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EE-403, Course Contents

BEE- 7 A & C, Fall, 2013

Industrial Automation

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Course Goals Raise interest for industrial automation systems

Understand industrial control systems (purpose,structure)

Automation hierarchy

Be able to analyze a process and proposeautomation solutions

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Course Title: Industrial Automation (EE-403)

Credit hrs: (3-1-4) Prerequisite(s): None Instructor: Saleem Tariq

Office:Academic Block A, 1st floor Ext. 224 Office Hours:

E-mail : saleem.tariq@mail.au.edu.pk

Text Book: Handouts, Class Lectures Reference Book(s):

(i) Modern Control Technology: Components and Systems, 3rd

Ed. by Christopher

Killian

(ii) Pocket Guide on Industrial Engineering, Ed: Srinivas Medida, IDC

technologies

mailto:saleem.tariq@mail.au.edu.pkmailto:saleem.tariq@mail.au.edu.pkmailto:saleem.tariq@mail.au.edu.pkmailto:saleem.tariq@mail.au.edu.pkmailto:saleem.tariq@mail.au.edu.pkmailto:saleem.tariq@mail.au.edu.pkmailto:saleem.tariq@mail.au.edu.pkmailto:saleem.tariq@mail.au.edu.pkmailto:saleem.tariq@mail.au.edu.pk

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Course Outline

Introduction to industrial automation, architecture

of industrial automation, measurement system

specifications, signal conditioning circuits, error and

calibration, sensors (temperature, RPM meters,position, force, flow, tilt and acceleration),

actuators, ADC/DACs, Supervisory Control And Data

Acquisition ( SCADA), safety instrumentation and

future trends

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Grading Policy

Assignments/ Quizzes: 10%

Mid Term: 20%

Labs: 20%

Term Project: 10%

Final: 40%

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Lecture Plan

Week 1 Introduction to Industrial AutomationWeek 2 Architecture of Industrial Automation and measurement

system specificationsWeek 3 Signal conditioning Circuits, Errors and calibrationWeek 4 Sensors (Temperature)Week 5 Sensors ( RPM meters, Position and Force)Week 6 Sensors (Flow, Tilt and Acceleration)Week 7 ADC/ DAC circuitsWeek 8 Trends in Instrumentations and Valve developmentsWeek 9 Mid Term Exam

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Notes1. This course is application of concepts studied in previous courses;

students are advised to study from the reference books and develop ahabit of consulting online resources.

2. Check your emails regularly as you will be provided with selected studymaterial and assignments through this media.

3. A special feature of the course would be a Term project which willconsolidate the course learning.

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Ground Rules - I

Attendance in class is Mandatory

You are expected to rise when

instructor enters the class

Time keeping

Only one conversation!

Keep your mobiles OFF!

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Ground Rules-II

Listen for understanding Participate in class discussion

Ask questions!

Adhere to Air University Code of

Conduct Dress Code

Ethical Behavior

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Prerequisites for a Good Engineer

Curiosity: I want to understand

Basic Physics: I can make a model of my world

Mathematics I know how to calculate

Programming: I can structure

Systematic Work: I can plan

Initiative: I try various strategies to make things works

Team Work We can discuss the problem and jointlycome up with a solution.

Vision/Goal Each one of you, should have a vision abouthimself, where he would like to be in..

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Organization of the course instrumentation: hardware:

o how is the state of a plant read and controlled

controllers: hardware and software

o how controllers operate and how they are programmed

industrial communication networks:

o how are real-time data exchanged, in the field and in the plant

application protocols for devices

o how do devices appear to the programmer and operator

operator interface and SCADA

o how do operators see the plant they supervise

safety

Concerns for human safety and system hazards

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Lesson Objectives

To define Automation and Control and explain the

differences in the sense of the terms

To explain the relation between Automation and

Information Technology

To underline the basic objectives of a manufacturingindustry and explain how

automation and control technologies relate to these

To introduce the concept of a Product Life Cycle and

explain how Automation and Control technologies relate tothe various phases of the cycle

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Definition of terms

Industry In a general sense the term Industry is defined as

follows.

Definition: Systematic EconomicActivity thatcould be

related to Manufacture/Service/ Trade.

In this course, we shall be concerned with

Manufacturing Industries only.

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Definition of AutomationDefinition:

Automation is a set of technologies that results in operationof machines and systems without significant humanintervention and achieves performance superior to manualoperation

A Definition from Encyclopaedia Britannica

The application of machines to tasks once performed byhuman beings or, increasingly, to tasks that would otherwisebe impossible. Although the term mechanization is often

used to refer to the simple replacement of human labour bymachines, automation generally implies the integration ofmachines into a self-governing system.

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1. Automation Systems may include Control Systems but

the reverse is not true. Control Systems may be parts of

Automation Systems.

2. The main function of control systems is to ensure thatoutputs follow the set points. However, Automation Systems

may have much more functionality, such as computing set

points for control systems, monitoring system performance,

plant startup or shutdown, job and equipment scheduling etc.

Controls vs Automation

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A. Industrial Automation involves significant amount of hardware technologies, related

to Instrumentation and Sensing, Actuation and Drives, Electronics for Signal

Conditioning, Communication and Display, Embedded as well as Stand-alone

Computing Systems etc.

B. As Industrial Automation systems grow more sophisticated in terms of the

knowledge and algorithms they use, as they encompass larger areas of operationcomprising several units or the whole of a factory, or even several of them, and as

they integrate manufacturing with other areas of business, such as, sales and

customer care, finance and the entire supply chain of the business, the usage of IT

increases dramatically.

C. However, the lower level Automation Systems that only deal with individual or, at best, a group of machines, make less use of IT and more of hardware,

electronics and embedded computing.

Characteristics of Industrial Automation

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A. Industrial information systems are generally reactive in the sense that they

receive stimuli from their universe of discourse and in turn produce responses thatstimulate its environment. Naturally, a crucial component of an industrial information

system is its interface to the world.

B. Most of industrial information systems have to be real-time. The computation

not only has to be correct, but also must be produced in time. An accurate result,

which is not timely may be less preferable than a less accurate result produced in time.Therefore systems have to be designed with explicit considerations of meeting

computing time deadlines.

C. Many industrial information systems are considered mission-critical, in the

sense that the malfunctioning can bring about catastrophic consequences in terms of

loss of human life or property. Therefore extraordinary care must be exercised duringtheir design to make them flawless. Fault-tolerance to emergencies due to hardware

and software faults must often be built in.

Automation Systems

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Control Tasks

measure - command - control

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Definition of Control

Definition:

Control is a set of technologies that achieves desired

patterns of variations of operational parameters and

sequences for machines and systems by providingthe input signals necessary.

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Control Systems Engineering,Fourth Edition by Norman S.Nise

Copyright 2004 by JohnWiley & Sons. All rightsreserved.

Computer hard disk

drive, showing

disks and

read/write head

Courtesy of Quantum Corp.

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Control Systems Engineering,Fourth Edition by Norman S.NiseCopyright 2004 by John

Wiley & Sons. All rightsreserved.

The search forextraterrestrial life is

being carried out with

radio antennas like the

one pictured here. A radio

antenna is an example ofa system with position

controls.

Peter Menzel.

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Control Systems Engineering,Fourth Edition by Norman S. NiseCopyright 2004 by John Wiley &Sons. All rights reserved.

a. system

concept;

b. detailed

layout;c. schematic;

d. functionalblock diagram

Antenna azimuth position control system

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Manual Control

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Automatic Control

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Open loop and closed loop

1

23

4

5

temperature

temperature is imprecise,depends on ambient temperature and

cooking quantity

but time of heating can be modulated.

120

140180

200

220 temperature closely controlled,

requires measurement of the output

variable (temperature)

+

-

higher

/lower

temperature sensor

open loop:

closed loop:

on

/off

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a. open-loopsystem;

b. closed-

loop system

Block diagrams of control systems

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Discrete and continuous plants

discrete control

(binary)

continuous control

(analogue)

Depends on industrial process

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Depends on industrial process

Automotive Manufacturing

Electronics

Machinery

Textiles

Pharmaceuticals

Fine Chemical

Food & Beverage

Metals & Mining

Water & Waste

Pulp & Paper

VehiclesPetrochemicals

Oil & Gas

Electrical Power

discrete

continuous

source: ARC

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The main categories in industry

industry distinguishes the following categories of applications:

"process control": continuous processes, associated with fluxes,

e.g. sewage water treatment, petrochemical process,

cement

"batch control": semi-continuous processes, associated withindividual products, e.g. fine chemicals,

pharmaceutical, brewery

"manufacturing": also called factory automation discrete

processes, associated with transformation of parts,e.g. automobile industry, bottle-filling, packaging

Organization of Course

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Organization of Course

9

execution

supervision

device access

communication networks

field devices, controllers

sensors, actors

enterprise

2.1

2.3

3

4

5

8

6

real-time

dependability

2.2

physical plant

numbers refer to the chapter

(EPA guide book)

( Slide Courtesy EPA)

Automation network view ( Slide Courtesy EPA)

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Automation network view ( Slide Courtesy EPA)

Sensor-Actuator Bus

Fieldbus

programmablecontrollers

Control Bus

SCADA level

Control level

Field level

FileEdit Engineering

Operator2

12

2

33

23

4

direct I/O

transducers / actors

microPLCs

Fieldbus

horizontal communication

verticalComm.

2.1

2.3

3

4.1

4.2

5

6

4.3