api i c1 - institute for systems and...
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Industrial Industrial AutomationAutomation(Automa(Automaçção de Processos Industriais)ão de Processos Industriais)
http://users.isr.ist.utl.pt/~jag/courses/api1213/api1213.html
Slides 2010/2011 Prof. Paulo Jorge Oliveira
Rev. 2011-2014 Prof. José Gaspar
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A steam engine built according to James Watt's patent in 1848 at Freiberg in Germany [wikipedia]
Industrial Revolution 1760/80 Industrial Revolution 1760/80 –– 1820/40 (historians E. 1820/40 (historians E. HobsbawmHobsbawm, T. S. Ashton), T. S. Ashton)
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Steam engine and detail of the governor, James Watt's [wikipedia].
Industrial Revolution 1760/80 Industrial Revolution 1760/80 –– 1820/40 (historians E. 1820/40 (historians E. HobsbawmHobsbawm, T. S. Ashton), T. S. Ashton)
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A jewel: A jewel: Maillardet'sMaillardet's Automaton, 18Automaton, 18thth century, the largest known mechanical memorycentury, the largest known mechanical memory
http://www.fi.edu/learn/sci-tech/automaton
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Maillardet'sMaillardet's Automaton, 18Automaton, 18thth century: the largest known mechanical memorycentury: the largest known mechanical memory
http://www.fi.edu/learn/sci-tech/automaton
Four drawings and three poemsFour drawings and three poems
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Many options for controlling real world devices! Why PLCs?
Microcontrollers Computer + IO PLCAr
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Objectives of the course:Objectives of the course:
Industrial Automation
• Analysis of systems for industrial automation.
• Methodologies for the implementation of solutions in industrialautomation.
• Programming languages of PLCs (Programmable Logic Controllers).
• CAD/CAM and Computerized Numerical Controlled machines.
• Discrete Event Systems Modeling.
• Supervision of Processes in Industrial Automation.
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1. Introduction to Automation [1 week]Introduction to components and methodologies.
2. Introduction to PLCs [2 weeks]Components of Programmable Logic Controllers (PLCs). Architecture, functional structure, IO.
3. PLCs Programming Languages [2w]Standard languages (IEC-1131-3): Ladder Diagram; Instruction List and Structured Text.
4. GRAFCET (Sequential Function Chart) [1 week]Norm, elements of the language, modelling.
Program at a glance:Program at a glance:
Industrial Automation
5. CAD/CAM and CNC Machines [1 week]Types of Computerized Numerical Controlled machines. Interpolation of trajectories. Flexible fabrication cells.
6. Discrete Event Systems [1 week]Modeling of discrete event systems (DESs). Automata. Petri networks. State and dynamics of PNs.
7. Analysis of DESs [2 weeks]Properties of DESs. Methodologies for the analysis: reachability graph and matricial equation.
8. DESs and Industrial Automation [1week]Relations GRAFCET / Petri networks. Analysis of industrial automation solutions as DESs.
9. Supervision of Industrial Processes [2w]Methodologies for supervision. SCADA. Synthesis based on invariants. Examples of application.
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AssessmentAssessment andand gradinggrading::
• 2 Preliminary laboratory assignments - training purposes (0% of the final grade).
• 2 Laboratory assignments (20%+20% of the final grade). Groups of 3 or 4 students.
• 1 Seminar (20% of the final grade). Topics to be selected with each group.
• 1 Exam (40% of the final grade).
Upon student choice, the second exam can be oral.
• Minimum grade: 9.0/20.0 val. in each component.
Industrial Automation
One extra value for students attending more than 70% of recitations and do short summaries of the classes.
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Assessment and grading:Assessment and grading:
ShortShortsummariessummariesof theof theclassesclasses
Download this Download this XLS file from the XLS file from the webpage of the webpage of the course.course.
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16Jan, 1Fev 20133hExams
One date >= week 80.5h seminar3rd lab. assignment
11/11-29/11/20133 weeks2nd lab. assignment
14/10-01/11/20133 weeks1st lab. assignment
7/10-11/10/20131 week2nd preliminary lab.
30/9-4/10/20131 week1st preliminary lab.
16-20/09/2013First weekLab. registration1
Schedule Schedule ((laboratorieslaboratories & & examexam))::
1 Important: define the students’ representative
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3h, 16Jan or 1Fev 2013Exams
0.5h seminar (one date >= week 8)3rd lab. assignment
3 weeks2nd lab. assignment
3 weeks1st lab. assignment
1 week2nd preliminary lab.
1 week1st preliminary lab.
First weekLab. registration1
Schedule Schedule ((laboratorieslaboratories & & examexam))::
1 Important: define the students’ representative
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Schedule Schedule (according to IST(according to IST--GOP)GOP)::
• Recitation classes
Monday 11.00 h – 12.30h Ea5Friday 11.00 h – 12.30h Ea4
• Lab. Classes (once per week)
Monday 09.30h – 11.00h L1 LSDC4 (room 5.21)Friday 09.30h – 11.00h L2 LSDC4 (room 5.21)
• Groups registration for the LaboratoryBy September 25th 2009 with the students’ representatives.
Industrial Automation
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BibliographyBibliography::
Industrial Automation
• Automating Manufacturing Systems with PLCs, Hugh Jack (online version available).
• Peterson, James L., "Petri Net Theory and the Modeling of Systems", Prentice-Hall,1981.
• Modeling and Control of Discrete-event Dynamic Systems with Petri Nets and other Tools, Branislav Hruzand MengChu Zhou, 2007. New reference…
--- secondary---
• Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, 1996.
• Petri Nets and GRAFCET: Tools for Modeling Discrete Event Systems, R. DAVID, H. ALLA, New York : PRENTICE HALL Editions, 1992.
• Computer Control of Manufacturing Systems, Yoram Koren, McGraw Hill, 1986.
• Christos Cassandras, "Discrete Event Systems - Modeling and Performance Analysis", Aksen Associates, 1993.
• Moody and Antsaklis, Supervisory Control of Discrete Event Systems, Kluwer Academic Publishers, 1998.
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Slides 2010/2011, Prof. Paulo Jorge OliveiraRev. 2011-2014, Prof. José Gaspar
Industrial Industrial AutomationAutomation(Automa(Automaçção de Processos Industriais)ão de Processos Industriais)
IntroductionIntroduction to to AutomationAutomation
http://www.isr.ist.utl.pt/~jag/aulas/api1314/api1314.html
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Industrial Process: Industrial Process:
Making Cement Making Cement
[[OutãoOutão / / SetSetúúbalbal / / Portugal]Portugal]
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Industrial Process: Industrial Process:
Tetra Pak / Tetra Pak / ParmalatParmalat
Complexity handled Complexity handled with modularitywith modularity
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Ctrl Actuator
Sensor
Robot +Robot + ... + Global
Controller
= Automated
Industrial
Process
The subject of this course
+Robot
Other courses as e.g. Control
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Ch. 1 Ch. 1 –– Introduction to Automation [1 week]Introduction to Automation [1 week]
Introduction to components in industrial automation.
Cabled logic versus programmed logic versus networked logic.
Introduction to methodologies for problem modeling. Methodologies of work.
Industrial Automation
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Components used in industrial automationComponents used in industrial automationThe production of increasing amounts of goods requires the storage and handling of large quantities of resources.
The use of specialized, automatic tools are mandatory.
Consistent trend in the last three centuries (since the Industrial Revolution).
Automation was also fostered by the invention of computers,
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RoboticRobotic ManipulatorsManipulators
Chap. 1 – Introduction to Automation
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Riding an ABB IRB 6600 Robot 1 [Youtube]API Note: please understand the power, and do not do this; keep always the safety!
RoboticRobotic ManipulatorsManipulators
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Robotic Manipulators Robotic Manipulators -- End EffectorsEnd Effectors
Chap. 1 – Introduction to Automation
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Major characteristics:
• Number of degrees of freedom• Types of joints (prismatic/revolution)• Programming tools and environments(high level languages, teach pendent, ...)
• Workspace• Accuracy, reliability• Payload and robustness
Chap. 1 – Introduction to Automation
Robotic ManipulatorsRobotic Manipulators
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Workspace:
Examples
Chap. 1 – Introduction to Automation
Robotic ManipulatorsRobotic Manipulators
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Central problems to address and solve:
• Direct / Inverse kinematics• Trajectory generation• Coordinate frames where tasks are specified• Level of abstraction of the programming languages
Chap. 1 – Introduction to Automation
Robotic ManipulatorsRobotic Manipulators
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Use in Flexible
Cells of Fabrication:
it is required that the manipulatorshave correct interfaces for the synchronization and inputs for
external commands.
Chap. 1 – Introduction to Automation
Robotic ManipulatorsRobotic Manipulators
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Computerized Numerical Controlled MachinesComputerized Numerical Controlled Machines
Examples:Milling, Lathes, ...
Major characteristics:
• Number of degrees of freedom• Interpolation methods• Load/unload automation, and also in tool change• Programming (high level languages, teach pendent, ...)• Workspace• Accuracy, reliability• Payload and robustness• Interface • Synchronization with exterior
Chap. 1 – Introduction to Automation
MITSUI SEIKI Machining Center
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Computerized Numerical Controlled MachinesComputerized Numerical Controlled Machines
Compact CNC plasma cutting machineEffective cutting :1.5 m X 3 mPlasma torch cutting capacity up to 5cm (mild steel), Gas torch option allows up to 10cm.
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For transport...
Solutions for Handling materialsSolutions for Handling materials
Chap. 1 – Introduction to Automation
Major characteristics:
• Load/unload automation
• Accuracy, reliability
• Payload and robustness
• Interface
• Synchronization with exterior
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AGVsAGVs (Automatic Guided Vehicles)(Automatic Guided Vehicles)
Chap. 1 – Introduction to Automation
Major characteristics:
• Load/unload automation
• Accuracy, reliability
• Payload and robustness
• Interface
• Synchronization with exterior
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Example of fleet operating in industry
AGVsAGVs (Automatic Guided Vehicles)(Automatic Guided Vehicles)
Chap. 1 – Introduction to Automation
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AGVsAGVs (Automatic Guided Vehicles)(Automatic Guided Vehicles)
Kiva Systems Inc- warehouse automation- used by Staples, Toys R Us, ...- 2012 bought by Amazon ($775 million)
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Factory example: production of aluminum packs
Specific ComponentsSpecific Components
Chap. 1 – Introduction to Automation
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Cabled Logic versus ...Cabled Logic versus ...
Chap. 1 – Introduction to Automation
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... versus ... versus ProgrammedProgrammed LogicLogic ……
Chap. 1 – Introduction to Automation
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Cabled Logic versus ...Cabled Logic versus ...
... versus ... versus ProgrammedProgrammed LogicLogic ……
Relaycontrolpanel
PLCcontrolpanel
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... versus ... versus NetworkedNetworked LogicLogic
Chap. 1 – Introduction to Automation
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Introduction to methodologies Introduction to methodologies
for problem modeling infor problem modeling in
Industrial AutomationIndustrial Automation
Chap. 1 – Introduction to Automation
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Refs: Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, 1996.
ActuatorsMotorsSolenoide valveCommand relayPneumatic cylinderElectro pneumatic
SensorsPressure switchTemperature sensorsProximity sensors
Relay diagram / Ladder diagram
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ActuationActuation
Major characteristics:
• Type of start
• Type of control
• Accuracy, reliability
• Payload and robustness
• Interface with exterior
• Synchronization
Motors
Chap. 1 – Introduction to Automation
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Exemple of AC motor, with driver
Chap. 1 – Introduction to Automation
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SolenoideSolenoide ValveValve
Chap. 1 – Introduction to Automation
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CommandCommand RelayRelay
Chap. 1 – Introduction to Automation
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CylindersCylinders ((PneumaticsPneumatics))
Chap. 1 – Introduction to Automation
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ValvesValves ((ElectroElectro--pneumaticspneumatics))
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PushPush buttonsbuttons
Chap. 1 – Introduction to Automation
SensorsSensors
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Selector Selector withwith threethree positionspositions
Chap. 1 – Introduction to Automation
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SensorsSensors
PressurePressure SwitchSwitch
Chap. 1 – Introduction to Automation
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TemperatureTemperature
SensorsSensors
Chap. 1 – Introduction to Automation
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ThermocoupleThermocouple ProximityProximity detectordetector
Chap. 1 – Introduction to Automation
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MagneticMagnetic detectordetector MagneticMagnetic switchswitch
Chap. 1 – Introduction to Automation
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SymbolsSymbols associatedassociated to to allall componentscomponents
Standards
Chap. 1 – Introduction to Automation
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ContactContact DiagramDiagram or LadderLadder DiagramDiagram
Chap. 1 – Introduction to Automation
Methodologies for the implementation of solutions in industrial automation
DeviceDevice: : RelayRelay
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LadderLadder DiagramDiagram
OrOr
ContactContact DiagramDiagram
Chap. 1 – Introduction to Automation
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Methodologies for the implementation of solutions in industrial automation
ContactsContacts diagramdiagram
ExampleExample
Chap. 1 – Introduction to Automation
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ExampleExample::
Chap. 1 – Introduction to Automation
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LogicLogicFunctionsFunctions
Chap. 1 – Introduction to Automation
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ExampleExample::
Chap. 1 – Introduction to Automation
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To To exploitexploit thethe advantagesadvantages ofof ProgrammedProgrammed LogicLogic
Chap. 1 – Introduction to Automation