which take the process parameters from the
various sensors & perform the control
technique.

32. SUPERVISION &
PRODUCTION
CONTROL LEVEL
In this level, Automatic devices are
monitored and controlled by HMI (Human
Machine Interface). In this level various
functions are Carried out like supervising
various parameters, setting production
targets , setting of machines like start or
shutdown etc.
In this level Mostly DCS (Distributed Control
System) or SCADA (Supervisory Control and
Data Acquisition) are popularly used.

33. INFORMATION &
ENTERPRISE
LEVEL
This is the top level of Industrial Automation,
which manages the whole Automation
system.
The task of this level includes Production
Planning, Customer and Market Analysis,
Orders and Sales, etc.

34. BASIC COMPONENTS
OF AUTOMATION
SYSTEMS
Input Devices or Sensing Elements
Controller
Output Devices

35. INPUT DEVICES
OR SENSING
ELEMENTS
The I/P devices are Sensors, Transducers,
Manual Switches, etc. They Sense the
parameters like pressure, Temperature and
gives feedback to the controller.

36. CONTROLLER
Controller is a heart of Automation Systems.
It may be PLC Or any other embedded
system devices.
Controller handles the operating systems,
Manages the memory, Monitor the I/P and
control the O/P devices.

37. OUTPUT
DEVICES
Output Devices are Controlled by the
controller, as according to the user logic or
coding.
Output devices may be Analog or Digital
devices.

38. DIFFERENT
SYSTEMS/
TECHNOLOGIES
FOR
INDUSTRIAL
AUTOMATION
PLC (Programmable Logic
Controller)
SCADA (Supervisory Control &
Data Acquisition)
DCS (Distributed Control
Systems)
HMI (Human Machine Interface)
VFD (Variable frequency drive)

39. PLC
PLC is an Industrial digital computer. It is used to
control a manufacturing process, such as
assembly lines or Robotics devices.
PLC can store the programs into a memory . It
also stores the parameters like Temperature,
Pressure, etc.

40. SCADA
SCADA is a control system Architecture, that uses
computers, Networked Data Communication and
graphical user Interface for high level Process.
It is a system of software and hardware elements,
that allows industrial organization to
a) control Industrial Process locally or an remote
location.
b) Monitor, gather and process realtime data.
c) Directly interface with devices such as
switches, Pumps, Motors etc.

41. DCS
A DCS is a Digital Automated Industrial Control
System.
It is not a centralized control system but are
distributed throughout the system, that operates
all the machineries.

42. HMI
HMI is a user interface of a control panel that
connects a person to a Machine, system or
device.

43. VFD
In Automation Systems any Motion Control is
done by drives.
Motion Control means:
a) Speed Control
b) Direction Control
c) Energy Saving

44. THANK YOU!
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