capitulo1

1

1IAS, Universität Stuttgart

Industrial Automation

§ 1 What is Industrial Automation?

§ 2 Automation Device Systems and Structures

§ 3 Process Periphery

§ 4 Real-time Programming

§ 5 Real-time Operating Systems

§ 6 Programming Languages for Industrial Automation

§ 7 Reliability and Safety of Industrial Automation Systems



1.1 Definition of Several Basic Terms

1.1.1 Technical Process

1.1.2 Industrial Automation

1.1.3 Real-time System

1.1.4 Automation Computer

1.2 Degree of Automation and Computer Deployment

1.3 Automation of Technical Products and Technical Plants

1.4 Components of an Industrial Automation System

1.5 Levels of Process Management and Automation Functions

1.6 Technical Systems

1.7 Graphical representation of technical processes

1.8 Examples of Industrial Automation Systems

1.9 Effects of Industrial Automation on People, Society and Environment


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1.1.1 Technical process


Definition #1:A technical process is a process during which material, energy or information is altered in its state. This modification of state can implythe transition of an initial state to a final state.

process, procedure, event

final state ofmaterial, energyor information

TECHNICALPROCESS

in a technical system

initial state ofmaterial, energyor information

transformation

transport storage

refers to: flow of material, energy or information



Examples

Initial State Technical Process


Final State

Low ambienttemperature

Thermal process regardinghouse heating with an oil-fueledheating system

Higher ambient temperature

Dirty laundry Washing process in a washingmachine

Fresh laundry

Unsorted parcels Transportation and distributionprocess in a parcel distributionsystem

Parcels sorted by destinations

Energy of fossil ornuclear fuels

Enegry transformation andenergy generation processes ina power plant

Electric energy

Parts to be stored Storage process in a high baywarehouse

Parts compiled for commissions

Train at location A Traffic process of a train journey Train at location B

Monomere substance Process in a chemical reactor Polymeric substance

Untested device Test process in a test laboratory Tested device

Parts without a drill-hole

Drilling process of a drillingmachine

Parts with drill-hole

Pollutants Process in a system for pollutionmonitoring

Information on pollutionconcentrations are indicated inmonitoring center

3



Definition #2: DIN 66201A process is the entirety of all interacting processes within a systemthat transforms and stores material, energy or information.A technical process is a process in which its physical parameters are recorded and influenced by technical means.

– from simple to highly complex

– different partial processes are combined to an overall process

washing machine, power plant

car with automotive electronics

TECHNICAL PROCESS


affectuatingvariables

outputquantities

material,energy orinformationinflow

material, energyor informationoutflow



Technical system with technical process

Technical Process

Technical System

(device, machineor technical plant)

processinputvariables

processoutputvariables

material, energy orinformation inflow

material, energy orinformation outflow

actuatingsignals

process-influencinginformation

processoutcomeinformation

measuredsignals

the technicalprocess runs ontechnical system

4



Example for a technical plant with technical process

fill reac-tion empty

outflowreactionproductsubstance C

feedsubstance A

feedsubstance B

Technical Process

substance A

substance B

actuating signals

substanceC

measured signals

Technical Plant

– technical plant: chemical reactor– technical process: 3 sub-processes (fill, reaction, empty)

















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Industrial automation

= process + automation

= independently operating technical systems

cigarette vending machine

ticket vending machine

= to enable machines,installations and facilitiesto operate independently

office automation,

traffic automation,

railway automation,

industrial automation

automat

automation



= the automation of a technical process

industrial automation system

= technical system with technical process

+ computer and communication system

+ process operators

industrial automation

6



Structure of an industrial automation system

computer and communication systemconsisting of e.g., programmable logiccontrollers (PLC), industrial PCs, microcontrollers, bus systems, etc.

technical system(technical product or technical plant ), inwhich a technical process takes place

people (process operators) for managing and

operating the technicalprocess as well as

intervening inexceptional situations

processoutcome

processinfluence

control signalsto thetechnical process

signals from thetechnical process



– goal is the automation of operations in the technical process with thehelp of appropriate information processing units

– human operators only places requests on the operating results

– goal is the management of the procedure of the technical process byhuman operators, supported by the automation of individual operations

– managing refers to controlling and regulating

– goal is an automation software system

– real-time system

automation of the technicalprocess in the foreground

operation in theforeground

computer and communicationsystem in the foreground

industrial automation system

process control system

process computer sciences

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Definition: DIN 44300Real-time operation is the operation of a computer system, in which programs required for the handling of arising data are in constant operation so that the processing results are available within a given periodof time.This data may appear according to a random time distribution or at regularintervals.

– hardware/software system

– data reception, data processing, data delivery to the process within agiven time limit

– external events

– processing priority

Features of a real-time system

Real-time system allows real-time operation

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Requirements on real-time systems

– timelinessreaction right on time

– simultaneousnesssimultaneous reaction to various events

– dependabilityreliable, safe, available

– predictabilityall reactions must be planable and deterministic

not too soon, not too late

parallel processes

important reason for purchase

comprehensible in case errors occur



Industrial automation system are real-time systems

computer andcommunicationsystem

technical processin atechnical plant

sensor signals

control signals

people

time time

externalinfluences

operating personnel

computer and communicationsystem

technical process

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Features

Processors applicable in a process automation system are freeprogrammable digital processors (computers) that have to showmainly 3 features:

– Compliance of real-time operation requirements, that is recording,processing and output of process data in a timely manner

– Possibilities for input/output of process signals (directly or via a communication system) for process connection

– Processing of numbers, characters and bits

In 60th and 70th years specific „process computers“- Term antiquated, because differences disappeared

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Different forms of automation computers

– programmable logic controller (PLC)

– micro controller

– personal computer (PC)

– process control system













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Degree of automation:

The sense and benefit of an automation depends of the technical process(accessible / inaccessible) and the general conditions (economicallyreasonable / senseless). The degree of automation describes the extend ofthe processes included in the automation.bandwidth: from zero up to fully automated operation

Types of operation:

– off-line operation (operation with indirect process connection) with thelowest degree of automation

– on-line / open-loop operation (open on-line operation) for a mediumdegree of automation

– on-line / closed-loop operation (closed on-line operation) for a high degreeof automation

Caution! - Also with fully automated operation the human being canmake interventions (set point default or malfunction)!



Operation without computer use

operationaccounting

general managementorders

applications forthe processmanagement

operationprotocol

processpersonnel

control andregulationdevices

manualdevice

display deviceand graphicalrecorder

technical plant

no automation

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Off-line operation (indirectly connected operation)

low degree ofautomation, noconnection tothe technical

process

general management orders

processpersonnel


manualdevice

display deviceand graphicalrecorder

technical plant

off-line-computer instruc-tions

for theprocessmanage-ment

operationprotocol

input,operation modes,instructions

input of theoperationprotocol



On-line/ open-loop operation

medium degreeof automation,

data acquisitionfrom the

technical process

general managementorders

processpersonnel


manualdevice

technical plant

operationprotocol

instructions

operationmonitoring

computersystem

control board

on-line

open-loop

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orders

technical plant

operationprotocol

computer and communication system

emergencycontrol

emergencyinstruments

operation managementand control

On-line-/ closed-loop operation

high degree ofautomation, data

recording andinfluence of the

technical process

on-line undclosed-loop






1.3.1 Types of automation systems

1.3.2 Product automation

1.3.3 Plant automation








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product automation

plant automation

industrial automation systems, in which the technical process takes placewithin a device or within a single machine

large quantities

industrial automation systems, in which the technical process is composed ofsingle partial processes that take place on greater, often geographically widespread plants

unique systems



Examples for the two types of industrial automation systems

Examples of products in productautomation

Examples of technical plantsIn plant automation

heating systems

washing machines

sewing machines

kitchen tools (e.g., dish washer,microwave, etc.)

TVs, radios

cameras

alarm systems

toys

navigation systems

answering machines

musical instruments

machine tools

measuring devices

automobiles with sub-systems:motor control, ABS, distancewarning system, route planing, etc.

power plants (steam generator,turbines, generators)

energy grid

high bay warehouse

parcel distribution installations

chemical reactors

process engineering installations

steal production plants

milling installations

railway traffic system ( long distancetrains, commuter railways, metros)

traffic light installations

gas supply installations

purification and water plants

building system installations

laboratories and test fields

environmental measurementinstallations

etc.

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Characteristic criteria regarding product automation

– technical process in a device or machine (embedded systems)

– dedicated automation functions

– automation computer in the form of a micro controller or PLC

– few sensors and actuators

– degree of automation 100%, on-line/closed-loop operation

– high quantities (serial or mass products)

– engineering and software costs of inferior importance since they aredistributed among large unit numbers

simple

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Structure with simple product automation

example:

kitchen tool

technical product

useror

operator

micro controller

set v

alue

s

disp

lay

man

ipul

ated

var

iabl

es

proc

ess

resu

lts



Structure with complex product automation

useror

operator

micro-controller

micro-controller

1

micro-controller

2

micro-controller

n

subsystem1

subsystem2

subsystemn

bus system

technical product

example:automotiveelectronics

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Characteristic criteria regarding plant automation

– technical process in an industrial plant, often geographically wide spread

– extensive and complex automation functions

– PLCs, PCs and process control systems are used as automation computer systems

– large number of sensors and actuators

– medium to high degree of automation

– unique system

– engineering and software costs are critical for overall costs

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Structure for a larger technical plant

mastercomputer PC PC

PLC PLC PLC

factory bus

observation,operating,protocolling

level 3

plant bus

level2

field bus field bus

level1

sub-system

sub-system

sub-system

technical plant




1.2 Degree of Automation and Computer Deployment1.3 Automation of Technical Products and Technical Plants

1.4 Components of an Industrial Automation System1.4.1 Technical components

1.4.2 Sensors and actuators

1.4.3 Communication system

1.4.4 Automation computer system1.4.5 Automation software system



1.7 Graphical representation of technical processes1.8 Examples of Industrial Automation Systems



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1.4.1 Technical components


technical components of anindustrial automation system

technical system to beautomated (automation object)

facilities necessary forautomation (automation system)

technicalproduct

technicalplant

interface to thetechnical process:sensors and actuators

facilities foruser - processcommunication

hardwired individualdevices

communication system

communicationsystem close to the process(field bus)

bus system for thecommunicationbetweenautomation computers

automation computersystem

hardware system(device system)

automation softwaresystem

computerhardware

processperiphery

usersoftware

systemsoftware














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Sensors

– acquisition of information on the progression of process variables – sensors, detection devices, measuring devices

– conversion into electrical or optical signals

examples: temperature,pressure ,velocity

Actuators

– conversion of control information in order to influence process variables– actuators (correcting element)

examples : relays,magnets,servomotors














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Communication system in product automation

simple products

– few sensors and actuators

– short line distances

complex products

– communication between subsystems via bus system

– examples: CAN bus, Interbus-S

technical product

useror

operator

micro controller

set v

alue

s

disp

lay

man

ipul

ated

var

iabl

es

proc

ess

resu

lts

useror

operator

micro-controller

micro-controller

1

micro-controller

2

micro-controller

n

subsystem1

subsystem2

subsystemn

bus system

technical product



Communication system in plant automation

– many sensors and actuators, geographically distributed

– many automation computers, geographically distributed

Communication tasks on several levels

mastercomputer PC PC

PLC PLC PLC

factory bus

observation,operating,protocolling

level 3

plant bus

level2

field bus field bus

level1

sub-system

sub-system

sub-system

technical plant

– factory bus

– plant bus (process bus)

– field bus

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1.4.4 Automation computer system


Programmable Logic Controller (PLC)

– originally replacement for relay and contactor control (1-bit-computer)

– today wide range of service up to the operation of big machine compounds

– programming through specific programming devices with the aid of ladder diagram or function diagram

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Micro controller (One-chip-computer)

– highly integrated components

– employment for mass products

– composition of

• standard Micro processor• data memory / program memory• bus interfaces• process signal interfaces

– programming with development system



Personal Computer (PC) resp. Industrial PC (IPC)

– for adverse environment deployment of industrial PCs

– plugable circuit boards for connection of

• electrical process

signals

• optical process

signals

• bus systems

– programming in high-level language

– use of real-time operating systems

• as single operating system

• in addition to standard operating systems

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Process control system - PCS (1)

– distributed computer systems, connected via bus systems

– usage of prefabricated program modules developed by the

manufacturer of the PCS

– configuration by operator

– interconnection with PLC computers



Process control system (2)

display andoperation

component

engineeringstation

display andoperation

component

field levelcomponent



operationmaster

computer

sensors and actuators field bus field device

redundant manufacturer-specific system bus

factorybus

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1.4.5 Automation software system


Automation software system

– set of all programs necessary for the execution of automation tasks,including their documentation

– differentiation between executive and organizational/administrationaltasks

executive programs(application software)

input measured values

calculation of controlvariables

organizing and administratingprograms (operating softwareor system software)

software device drivers

operating system

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1.4.5 Automation software system


programs for organizingexecution of applicationprograms

programs for managingperipheral devices

programs for organizingdata traffic with externalmemories

programs for the dialoguebetween human andcomputer

compilation programs

run-time programs

programs for acquisition ofprocess variables

programs for processmonitoring

programs for process control

programs for processregulation

programs for processoptimization undmanagement

programs for process safetyand security

oper

atin

g sy

stem

System softwareApplication software













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Model of levels in the management of a technical process

strategiclevel

long-termdistribution policy

distribution planning

distribution tactic

sales

business managementlevel

productionmanagement level

process control level

level of measuringcontrolling and regulating process variables(process variable level)

technical process in atechnical system

dispositivelevel

tactical level

operative level

levels of hierarchy levels in distribution levels of a company

field of action market



Time requirements on the different levels

process control level:

business management level:

operation / production management level:

process variable level:

Effects ranging betweenmonths-years

Effects ranging betweendays-weeks-months

Effects ranging betweenminutes-hours

Effects ranging betweenmicroseconds-seconds

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Automation functions

cost analysis,statistical evaluations

work sequence planning,capacity optimization,

evaluation of process results

process monitoring,start-up and shut-down,

malfunction handling, processguidance, process security

measuring, controlling,manipulating, regulatinginterlocking, emergency

handling of processvariables,shut-down, protection

recording and influencingprocess variables with sensors

and actuators

businessmanagement level

production andoperation

management level

process controllevel

process variablelevel

field level

Levels of a company Automation functions



1.1 Definition of Several Basic Terms1.2 Degree of Automation and Computer Deployment1.3 Automation of Technical Products and Technical Plants1.4 Components of an Industrial Automation System1.5 Levels of Process Management and Automation Functions

1.6 Technical Systems1.6.1 Process variables in technical systems1.6.2 Processes in technical systems1.6.3 Classification of technical systems1.6.4 Assignment of technical production processes to

process types1.7 Graphical representation of technical processes1.8 Examples of Industrial Automation Systems1.9 Effects of Industrial Automation on People, Society and Environment


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1.6.1 Process variables in technical systems


Types of occurring process variables

– Process variables, that are allocated to the course of physicalstate-variables with a continuous or piecewise continuous range of values

example: temperatures in a heating system

– Process variables, that are allocated to certain discrete process states• physical variables with a continuous range of values that characterize

the process states• binary process variables that are allocated to state transitions i.E., To

events that cause the change of state

example: switch setting: 0/off - 1/on

1.6.1 Process variables in technical systems


Types of occurring process variables

– process variables that are allocated to individually identifiable objects• physical variables with a continuous range of values

example: temperature of a slab in a clogging mill,size of a part in a store

• identification numbers i.e., non-physical variables example: type, design, application, depot number

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1.6.2 Processes in technical systems


Definition of three process types in technical systems

– continuous processes

– sequential processes, discrete event type processes

– object-oriented processes

Caution! - a clear distinction is not always possible !

example: transportation as a continuous and object-oriented process

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Continuous processes in technical systems

Characteristics processes containing time–dependent continuousprocess variables

Process variable physical variables with a (at least piece-wise)continuous range of values

Examples generation processes,

transformation processes,

movements, etc.

Mathematicmodels

differential equations (time as an independentvariable), transfer functions



Sequential processes in technical systems

Characteristics processes containing sequences ofdifferent, distinguishable process states

Process variables binary signals that cause or indicatediscrete process states as well ascontinuous physical variables allocated toprocess states

Examples sequences of process states during start-up or shut-down of a turbine,sequence of states during the operation ofan elevator, sequence of states duringproduction using a machine tool

Models flow charts, state models, Petri nets,function plans according to DIN 40719

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Object-oriented processes in technical systems

Characteristics processes during which individuallyidentifiable objects are transformed,transported or stored

Processvariables

physical variables with a continuousrange of values or non-physicalvariables (e.g., type, design,application, bay number) that areallocated to the objects, as well asbinary variables, that cause or indicatestate changes of objects

Examples processes during the manufacturing ofparts, traffic processes, storageprocesses, information processes incomputers

Models simulation models, queue-models, statemodels, Petri nets







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1.6.3 Classification of technical systems


Classification methods

Classification according to the kind of...

– transformed or transported medium

– effect

– material-related transformation

– dominating process type

material related processes, energy related processes, information related processes

generation processes, distribution processes, storage processes

chemical processes, production processes

flow processes (continuous), successive processes (sequential), piece-related processes (object-related)







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1.6.4 Assignment of technical production processes to process types


Assignment of technical production processes to processtypes

Technical productionprocesses

Process types

Energy-related

processes

continuous processes,

sequential processes

chemical processes continuous processes,sequential processes

production processes continuous processes,sequential processes,object-related processes

material-handlingprocesses

continuous processes,sequential processes,

object-related processes

Technical processes can contain processes of different types,on the other hand a process in turn can be a technical process.

1.6.4 Assignment of technical production processes to process types


Examples:

– generation of electric energy in a turbo generator• continuous process• sequential process (start-up sequence of plant)

Chemical processes

– batch processes• single process steps are continuous processes• sequence of steps is a sequential process

production process

– manufacturing a turned part• transportation of the sleeve is an object-related process• manufacturing process consists of a sequence of steps (“mount part”,

“drive drilling machine to position “ etc.), thus it is a sequential process• machine-cutting process is a continuous process

energy-related processes

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Flowchart

– similar to block diagrams used in control engineering

– processes and process steps are represented as rectangles

– arrows represent the information or material flow

– bundles of connections are shown as double lines with arrow

Example:

dissolve reaction separatematerialdissolved

inter-mediateproduct

solvent

final product

additivechrused

additive

raw material

solvent

crush

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Information/material-oriented representation

– information/materials as circles– processes/functions as linking arrows

Example

inter-mediateproduct

additive

material

solvent

materialdissolved

additivecrushed

crush

dissolve

dissolve

reaction

reactionsolvent

finalproduct

separation

separation



Phase model representation

– mixture of flowchart and information/material-oriented representation

additive

rawmaterial

solvent

subprocess"crush"

subprocess

"dissolving"

reactioninter-

mediateproduct

separate

additivecrushed

materialdis-

solved

solvent

finalproduct

Example

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Examples for the flowchart representation

crushing

dissolving reaction separation

additive

raw material

solvent

solvent

final product

additive350 kg/h

solvent1000 kg/h

raw material800 kg/h

x

M M

M1 M2z1

1 bar20° C

B2B1

P1 P2

1 bar20° C

heat

ing

stea

m

3 ba

r

W1

heatingsteam

solvent700 kg/h

1 bar108° C

final product1450 kg/h

depot

simple flow chart

process flow chart



additive350 kg/h

F1

solvent1000 kg/h

raw material800 kg/h

FRC

1.01

FRC

2.01

TRC1.02 LRC

1.03

P1

V106

V101V201 V202

V102V203V103

V204

V105

B1 B2

LRC

1.04

P2

V106

XZ1M

3 h M1

M3 h

M3 h

M3 h

M3 h

V111

TRC

1.02

V304

V301

V302

V303

solvent700 kg/h

V206

heating steam5 bar

W1M2

V110V107

V112

V305

V306

condensate

LRC

1.04

M3 h

K1

final product1450 kg/h

V301

V302

V303

V116

W3A1

LRC+

1.04W2

Pipes and instrumentation flow diagram

38

















Automation system of an industrial washing machine

PI-flowchart

A B C

drawer

dosage pump

drumsteam or electricalheating

soft cold

soft hot

hard cold

Mfilter

waterpump

drain

tank

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Simplified block diagram

micro computer

human-process-communication

chip card interfaceinput and display

modul

program system 1: evolution & operating

program system 2: control and monitoring

sensors actuators

tem

per

ature

level

unbala

nce

doo

r pos

itio

n

valv

e 1

valv

e n

tank

valv

e

moto

r

pum

p

heat

ing

technical process in technical system"washing machine"

user

automation system








1.6 Basic Process Types in Technical Systems







40



Automation system of a heating and industrial water system

radiator im room 1 radiator in room n

low-temperature

boiler

circulationpump

fuel-oilfeed

industrialwaterreservoir

industrial water

load pump

coldfeed-water

forced-airburner

exhaust gas flap

smokestack

PI-flowchart



Simplified block diagram

TECHNICAL PROCESS consists of the thermal process

in the building and of the process in the low-temperature heating system

"sensors"

detection devices for measurment of

process variables

room

tem

pera

ture

n

room

tem

per

ature

1

oil le

vel

CO

2 in e

xhau

st g

as

smok

e st

ack

pre

ssure

inle

t-air tem

pera

ture

exhaust

gas

tem

p.

outd

oor

tem

per

ature

inle

t te

mpera

ture

indu

strial

wat

er t

emp.

boile

rtem

pera

ture

circ

ula

tion p

um

p

load

pum

p

forc

ed-a

ir b

urn

er

exh

aust

gas

flap

residents

equipment for human-process communication

program system 1 "control andmonitoring"

hardware 1

program system 2 "evalution andoperating"

hardware 2

computer 1 (PLC) computer 2 (PLC)

"actuators"

correcting element to influence the

technical process

automation system

prozess automation system

41











1.9 Effects of Industrial Automation on People, Society and

Environment




Intentional (positive) effects of industrial automation

– simplified and more convenient operation• automation of a washing machine

• automation of a heating system

– production of better, cheaper products of even quality with loweredproduction costs

• automation of chemical production processes

– reduction of of the endangerment of people• ABS system• traffic system automation (like inductive train security, automatic

barrier close)

– better, more humane working conditions• automation of painting or foundry work

– Securing jobs through higher competitiveness• use of robots in automobile manufacturing

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Unintentional (negative) effects of industrial automation

– redundancy of workers may lead to unemployment• use of robots in manufacturing

– restructuring of jobs due to changes in work flow and fields of work• lower/ higher qualified jobs• drop of ancillary tasks

• increase of jobs in the service sector

– reduction of human relationships• introduction of ticket vending machines and information systems

– increase of stress and reduction of relaxing tasks• automation of testing systems

– overtaxing in difficult situations• safety-critical decision in a nuclear power plant



The automation engineer is responsible for the effects of industrial automation

direct, immediate responsibility

– damages in industrial automation systems designed by him

– violations of generally accepted guidelines and regulations (regulations of the VDE, etc.)

– safety of automation systems

Dilemma: trade-off between benefits and damage

industrial automation has effects on:

– people– society– environment– energy and resources

43



ý important: sense of responsibility of the automation engineer

indirect, oblique responsibility

– unintentional side effects

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