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
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.
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.
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
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.
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