Industrial Automation T Rajendran
Industrial Automation Control Systems Process Control Industrial Control Computer Integrated Manufacturing Systems Modeling Systems Engineering Real Time Programming Software tools
Expectation of Automation High Reliability Fast Trouble shooting Simple Operation Easily Configurable High Accuracy Optimization functions and processing of operating data Flexibility
Process Controls PC IS Integrated Control & Management systems … MIS
History Pioneering period – 60 – Electronic devices Direct Digital control Microcomputer Computer controlled Process plants –Centralized –Distributed –Process Models –Advanced Control (AI)
Process Controls
Process Control Control Signal generation Steam out Water in Water out Temp sensor- + Set point (desired value) Deviation (error) Steam in
Basic principles of controller loop Memory - Set Point Comparator for set point (measured value MV) as reported by transmitter Deviation = error Amplifier – amplifies the control deviations – output of the controller
Process Control Open Loop Control Closed Loop control
Process Control Two position control Multi position control PID Proportional control (proportional, integral or derivative) Ratio control Cascade control
Controller Operation controller - Set point error Control signal Control element sensor process Measured value Auto/manual
Position control High set point Low set point
Control actions No control Proportional only PI PID Set point Time Control value
Instrumentation
Instrumentation Pressure Flow liquid level Temperature Pneumatic and control valves
Transducers Sensors high / low limits of measurand
Transducers To measure / sense to convert measured value to a useful output
Transducers Measurement –Type of measurand – Number of measurements – Sensing measurement – Transduction element – Range of measurement Conversion –Specific format –Amplified –Conversion of AC to DC
Transducers Conventional Silicon Fiber Optic
Transducers Conventional Silicon Fiber Optic Displacement / motion transducers Temperature Transducers Pressure Transducers Liquid level Transducers Liquid Flow
Intelligent Sensors On-chip signal processing MEMS (Micro Electro Mechanical Systems) sensors BIOSENSORS NANOSENSORS
NANOSENSORS & future trends 1 nm = 1 millionth of a mm
Building Blocks in Automation
Building blocks The Processor Analog & Digital I/O modules interrupts, Timers/counters Display controls SCADA (Supervisory control and data acquisition systems)
Processing System The use of Microprocessors (calculator chips & Mini computers) Architecture –Input, Memory, Output, MicrpP Address bus, Data bus, control bus Address bus, Data bus, control bus 8, 16, 32, 64 bits Microprocessors & microcontrollers
Analog & Digital I/O modules Basic signals Analog inputs Digital inputs Interrupt inputs Timer / counter inputs Control outputs Display outputs
Analog & Digital I/O modules Basic signals Analog inputs Digital inputs Interrupt inputs Timer / counter inputs Control outputs Display outputs
Inside look of a real time sysytem Processor & memory module Analog inputs Digital inputs Interrupt inputs Timer / counter inputs Control outputs Display outputs Interrupt controller Timer / counter Analog input module
I/O modules Analog input –From Sensors –Measurand like flow, position, temperature … –Signal may be amplified, filtered or/and isolated Digital input –Refer to ON-OFF status of valves, linit switches.. (1 bit )
I/O modules Interrupt input –Draw attention of real time system towards abnormal situations –Attends to interrupt and resumes normal work Timer / Counter –Clock input or Gate input to enable/ disable timer/counters –Output of timer/counter can be used as interrupts
I/O signals Display output signals –LED, LCD, VDU, alarms –Status of process, limits sets –May control or operator assisted Control output signal –Required to drive the control valves, motors etc –May be simple ON/OFF or fine control of motor speed, position, displacement, flow.. –Analog signals / digital actuators
Analog input The module continuously scans the analog input signals in the pre defined order and frequency Amplifies -> converts to digital -> processor and memory module for processing EPROM or switches Local intelligence
Digital Input Directly accepted by processor N bits in parallel Local intelligence
Analog Output Digital multiplexer Digital to Analog converter Master processor executes two I/O instructions –Write Data byte/word in digital output port –Write address byte/word in address port
Interrupt control Interface between no. of interrupting devices and master processor Priorities allocation- static or dynamic.
Timer / Counter Number of timers and counters which may be cascaded or used independently Count in the form of data byte/word Clock from the processor or external
Display Control module Manual entry sub module CRT controller sub module LED / LCD control sub module Alarm annunciator sub module Printer controller sub module
SCADA Supervisory Control And Data Acquisition Systems –Channel scanning –Conversion into engineering units –Data processing
CAD / CAM / CIM
CIM cim Process planning draf ting MeM fe CNC Robots Sche dudle Prod plan cad Tool design fms simul ation ERP Shop floor data
CAD / CAM / CIM CIM, Concurrent Engineering Product Life Cycle Management Engineering Modeling CIM databases Computer aided process planning IT & ERP Manufacturing automation – PLC, CNC, Robots
CAD/CAM/CIM Flexible Manufacturing Shop Floor Data Collection Simulation
Concurrent Engineering DESIGN software –Solid Modeling –Assembly modeling –Sheet metal design –Drafting –Tolerance analysis –Mechanism Design –Mould Design –Thermal Analysis –Piping Design –Optimization –Tool Design
Concurrent Engineering Process Planning ERP Shop Floor Data Collection PLM EDM
Concurrent Engineering Visualization / Simulation –Factory simulation –Rapid prototyping –Plastic injection moulding –Forming –Forging –Casting