PHY461 Industrial Automation

Lecture # 1 Introduction to Automation & Process Control

Department of Physics COMSATS Institute of Information Technology Islamabad

Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

Course Overview
3(3, 0) credit hours course Prerequisite: PHY221 Circuit Theory Aim
Study the elements and methods of control system operations used in the industry to control industrial processes Gain an understanding of common industrial electronics concepts, components, and applications
Department of Physics COMSATS Institute of Information Technology Islamabad
Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

Course Outline
1. 2. 3. 4. 5. 6. Introduction to process control, control systems, process control block diagram, control system evaluation, units standards and definitions, sensor time response, significance and statistics Analogue signal conditioning, principle of analogue signal conditioning, passive circuits, operational amplifiers, operational amplifier circuits in instrumentation, design guidelines Digital signal Conditioning, review of digital fundamentals, converters, data acquisition systems Thermal sensors, metal resistance versus temperature devices, thermistors, thermocouples, other thermal sensors, design considerations Mechanical Sensors, displacement, location or position sensors, strain sensors, motion sensors, pressure sensors, flow sensors Optical sensors, fundamentals of EMR radiation, photo detectors, pyrometery, optical sources, applications Final control, final control operation, signal conversions, industrial Electronics, actuators, control elements Discrete state process control, definition of discrete state process control, characteristics of system, relay controllers and ladder diagrams, programmable logic controllers (PLCs) Controller principles, process characteristics, control system parameters, discontinuous controller modes, continuous controller modes, composite control mode Analogue controllers, general features, electronic controllers, pneumatic controllers, design considerations Digital control, digital electronic methods, computers in process control, process control networks, characteristics of digital data, controller software, computer controller examples
Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

7.
8. 9. 10. 11.

Department of Physics COMSATS Institute of Information Technology Islamabad

Automation
Use of machines, control systems and information technology to optimize throughput in the production of goods and delivery of services Objective of applying automation is to increase productivity, and/or quality beyond that possible with current human labour levels so as to realize economies of scale, and/or realize predictable quality levels Though, automation doesnt emphasise replacing human labour with machines To achieve automation, a process control system must be devised
Department of Physics COMSATS Institute of Information Technology Islamabad
Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

Reasons for Automating

1. 2. 3. 4. 5. 6. 7. 8. 9. To increase labor productivity To reduce labor cost To mitigate the effects of labor shortages To reduce or remove routine manual and clerical tasks To improve worker safety To improve product quality To reduce manufacturing lead time To accomplish what cannot be done manually To avoid the high cost of not automating
Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

Department of Physics COMSATS Institute of Information Technology Islamabad

Automation Principles
1. Understand the existing process
Input/output analysis Value chain analysis ( identify the key activities within the firm which form the value chain for that organisation, and have the potential of a sustainable competitive advantage for a company) Charting techniques and mathematical modeling

2. Simplify the process

Reduce unnecessary steps and moves

3. Automate the process

Automation strategies and production systems
Department of Physics COMSATS Institute of Information Technology Islamabad
Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

Examples of Automation
Automated machine tools Transfer lines Automated assembly systems Industrial robots Automated material handling and storage systems Automatic inspection systems for quality control
Department of Physics COMSATS Institute of Information Technology Islamabad
Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

Elements of an Automation System

Resources to accomplish the process and operate the system A program of instructions to direct the process A control system to realize the process
Resources

Program of instructions
Department of Physics COMSATS Institute of Information Technology Islamabad

Control System Figure: Automation System

Process

Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

Definitions
Process Resources
The manufacturing operation that is performed on a work unit
Mainly includes different energy sources (Electrical, Thermal, Mechanical, Light) for corresponding action needed to be accomplished Defines the actions performed by an automated process

Program of Instructions Control System

Executes the program of instructions Causes the process to accomplish its defined function (in this case, manufacturing)
Industrial Automation Created & Presented by Muhammad Zeeshan Saeed

Department of Physics COMSATS Institute of Information Technology Islamabad