Industrial Automation

Created & Presented by

Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
PHY461
Industrial Automation
Lecture # 3
Automation Types & Signal
Conditioning (Analogue)
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Automation Types
Fixed Automation
Sequence of processing (or assembly) operations
is fixed by the equipment configuration
Many simple (reliable) operations (complex
system)
High initial investment (custom-engineered
equipment)
High production rates
Relatively inflexible in accommodating product
variety
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Automation Types
Programmable Automation
Sequence of operations can be changed (variety
of products that are made by similar processes)
High investment in programmable equipment
Low Medium production rate (relatively longer
time lost for changeovers of programming and
set-up)
Most suitable for batch production
Physical setup and part program must be
changed between jobs (batches)
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Automation Types
Flexible Automation
Extension of Programmable Automation
Lower time lost on changeovers
High investment for custom-engineered
system
Mid volume/variety range
Continuous production of variable mixes of
products
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Sensors
Motion (Orientation/inclination )sensors
Force/pressure/strain
Position
Temperature and humidity
Rotary position
Light and magnetic field sensors
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Signal Conditioning
Signal conditioning is the operation
performed on the signal to convert them
to a form suitable for interfacing with
other elements in the process control e.g.
Filtering, Amplifying
Analogue Signal Conditioning
Digital Signal Conditioning

Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Analogue Signal Conditioning
Categorized into 6 types
Signal-level and bias changes
Linearization
Conversions
Filtering and impedance matching
Concept of loading
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Signal-level and bias changes
The method to adjust the level
(magnitude) and bias (zero value) of
voltage signal

Signal conditioning circuit
0.2 V 0.6 V 0 V 5 V
Zero shift
0.2 V 0.6 V 0 V 5 V
Amplification
0 V 0.4 V
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Linearization
Often, the characteristic
of a sensor is nonlinear
Special circuit are
devised to linearize
signals
Modern approach is to
use computer software
to linearize
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Conversion
The circuit to covert one form of signal or
physical values into the other form
Resistance to voltage
Typical conversion is to convert resistance
or voltage to 4 to 20 mA and convert back
to voltage at the receiving end
Thus, voltage-to-current and current-to-
voltage circuits are essential

Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Digital Interface
The use of computer is process control
requires the conversion of analog to digital
signal
ADC
DAC
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Filtering
Some signals input are spurious (contain
more than 1 frequency)
It is necessary to filter the frequency
matched with the devices
The electric line frequency is 50 Hz
The transient of motor is kHz
Example
Highpass, lowpass, bandpass filter

Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Impedance Matching
Connecting the sensors or process control
element with different impedance causes
signal reflection
The network or circuit to match
impedance thus to reduce signal reflection
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Concept of Loading
When the sensor or circuit is connected to
load, this will introduce the uncertainty in
the measurement (amplitude of voltage)
R
x
R
L
V
x
Sensor
V
y
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Concept of Loading
The output voltage is calculated using
voltage division as




Output voltage is reduced by the voltage
drop
To reduce the uncertainty,
1
L
y x
L x
x
x
L x
R
V V
R R
R
V
R R
| |
=
|
+
\ .
| |
=
|
+
\ .
L x
R R >
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Concept of Loading
Example
An amplifier outputs a voltage that is 10 times the
voltage on its input terminals. It has an input
resistance of 10 kO. A sensor outputs a voltage
preoperational to temperature with a transfer
function of 20 mV/C. The sensor has an output
resistance of 5.0 kO. If the temperate is 50 C,
find the amplifier output.

Sensor
50 C ? V
Amplification
Industrial Automation
Created & Presented by
Muhammad Zeeshan Saeed
Department of Physics
COMSATS Institute of Information
Technology Islamabad
Concept of Loading