Chapter 4
Introduction to Automation
Dr. Osama AlHabahbah
Introduction to Automation
Automation is the technology by which a process
or procedure is accomplished without human
assistance.
Powe
r
Automation
Implementation
Program of Instructions
Control System
1 Basic Elements of an Automated System
1.
Power to operate the process.
2.
Instructions Program.
3.
Control System to actuate the instructions.
Power
Program of
Instruction
s
Control
System
Process
4.1.1 Power to Accomplish the Automated Process
The principal source of automation power is electricity
,that is due to:
1.
Availability.
2.
Moderate cost.
3.
Ease of conversion to other forms of energy ,such as
mechanical,thermal, and hydraulic.
4.
Ability of data storage and transmission.
5.
Ability of storage in batteries to be used anywhere.
4.1.2 Program of Instructions
It defines the actions performed by an automated
process.
Work Cycle Programs:
the simplest example is the control of a 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(such as cutting ,stamping,
.)
Disadvantages of using Hardware Components
to Control Work Cycles (such as timers , cams ,
relays ,.. )
1.
Their design and fabrication is time
consuming.
2.
Not flexible.
3.
Cant interface with computer.
Decision Making in the Programmed Work Cycle
Process input
process parameter
Process output
process variable
Work cycle has two features :
1. Number and Sequence of processing steps:
Load.
Process.
Unload.
2. The process parameters change in each step Open/close (discrete)
Lower temperature/higher temperature (continuous ).
Possible Cases of variation in work cycle are:
1-Operator interaction with the program of instructions, such as
ATM machine.
2- Different part or product styles processed by the system; such as
a welding robot dealing with more than one car model at the same
assembly line (batch production or flexible automation ).
3-Variations in the starting work units; (They are not consistent);
such as sand castings prior to machining, adjustments might be
needed for individual pieces.
4.1.3 Control System
The control system executes the program of instructions to
accomplish the defined function.
Automated System Controls:
1- Closed-loop AKA.(feedback control system)
2- Open-loop control system.
Feedback control system
Input
parameter
AKA (set
point )
Controller
Actuator
process
Output
variable
Feedback
sensor
Example of input: desired thermostat setting in a home temperature
control system.
Feedback control system
Do you control the input or the output?
The controller reduces the difference between the input and the output
(by adjusting the output using the actuator )
Open loop Control System :
input
Controller
Actuator
process
Disadvantage: Not the right adjustment maybe done .
Advantage : Cheaper.
Outp
ut
varia
ble
4.2 Advanced Automation Functions
4.2.1 Safety Monitoring :
Automation serves to reduce hazard at the work place.
This is accomplished by designing the automation system for safety.
Safety monitoring capability of the automated system protects human
workers as well as the equipment.
Sensors are used to track the systems operation and identify unsafe
conditions
Safety Monitoring
The safety monitoring system may responds to these
conditions by:
Stopping the system.
Sounding an alarm.
Reduction operation speed.
Taking corrective actions; (most sophisticated).
Safety Monitoring
Sensors used for safety monitory include:
1- Limit switches to detect proper positioning of a part in a
workholding device .
2- Photoelectric sensors triggered by the interruption of a light beam;
(presence detector).
3- Temperature sensor.
4- Heat or smoke detectors
5- Pressure-sensitive floor pads to detect intruders.
6- Machine vision systems for surveillance.
4.2.2 Maintenance and Repair Diagnostics
They have three modes of operation:
1. Status monitoring: current system parameters.
2. Failure diagnostics: detects malfunctions and identifies the causes
of the failure.
3. Recommendation of repair procedure: using artificial intelligence
to suggest repair steps
4.2.3 Error Detection and recovery
In case of a malfunction, the control computer automatically takes
corrective action.
Production system errors:
1- Random errors: due to the stochastic nature of the process.
2- Systematic errors: result from some assignable cause, such as
change in raw material properties.
3- Aberrations: deviations resulting from either equipment failure
or human mistake.
All possible errors should be anticipated in order to specify the
proper sensors and software to detect them.
Types of Error recovery strategies (by level of urgency):
1. Make adjustments at the end of the current work cycle.
2. Make adjustments during the current cycle.
3. Stop the process to invoke (call up) corrective action; (automatic
action).
4. Stop the process and call for help, If automation is not able to fix
it; (manual action).
4.3 Levels of Automation (Hierarchy)
5
Enterprise level
Plant level
Cell or system level
Machine level
Device level
4.3 Levels of Automation (Hierarchy)
5. Enterprise Level: Marketing, Sales, Accounting, Design, Research
(e.g: Planning) Corporate information system
4. Plant Level: Production systems (shop floor control, quality control,
order processing, inventory control)
3. Cell or System Level: Manufacturing system, groups of machines
(e.g. Production line)
2. Machine Level: Individual machines ( PLC, CNC, Robots)
1. Device Level: Sensors, Actuators, other hardware elements
