Download - AI_011_Intro
-
7/29/2019 AI_011_Intro
1/31
EE-403, Course Contents
BEE- 7 A & C, Fall, 2013
Industrial Automation
-
7/29/2019 AI_011_Intro
2/31
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
-
7/29/2019 AI_011_Intro
3/31
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 : [email protected]
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:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected] -
7/29/2019 AI_011_Intro
4/31
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
-
7/29/2019 AI_011_Intro
5/31
Grading Policy
Assignments/ Quizzes: 10%
Mid Term: 20%
Labs: 20%
Term Project: 10%
Final: 40%
-
7/29/2019 AI_011_Intro
6/31
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
-
7/29/2019 AI_011_Intro
7/31
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.
-
7/29/2019 AI_011_Intro
8/31
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!
-
7/29/2019 AI_011_Intro
9/31
Ground Rules-II
Listen for understanding Participate in class discussion
Ask questions!
Adhere to Air University Code of
Conduct Dress Code
Ethical Behavior
-
7/29/2019 AI_011_Intro
10/31
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..
-
7/29/2019 AI_011_Intro
11/31
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
-
7/29/2019 AI_011_Intro
12/31
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
-
7/29/2019 AI_011_Intro
13/31
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.
-
7/29/2019 AI_011_Intro
14/31
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.
-
7/29/2019 AI_011_Intro
15/31
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
-
7/29/2019 AI_011_Intro
16/31
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
-
7/29/2019 AI_011_Intro
17/31
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
-
7/29/2019 AI_011_Intro
18/31
Control Tasks
measure - command - control
-
7/29/2019 AI_011_Intro
19/31
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.
-
7/29/2019 AI_011_Intro
20/31
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.
-
7/29/2019 AI_011_Intro
21/31
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.
-
7/29/2019 AI_011_Intro
22/31
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
-
7/29/2019 AI_011_Intro
23/31
Manual Control
-
7/29/2019 AI_011_Intro
24/31
Automatic Control
-
7/29/2019 AI_011_Intro
25/31
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
-
7/29/2019 AI_011_Intro
26/31
a. open-loopsystem;
b. closed-
loop system
Block diagrams of control systems
-
7/29/2019 AI_011_Intro
27/31
Discrete and continuous plants
discrete control
(binary)
continuous control
(analogue)
Depends on industrial process
-
7/29/2019 AI_011_Intro
28/31
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
-
7/29/2019 AI_011_Intro
29/31
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
-
7/29/2019 AI_011_Intro
30/31
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)
-
7/29/2019 AI_011_Intro
31/31
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