Introduction To Automation: BITS Pilani

Introduction to
Automation
BITS Pilani EA ZC412 Flexible Manufacturing Systems – Session 1
Pilani Campus
BITS Pilani
Pilani Campus
Basic Elements of an Automated System

Production System
Manufacturing has evolved from a simple process / product

to a complex product requiring numerous processes.
Production System has evolved out of different systems of

production which rely on separate and interacting
functions.
BITS Pilani, Pilani Campus

Approaches and Technologies
in Modern Manufacturing
1. Automation
2. Material Handling Technologies
3. Manufacturing Systems
4. Flexible Manufacturing Systems
5. Quality Programs
6. Computer Integrated Manufacturing
7. Lean Production
8. Agile Manufacturing

Production Systems can be divided into two categories
• Facilities: Factory, machines, tools, jigs & fixtures, MHS,
Inspection equipment, computer systems etc..
• Manufacturing Support Systems: design the processes
and equipment, plan and control the production orders,
satisfy quality requirements.
Manufacturing support consists of functions

1. Business
2. Product design
3. Manufacturing Planning
4. Manufacturing Control
Automation and Control Technologies
in the Production System

Basic elements of an
Automated System
Automation is the technology by which a process or

procedure is accomplished without human assistance.
1. Power - to accomplish process and operate the system.

2. Program of instructions - to direct the process.
3. Control system - to actuate the process.

Elements of an Automated
System

Electricity -
The Principal Power Source
• Electrical power is widely available at moderate costs.
• Electrical power can be readily converted to alternate
energy forms: mechanical, thermal, light, acoustics,
hydraulic and pneumatic.
• Electrical power at low levels can be used for signal
transmission, info processing, data storage &
communication.
• Electrical power can be stored in batteries for use in
locations where external source of power is not
conveniently unavailable.

Power to Accomplish the
Automated Process
• Power for the process
– To drive the process itself
– To load and unload the work unit
– Transport between operations
• Power for automation

– Controller unit
– Power to actuate the control signals
– Data acquisition and information processing

Program of Instructions
Set of commands that specify the sequence of steps in the

work cycle and the details of each step
Example: CNC part program / steps in machining.
During each step, there are one or more activities involving
changes in one or more process parameters
– Examples:
• Selection of a particular tool.
• Axis position in a positioning system
• Motor on or off

Decision-Making in a
Programmed Work Cycle
The following are examples of automated work cycles in
which decision making is required:
– Operator interaction
• Automated teller machine
– Different part or product styles processed by the
system
• Robot welding cycle for two-door vs. four door car
models
– Variations in the starting work units
• Additional machining pass for oversized sand
casting

Features of a Work Cycle
Program
• Number of steps in the work cycle
• Manual participation in the work cycle (e.g., loading and
unloading work parts)
• Process parameters - how many must be controlled?
• Operator interaction - does the operator enter processing
data?
• Variations in part or product styles
• Variations in starting work units - some adjustments in
process parameters may be required to compensate for
differences in starting units

Control System – Two Types
1. Closed-loop (feedback) control system – a

system in which the output variable is compared
with an input parameter, and any difference
between the two is used to drive the output into
agreement with the input
2. Open-loop control system – operates without
the feedback loop
– Simpler and less expensive
– Risk that the actuator will not have the intended
effect

Closed Feedback Control
System

Open-Loop Control System

Positioning System Using
Feedback Control
A one-axis position control system consisting of a lead-
screw driven by a dc servomotor and using an optical
encoder as the feedback sensor

When to Use an
Open-Loop Control System
• Actions performed by the control system are
simple
• Actuating function is very reliable
• Any reaction forces opposing the actuation are
small enough as to have no effect on the
actuation
• If these conditions do not apply, then a closed-
loop control system should be used

BITS Pilani
Pilani Campus
Advanced Automation Functions

Advanced Automation
Functions
1. Safety monitoring
2. Maintenance and repair diagnostics
3. Error detection and recovery

Safety Monitoring
Use of sensors to track the system's operation and identify

conditions that are unsafe or potentially unsafe
• Reasons for safety monitoring
– To protect workers and equipment
• Possible responses to hazards:
– Complete stoppage of the system
– Sounding an alarm
– Reducing operating speed of process
– Taking corrective action to recover from the safety
violation

Maintenance and Repair
Diagnostics
• Status monitoring
– Monitors and records status of key sensors and
parameters during system operation
• Failure diagnostics
– Invoked when a malfunction occurs
– Purpose: analyze recorded values so the cause of the
malfunction can be identified
• Recommendation of repair procedure
– Provides recommended procedure for the repair crew
to effect repairs

Error Detection and Recovery
1. Error detection – functions:

– Use the system’s available sensors to determine
when a deviation or malfunction has occurred
– Correctly interpret the sensor signal
– Classify the error
2. Error recovery – possible strategies:
– Make adjustments at end of work cycle
– Make adjustments during current work cycle
– Stop the process to invoke corrective action
– Stop the process and call for help

Levels of Automation
1. Device level – actuators, sensors, and other hardware

components to form individual control loops for the next
level
2. Machine level – CNC machine tools and similar
production equipment, industrial robots, material
handling equipment
3. Cell or system level – manufacturing cell or system
4. Plant level – factory or production systems level
5. Enterprise level – corporate information system

Levels of Automation

Introduction To Automation: BITS Pilani

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Introduction to

Basic Elements of an Automated System

Manufacturing has evolved from a simple process / product

Production System has evolved out of different systems of

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

Manufacturing support consists of functions

BITS Pilani, Pilani Campus

Automation is the technology by which a process or

1. Power - to accomplish process and operate the system.

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

• Power for automation

BITS Pilani, Pilani Campus

Set of commands that specify the sequence of steps in the

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

1. Closed-loop (feedback) control system – a

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

Advanced Automation Functions

BITS Pilani, Pilani Campus

Use of sensors to track the system's operation and identify

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

1. Error detection – functions:

BITS Pilani, Pilani Campus

1. Device level – actuators, sensors, and other hardware

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

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