AUTOMATION SYSTEMS

C.Antony NishanthUniversity V.O.C College of Engineering

Tuticorin

What is automation?

Automation refers to the stateof being automaticallyoperated equipments ormachines and is the stepbeyond mechanization whereit requires physical labor toperform the functionsmanually.

WHAT IS AUTOMATION?

It is a technology dealing with the

application of

mechatronics,computers for

production of goods.

Need of Automation

i. Saves time

ii. Save money(long run)

iii. Self maintenance

iv. Security

v. Increaseed producivity

vi. Reliablity and Accuracy

AUTOMATION SYSTEMit usually needs these 3parts:

i. Sensor

ii. Controller

iii. Actuator

2 Types of automation system

Industrial automation

Home automation

1. Industrial Automation

Industrial automation is the process of making industrial production processes more flexible and simpler at higher efficiencies. Automation integration to the industries results intelligent manufacturing solutions at improved product quality and productivity with reduced downtime and wastes.

1. Industrial Automation

Types

I. Numerically Controlled Machines

II. Computer –Aided Manufacturing

III. Industrial Robots

IV. Flexible manufacturing Systems

These machines are of computer controlled machines which uses computers to perform the control operations by acquiring, processing, calculating and controlling the process variables. This automation is a programmed version of machine tools and also called as Computerized Numerical Controlled (CNC) Machines.

Applications

These CNC machines are used in cutting and milling applications for high accuracy and accurate precision operation

These automation systems also make use of computers to plan, design and layout the various products.

Examples of this automation systems are computer-aided design (CAD), computer-aided design and drafting (CADD) and computer-aided process planning (CAPP).

Industrial Robots

Difinition

These are a type of automated machines or

equipment’s that can perform the different

tasks for longer duration. These are mostly

implemented in the areas that are highly

dangerous or hazardous for humans.

Robot as Transportation Device

Painter robot

Welding robot

They are more expensive

Assembly robot

Assembly Robot : The Case of Printed Circuit Board (PCB)

•

Flexible Manufacturing Systems

This automation is of fully automated

one.

Starting from planning and

designing process to dispatching of

products, the whole system is

completely integrated to be

automated. This automation combines

numerically controlled machines,

industrial robots and other automation

equipment’s into one integrated

system.

Example

AGV: Automated Guided Vehicle

Flexible change among technological

alternatives.

Low level of workforce.

Small batches.

High productivity.

Reduced set-up times.

Home automation system does the operationslike lighting control and regulation, regulatingHVAC (Heating, Ventilation and Air Conditioning)equipment’s, energy and load management,security and monitoring, audio/ video systems,HMI’s and other control tasks.

Home automation uses the various sensors tosense parameters like temperature, pressure,motion, illumination, etc and sends these signalsto central controllers. These controllers areprogrammable devices like PLCs which areprogrammed according to the application it isemployed for.

Mood Lighting

CCTV Camera/Surveillance

Systems

Thermostats and HVAC Controls

Door Locks TV Control

Lighting and Fan Control

Motion Detectors/Gas Leakage

Detectors/Sensors

Ex :

Project in Action – Cellular Phone Communication

24

Thermostat

Fan

Lamp

Co

ntr

oll

ed D

evic

es…

Types

Powerline Automation System

Wired Home Automation system

Wireless Home Automation System

This automation is of low cost since it uses

powerlines to transfer the information or data

therefore it doesn’t require additional cables for

transferring the information. However, this system

is of little bit complex one that necessitates

additional converter circuits.

Wired Home Automation SystemThis type of automation uses a commoncommunication bus to which all the equipments inhomes are connected. This communication bus orcable is connected to a main controller (plc) in order toacquire input signals and to send control commandsignals to the actuators.

Wireless Home Automation

This is an advanced automation technology as compared with wired automation. This automaton uses wireless technologies like RF, Zigbee, GSM, WI-Fi and Bluetooth for achieving remote control operation.

This is a flexible type of automation requires negligible wires to connect different appliances in homes to the central control unit.

PLC(PROGRAMMABLE LOGIC CONTROLLER)

Programmable Logic Controller (PLC) is an industrial computer that monitors inputs, makes decisions based on its program and controls outputs to automate a process or machine.

The automation of many different processes, such as controllingmachines or factory assembly lines, is done through the use of smallcomputers called a programmable logic controllers (PLCs).

WHY PLC?

To reduce human efforts .

To get maximum efficiency from machine and control them with

human logic .

To reduce complex circuitry of entire system .

To eliminate the high costs associated with inflexible, relay-controlled

systems.

UNDERSTANDING OF PLC (Example )

Machine can be controlled by PLC without human efforts

PLC

INPUT OUTPUT

PUSH BUTTONS

1. INPUT MODULES accepts and converts signals from sensors into a

logic signal

Ex. : Switches, Pushbuttons.

2. OUTPUT MODULES that convert control instructions a signal that can

be used by actuators.

Ex. : lamps, alarm.

COMPONENTS (INPUT /OUTPUT)

3. CENTRAL PROCESSING UNIT(CPU)It is the brain of PLC and governs the activities of the entire PLC systems

The CPU consists of following blocks :Arithmetic Logic Unit (ALU), Internal memory of CPUInternal timers ,counters and Flags .

The various operations performed are :Scanning I/O bus traffic control, Program execution, Peripheral and External device communication, Data handling and self diagnostics.

PROCESSOR

4. MEMORY is the component that stores information, programs and data in

a PLC.

COMPONENTS (CPU ,MEMORY)

Types of memories used in PLCs are read only memory (ROM) and

random access memory (RAM).

5. POWER SUPPLY

Provides the voltage needed to run the primary PLC

components. POWERSUPPLY

6. PROGRAMMING DEVICE

The programming terminal is used for programming

the PLC and monitoring/sequencing PLCs

operation. PROGRAMMING

DEVICE

COMPONENTS (POWER SUPPLY, PROGRAMMING DEVICE)

CHECK INPUT STATUS

First the PLC takes a look at each

I/O to determine if it is on or off.

EXECUTE PROGRAM

Next the PLC executes the program

one instruction at a time.

UPDATE OUTPUT STATUS

Finally the PLC updates the status of

the outputs .It updates the outputs

based on which inputs were on during

the first step.

PLC OPERATION

Ladder logic is a programming language used to

develop software for PLC used in industrial control

applications.

PLC PROGRAMMING

Manufacturing / Machining

Food / Beverage

Textile Industry

Travel Industry

Aerospace

Printing Industry

AREAS OF APPLICATION

Replacing Human Operators

Dangerous Environments

Beyond Human Capabilities

Fast

Easily programmed and have an easily understood

programming language.

Improves Productivity

Improves Quality

ADVANTAGES

PLC Devices Are Proprietary

Initial Costs Are High

There's Too Much Work Required In

Connecting Wires

Unemployment Rate Increases

DISADVANTAGES

THANKS FOR YOUR

ATTENTION!!!!!!!!!!