Introduction to basic automation and types and components of automation for mechanical engineer.

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Automation
and
Artificial Intelligence
Objectives:
1. To understand the need and justification of automation.
2. To study design of pneumatic and hydraulic circuits.
3. To study and understand electropneumatic circuits and PLC Design
4. To familiarize with robotic systems in automated manufacturing
processes.
5. To study and understand AI and machine learning technologies for
automation
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Outcomes: Learner will be able to…
1. Demonstrate understanding of fundamentals of industrial
automation and AI.
2. Design & develop pneumatic / hydraulic circuits.
3. Design and develop electropneumatic circuits and PLC ladder logics.
4. Demonstrate understanding of robotic control systems and their
applications.
5. Demonstrate understanding of various AI and machine learning
technologies.
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INTRODUCTION TO AUTOMATION

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Automation
➢The technology by which process or procedure is performed
with minimum human interference through the use of
technological and mechanical devices.
➢It is the technique of making process or system operate by itself
or automatic.
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Key Development milestones in
history of Automation
➢1769 - Invention of steam
Engine by James Watt
➢1820 – Relation b/w electricity & Magnetism invented
by Danish physicist Oersted.
➢1834 - Thomas Davenport invent the
DC motor with commutator.
➢1866 – Electric motor become widely used after Werner Von Siemens invented the
Dynamo that provided simple way of generating electric current in large quantities.
The electric motor Replaced the steam engine as driving component
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History of Automation
➢1913 - Henry Ford introduces first assembly line production system
➢1873 - Patent was granted for a fully automatic machine for manufacturing Screws. by
Christopher Spencer
➢1959 - Joseph Engelberger patented the prototype of industrial robot.
➢1968 – Team from American company Allen Bradley under the team of Odo Strugar.
Developed 1st PLC
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Pros and Cons of Automation
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Basic Elements of Automated System
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1. Power to accomplish the and operation
2. A program of instruction to direct the process
3. A control system to Actuate the instructions
Power Source
➢An automated process is used to operate some process and power is required
to drive the process as well as controls.
➢The principal source of power in automated systems is Electricity. Electric
power has many advantages in automated as well as nonautomated processes
➢Electrical power is widely “Available at moderate cost. It is an important part of our
industrial infrastructure
➢Electrical power can be readily converted to alternative energy forms: mechanical, thermal,
light, acoustic, hydraulic, and pneumatic.
➢Electrical power at low levels can be used to accomplish functions such as signal
transmission, information processing, and data storage and communication.
➢Electrical energy can be stored in long life batteries for use in locations where an external
source of electrical power is not conveniently available.
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Continue…
The actions performed by automated systems are generally of two types
➢Processing
➢Transfer and Positioning
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Program Of Instructions
➢The programmed instructions determine the set of actions that is to be
accomplished automatically by the system.
➢The program specifies what the automated system should do and how its
various components must function in order to accomplish the desired result.
➢Work Cycle Programs
➢The simplest example is the control of furnace temperature (process parameter) at a
specified value (One Step)
➢More Complicated Example :
1. Load the Part into the production machine
2. Perform the Process (eg. Machining, Welding, Shaping, Printing Etc.)
3. Unload the Part.
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Control System
The Control system of an automated system executes the
program of Instructions
The Controls in an automated system can be
a) Closed Loop
b) Open Loop
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Closed loop Control System
➢It is also known as feedback control system
➢In this system output variable compared with input parameter.
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Controller Process
Actuator
Feedback
Sensor
Input parameter Output parameter
1
5
4
3
2
6
Controller Process
Actuator
Input parameter Output parameter
1
5
3
2
6
Components of Control System
➢The input parameter, often referred to as the setpoint represent the desired value of
output.
➢The Process, is the operation or function being controlled.
➢The output variable, is some process variable perhaps the critical performance measure
in the process e.g. Temperature, Force, Flowrate etc
➢The feedback sensor, is used to measure the output variable and close the loop b/w Input
& Output. It is also performs as feedback function.
➢The controller, compares the output with input and make the required adjustment in the
process to reduce the difference b/w them.
➢The adjustment is accomplished using one or more Actuators, which are the hardware
device which physically carry out the control actions. E.g. Electric motor, Flow control valve etc.
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Open loop Control System
➢It is without the feedback loop.
➢In this case controls operates without measuring the output variables.
➢There is always risk that the actuator will not have intended effect on the
process
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Controller Process
Actuator
Input parameter Output parameter
1
2 4
3
Levels of Automation & Control in
Manufacturing
There are five Possible levels of automation for production plant
1. Device Level
2. Machine Level
3. Cell or System Level
4. Plant Level
5. Enterprise Level
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Enterprise Level
Plant Level
Cell or System
Level
Machine Level
Device Level
2
1
3
4
5
Corporate
Information System
Production System
Manufacturing System-
Groups of Machines
Sensors, Actuators, other
Hardware Elements
Individual Machine
Types of Automation
There are three basic categories of automation
1. Fixed Automation
2. Programable Automation
3. Flexible Automation
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i. Fixed Automation
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Programable Automation
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Flexible Automation
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Advanced Automation Functions
In addition to executing work cycle programs, an automated system may be
capable of executing advanced functions that are not specific to a particular
work unit. In general these functions are concerned with enhancing the
performance and safety of the equipment.
Advanced automation functions include the following:
➢Safety monitoring
➢Maintenance and repair diagnostics and
➢Error detection and recovery
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Safety Monitoring
Functions of safety monitoring
➢ To protect human workers in the vicinity of the system and
➢ To protect the equipment associated with system.
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Safety Monitoring
Possible responses to various hazards might include one or more of
the following:
➢ Complete stoppage of the automated system.
➢ Sounding an alarm
➢ Reducing the operation speed of the process
➢ Taking corrective actions to recover from the safety violation
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Safety Monitoring
The following list suggests some of the possible sensors and their
application for the safety monitoring:
➢ Limit switches.
➢ Photoelectric sensors
➢ Temperature sensors
➢ Heat or smoke detectors
➢ Pressure sensitive floor pads
➢ Machine vision system
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Maintenance and Repair
Diagnostics
Maintenance and Repair Diagnostics refers to the capabilities of
an automated system to assist in the identification of the source
of potential or actual malfunctions and failures of the system.
Three modes of the operation are typical of a modern
maintenance and repair diagnostics subsystems:
➢Status monitoring
➢Failure diagnostics
➢Recommendation of repair procedure
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Status monitoring
Status monitoring serves two important functions in
machine diagnostics:
➢ Providing information for diagnosing a current failure
➢ Providing data to predict a future malfunction or failure
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Error Detection and Recovery
Error Detection: As indicated by the term, error detection and
recovery consists of two steps:
➢ Error detection and
➢ Error recovery.
In analyzing a given production operation, the possible errors can
be classified into one of three general categories
➢ Random errors
➢ Systematic errors and
➢ Aberrations
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Example
Consider an automated cell consisting of a CNC machine tool, a parts storage unit,
and a robot for loading and unloading the parts between the machine and the
storage unit. Possible errors that might affect this system can be divided into the
following categories:
(1) machine and process,
(2) cutting tools,
(3) work holding fixture,
(4) part storage unit, and
(5) load/unload robot.
Develop a list of possible errors (deviations and malfunctions) that might be
included in each of the five categories
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Error Recovery
Error recovery is concerned with applying necessary corrective
action to overcome the error and bring the system back to normal
operation.
➢ Make adjustments at the end of current cycle
➢ Make adjustments during the current cycle
➢ Stop the process to invoke corrective action
➢ Stop the process and call for help
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Example
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