1. Introduction to Industrial Electronics
By James Rehg and Glenn Sartori
Chapter 1

2. 1 Industrial electronics deals with
PLCs – computers for industry
Sensors – eyes for PLC
Actuators – hands for PLC
Controllers – PLC helper
But not MATLAB which is the most popular computing tool for engineers

3. 2 Industrial revolution began mid-?
1500s – flush toilets, pocket watch, knitting machine, compound microscope
1600s – refracting telescope, first bacteria, slide rule, steam turbine, adding machine, air pump, universal joint, pressure cooker, steam pump
1700s – piano, steam engine, mercury thermometer, flying shuttle, capacitor, English dictionary, sextant, spinning jenny, carbonated water, flush toilets (again), submarine, spinning mule, bifocals, circular saw, parachute, self-winding clock, hot-air balloon, steel roller for steel production, threshing machine, power loom, bleaching, steamboat, gas lighting, ambulance, cotton gin, ball bearings, preserving jar, vaccinations, carding machine, metal lathe, soft drinks, lithography, battery, fourdrinier machine

4. 3 To Automated Manufacturing
Punch cards – Jacquard – 1801
Numerical engine – Babbage – 1834
Motorized crane – Babbitt – 1892
Vacuum tube – AC to DC – 1904
Vacuum tube diode amplifier – deForest – 1907
Remote controlled boat – Tesla

5. 4 To Automated Manufacturing
Production machines replacing workers – 1919
Vacuum tubes control DC motors – 1928
Car frame factory – A.O. Smith – 1930
Semiconductor diode – Schottky
Variable speed AC motor control – 1941
Electrically powered and controlled oil pipeline in California

6. 5 To Automated Manufacturing
1st computer – ENIAC – 1954
1st transistor – Shockley – 1947
Cybernetics (feedback) – Wiener – 1948
Robot programming – Chappman – 1954
Solid-state motor-speed control – 1957
Robot manufacturing company – Unimation

7. 6 To Automated Manufacturing
Computer controlled all-in-one machine – Kearney – 1960
Unimate 5k-lbf robot 500 lbf loads – 6 DOF – 1961
PLC – GM Oldsmobile Div – 1968
Molins Machine – integrated computer controlled batch manufacturing- 1969
Morat knitting machine – 1970
Lasers for processing and com

8. 7 To Automated Manufacturing
Microprocessor – Ted Hoff – Intel – 1971
Minicomputer-controlled robot (T3) – Richard Hohn – 1973
Microcomputer-comtrolled robot by ASEA ABB Inc. 1977
Apple II microcomputer – 1978
Computer-integrated manufacturing (CIM_ in Japan, US and GB 1980

9. 8 To Automated Manufacturing
Direct-drive robot arm Adept Corp 1984
64-bit microprocessor Intel Corp 1994
Tag-based PLCs 1998
Industrial networks (Ethernit/IP, DevicNet, Profibus, …) 2000
Wireless network for automation 2001

10. 9 Feedback Industrial Control
Automatically monitors a manufacturing process
Takes action if the process varies from required specifications
Feedback control developed after WWI
Feedback control perfected during WWII
Does not define the industrial process

11. 10 Manufacturing System Project – complex, parts are one of a kind.
Job shop
Repetitive
Line
Continuous

12. 11 Manufacturing System Project
Job shop - non-complex products with few parts and small production volume
Repetitive
Line
Continuous

13. 12 Manufacturing System Project Job shop
Repetitive - high volume spread over long periods with manual labor smaller than the automation component.
Line
Continuous

14. 13 Manufacturing System Project Job shop Repetitive
Line - Complex products, assembled in short time due to the large inventory of subassemblies.
Continuous

15. 14 Manufacturing System Project Job shop Repetitive Line
Continuous - Highly automated, little manual labor, usually stops only for cleaning and changeover.

16. Manual Machine

17. 15 Class of Machine or System
Manual machines - A group of machines operated in manual mode.
Programmable machine
Robot
Material moving system
Material tracking system

18. Programmable Machine

19. 16 Class of Machine or System
Manual machines
Programmable machine - A material-processing machine under computer control.
Robot
Material moving system
Material tracking system

20. Robot – Honda’s ASIMO

21. Robot – Friend

22. 17 Class of Machine or System
Manual machines
Programmable machine
Robot - One machine that performs many tasks under computer control.
Material moving system
Material tracking system

23. Material Moving System

24. 18 Class of Machine or System
Manual machines
Programmable machine
Robot
Material moving system - An automated system that moves raw material or finished product.
Material tracking system

25. Material Tracking System

26. 19 Class of Machine or System
Manual machines
Programmable machine
Robot
Material moving system
Material tracking system - Raw material or finished product tracking system that may read bar codes

27. Material Storage and Retrieval

28. 20 Class of Machine or System
Material storage and retrieval system - May be bench top size or whole warehouse size sometimes called ASRS.
Flexible manufacturing cell
Fixed automation machine
Flexible manufacturing system
Continuous process system

29. Flexible Manufacturing Cell

30. Flexible Manufacturing Cell

31. 21 Class of Machine or System
Material storage and retrieval system
Flexible manufacturing cell - A group of related machines that perform a process or step in a larger process.
Fixed automation machine
Flexible manufacturing system
Continuous process system

32. Fixed Automation Machine

33. 22 Class of Machine or System
Material storage and retrieval system
Flexible manufacturing cell
Fixed automation machine - Dedicated machine designed to manufacture and assemble parts with a minimum of human interaction.
Flexible manufacturing system
Continuous process system

34. Flexible Manufacturing System

35. 23 Class of Machine or System
Material storage and retrieval system
Flexible manufacturing cell
Fixed automation machine
Flexible manufacturing system - One or more manufacturing machines integrated by an automatic material handling system.
Continuous process system

36. Continuous Process System

37. 24 Class of Machine or System
Material storage and retrieval system
Flexible manufacturing cell
Fixed automation machine
Flexible manufacturing system
Continuous process system - Commonly used in food, chemical, pharmaceuticals, and paper products.

38. 25 Manufacturing System Classification
Project - Dominated by manual components - lowest product quality
Job shop
Repetitive
Line
Continuous

39. 26 Manufacturing System Classification
Project
Job shop – contains mostly manual components but has some automation
Repetitive
Line
Continuous

40. 27 Manufacturing System Classification
Project
Job shop
Repetitive - Contains many automated components, lacks flexible manufacturing systems, has average product quality
Line
Continuous

41. 28 Manufacturing System Classification
Project
Job shop
Repetitive
Line - Has excellent product quality and includes flexible manufacturing systems
Continuous

42. 29 Manufacturing System Classification
Project
Job shop
Repetitive
Line
Continuous - produces the highest quality, has the largest automation component and has the highest need for workers with skills in industrial electronics is:

43. 30 Experience makes the troubleshooter
faster at the process
better at guessing the fault
both of these

44. 31 Experienced troubleshooters
take time to think and analyze system data before springing to action
are always busy measuring something while they search for the fault

45. 32 Regarding troubleshooting, in most cases
a single failure has occurred
multiple system failures have occurred
single failures and multiple failures each occur about half of the time

46. 33 Regarding software troubleshooting, which one is NOT true?
Software failures are common.
Computer programs almost never fail.
Some knowledge of computer programs is required for troubleshooting.
Well documented software is important for machine troubleshooting.
Software with many inputs may fail due to particular inputs.