IST / DEEC / API

Industrial Automation
(Automação de Processos Industriais)

http://users.isr.ist.utl.pt/~jag/courses/api1718/api1718.html

Prof. Paulo Jorge Oliveira, original slides

Prof. José Gaspar, rev. 2017/2018

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Industrial Revolution 1760/80 – 1820/40 (historians E. Hobsbawm, T. S. Ashton)

A steam engine built according to James Watt's patent

in 1848 at Freiberg in Germany [wikipedia]
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Industrial Revolution 1760/80 – 1820/40 (historians E. Hobsbawm, T. S. Ashton)

Steam engine and detail of the governor, James Watt's [wikipedia].

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A jewel: Maillardet's Automaton, 18th century, the largest known mechanical memory

https://www.fi.edu/history-automaton

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Maillardet's Automaton, 18th century: the largest known mechanical memory

Four drawings and three poems

https://www.fi.edu/history-automaton

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Maillardet's Automaton, 18th century:

the robot saved for the future the name
of its manufacturer

Ecrit par L’Automate de Maillardet

https://www.fi.edu/history-automaton

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Microcontrollers Computer + IO PLC

Premium P57
Instruments
Raspberry-pi

National

AD/DA
Arduino

Many options for controlling real world devices! Why PLCs?

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IST / DEEC / API Industrial Automation

Objectives of the course:

• Analysis of systems for industrial automation.

• Methodologies for the implementation of solutions in industrial

automation.

• Programming languages of PLCs (Programmable Logic Controllers).

• CAD/CAM and Computerized Numerical Controlled (CNC) machines.

• Discrete Event Systems Modeling.

• Supervision of Processes in Industrial Automation.

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 IST / DEEC / API Industrial Automation

Program at a glance: 5. CAD/CAM and CNC Machines [1 week]

Types of Computerized Numerical Controlled machines.
Interpolation of trajectories. Flexible fabrication cells.
1. Introduction to Automation [1 week]
Introduction to components and methodologies. 6. Discrete Event Systems [1 week]
Modeling of discrete event systems (DESs). Automata.
2. Introduction to PLCs [2 weeks] Petri networks. State and dynamics of PNs.
Components of Programmable Logic Controllers
(PLCs). Architecture, functional structure, IO. 7. Analysis of DESs [2 weeks]
Properties of DESs. Methodologies for the analysis:
3. PLCs Programming Languages [2w] reachability graph and matricial equation.
Standard languages (IEC-1131-3): Ladder Diagram;
Instruction List and Structured Text. 8. DESs and Industrial Automation [1week]
Relations GRAFCET / Petri networks. Analysis of
4. GRAFCET (Sequential Function Chart) industrial automation solutions as DESs.
[1 week]
Norm, elements of the language, modelling. 9. Supervision of Industrial Processes [2w]
Methodologies for supervision. SCADA. Synthesis based
on invariants. Examples of application.

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IST / DEEC / API Industrial Automation

Assessment and grading:

• 2 Preliminary laboratory assignments - training purposes (0% of the final grade).

• 2 Laboratory assignments (20%+20% of the final grade). Groups of 3 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.

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:

Short
summaries
of the
classes

Download this
XLS file from the
webpage of the
course.
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Schedule (semester view, laboratories & exam):

Lab. registration 1 First week

1st preliminary lab. 1 week

2nd preliminary lab. 1 week

1st lab. assignment 3 weeks

2nd lab. assignment 3 weeks

3rd lab. assignment 0.5h seminar (one date >= week 8)

20min presentation + 10min discussion
Exams (do at least one) 3h, 18Jan or 02Feb 2018

1 Important: define the students’ representative

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IST / DEEC / API Industrial Automation

Schedule (week view, see also IST-GOP / fenix):

• Recitation classes

Monday 11.00 h – 12.30h Ea5

Tuesday 08.00 h – 09.30h 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 Laboratory

By September 25th 2009 with the students’ representatives.
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Bibliography :
--- References mostly found in the slides : --- More references :

• Automating Manufacturing Systems with PLCs, • Computer Control of Manufacturing

Hugh Jack (available online). Systems, Yoram Koren, McGraw Hill, 1986.

• Programmable Logic Controllers, Frank D. • Petri Nets and GRAFCET: Tools for
Petruzella, McGraw-Hill, 1996. Modeling Discrete Event Systems, R. David, H.
Alla, New York : Prentice Hall Editions, 1992.
• Petri Net Theory and the Modeling of Systems,
James L. Peterson, Prentice-Hall,1981. • Supervisory Control of Concurrent Systems:
A Petri Net Structural Approach, Marian V.
• Supervisory Control of Discrete Event Systems, Iordache, Panos J. Antsaklis, Birkhauser, 2006
Moody and Antsaklis, Kluwer Academic Publishers,
1998. • Modeling and Control of Discrete-event
Dynamic Systems with Petri Nets and other
• Modeling and Performance Analysis, Christos Tools, Branislav Hruz and MengChu Zhou, 2007.
Cassandras, Aksen Associates, 1993 (newer book in
2008). • Técnicas de Automação, João R. Caldas Pinto,
Lidel Ed. Técnicas Lda, 2010 (3ª Edição)

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Industrial Automation
(Automação de Processos Industriais)

Introduction to Automation

http://www.isr.ist.utl.pt/~jag/aulas/api1718/api1718.html

Prof. Paulo Jorge Oliveira, original slides

Prof. José Gaspar, rev. 2017/2018

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IST / DEEC / API Chap. 1 – Introduction to Automation

Industrial Automation is Necessary and is Happening

Consistent production growth in the last
three centuries (since the Industrial
Revolution)1.

The production of increasing amounts of

goods requires the storage and handling of
large quantities of resources.

Need to use automatic tools and systems.

Automation was fostered by the invention

of computers.
1 Motivated by the continuous growth of the world population and migration to cities.
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Industrial Automation - Industry 4.0

[Wikipedia]

1760-1840 1913 1955 NC/CNC 2011 Industrie 4.0

Industrial Assembly line 1968 Bedford / term revived at
Revolution by Henry Ford GM PLC the Hannover Fair
1807-1811 French invasions, 1821 Independence of Brasil
1974-1975 Independence of Guiné-Bissau, Moçambique, Cabo Verde, São Tomé
e Príncipe, Angola
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Industrial Process:

Making Cement

[Outão / Setúbal /
Portugal]

Some systems are very

large and complex but
still need to “work like
a clock”

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Industrial Process:

Tetra Pak /
Parmalat

Complexity handled with modularity.

Filling machine, complete line:
- 200 ml slim 20000 TP/h
- Straw Applicator
- Beverage Carton Film Wrapper
- Conveyors
- Carboardpacker
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Complex Systems based on Local and Global Controllers

Subsystem +Subsystem +Subsystem + … + Global = Automated

Industrial
Controller
Process
Ctrl Actuator

Sensor Subsystems sequencing,

synchronization, …
Start and stop digital
Other courses as
(binary) signals and events.
e.g. Control
The subject of this course.
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IST / DEEC / API Industrial Automation

Ch. 1 – Introduction to Automation [1 week]

1.1 Introduction to components in industrial automation.

1.2 Cabled logic versus programmed logic versus networked logic.

1.3 Introduction to methodologies for problem modeling.

Methodologies of work.

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1.1 Components used in industrial automation

Robotic Manipulators
– generic load, unload, handle, work

Computerized CNC Machines

– specialized workers

Handling materials
– specialized load and unload

How it is done:
– Low level actuation and sensing
– Motors, sensors, local and global integration

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Robotic Manipulators

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Robotic Manipulators - End Effectors

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Robotic Manipulators
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

Workspace, examples:
• Spherical
• Cylindrical
• …
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Robotic Manipulators
Central problems to address and solve:
• Direct / Inverse kinematics
• Trajectory generation / Trajectory following
• Coordinate frames where tasks are specified
• Level of abstraction of the programming
languages

Use in Flexible Cells of Fabrication:

it is required that the manipulators

have correct interfaces for the
synchronization and inputs for
external commands.
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Robotic Manipulators

Riding an ABB IRB 6600 Robot 1 [Youtube]

API Note: please understand the power, and do not do this; keep always the safety!
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IST / DEEC / API Chap. 1 – Introduction to Automation

Computerized Numerical Controlled (CNC) Machines

Major characteristics: Examples:

Milling, Lathes, ...
• 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
MITSUI SEIKI Machining Center

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Computerized Numerical Controlled (CNC) Machines

Compact CNC plasma cutting machine

Effective cutting :1.5 m X 3 m
Plasma torch cutting capacity up to 5cm (mild
steel), Gas torch option allows up to 10cm.

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Computerized Numerical Controlled (CNC) Machines

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Solutions for Handling materials

For transport...
Major characteristics:

• Load / unload automation

• Accuracy, reliability

• Payload and robustness

• Interface
Conveyors, wheels on the ground
• Synchronization with exterior

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Automatic Guided Vehicles (AGVs)

Major characteristics:

• Load/unload automation

• Accuracy, reliability

• Payload and robustness

• Interface

• Synchronization with exterior

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Automatic Guided Vehicles (AGVs)

Example of fleet operating in industry

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Automatic Guided Vehicles (AGVs)

Kiva Systems Inc
- warehouse automation
- used by Staples, Toys R Us, ...
- 2012 bought by Amazon ($775 million)

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AGVs (Automatic Guided Vehicles)

Kiva Systems Inc, warehouse automation

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IST / DEEC / API Industrial Automation

Ch. 1 – Introduction to Automation [1 week]

1.1 Introduction to components in industrial automation.

1.2 Cabled logic versus programmed logic versus networked logic.

1.3 Introduction to methodologies for problem modeling.

Methodologies of work.

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IST / DEEC / API Chap. 1 – Introduction to Automation

1.2 Cabled Logic

One Relay Two Relays making one AND gate

BC B2  C1  C2
B C
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1.2 Cabled Logic versus ...

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Cabled Logic versus ...

... versus Programmed Logic …

PLC
control
panel

Relay
control
panel

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... versus Networked Logic

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IST / DEEC / API Industrial Automation

Ch. 1 – Introduction to Automation [1 week]

1.1 Introduction to components in industrial automation.

1.2 Cabled logic versus programmed logic versus networked logic.

1.3 Introduction to methodologies for problem modeling.

Methodologies of work.

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Demonstration of precise actuation – Schneider Electric

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IST / DEEC / API Industrial Automation

Ch. 1 – Introduction to Automation [1 week]

1.1 Introduction to components in industrial automation.

1.2 Cabled logic versus programmed logic versus networked logic.

1.3 Introduction to methodologies for problem modeling.

Methodologies of work.

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IST / DEEC / API

Relay or Ladder diagram, design methodology:

• identify the main hardware, actuators & sensors, to build the system
• break the system into subsystems; tune hardware selection
• integrate hardware, logic and sequencing, locally and globally.

Actuators Sensors
Motors Pressure switch
Solenoid valve Temperature sensors
Command relay Proximity sensors
Pneumatic cylinder / Electro pneumatic

Ref: Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, 1996.

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Actuation

Motors
Major characteristics:

• Type of start
• Type of control
• Accuracy, reliability
• Payload and robustness
• Interface with exterior
• Synchronization

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Example of AC motor, with driver

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Solenoid Valve

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Command Relay

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Command Relay

from: http://www.engineersgarage.com/insight/how-relay-switch-works
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Cylinders (Pneumatics)

Force: F
P F  PA
A
where
P = the pressure of the hydraulic fluid
A = the area of the piston
F = the force available from the piston rod
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IST / DEEC / API Chap. 1 – Introduction to Automation

Solenoid Valves (Electrovalves, Electro-pneumatics)

The solenoid has two positions and when

actuated will change the direction that fluid flows
to the device. The symbols shown here are
commonly used to represent this type of valve.

Two types: ON/OFF valves, Proportional Valves

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Solenoid Valves and Cylinders

Proportional pneumatics (proportional valve),

Servo-pneumatics (e.g. feedback of the position of the piston).

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Sensors
Push buttons

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Selector with three positions

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Sensors
Pressure Switch

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Temperature

Sensors

RTD = Resistance Temperature Detector

IC = Integrated Circuit
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Thermocouple Proximity detector

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Magnetic detector Magnetic switch

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Symbols associated to all components

Standards - Joint International Committee (JIC) Wiring Symbols

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Methodologies for the implementation of solutions in industrial automation

Device: Relay Contact Diagram or Ladder Diagram

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Example of relay and ladder diagrams:

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Logic
Functions

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Example of relay and ladder diagrams, and gate logic:

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The world is always moving forward:

Exploit the advantages of Programmed Logic!

Relay control panel PLC control panel

Rule of thumb: if using more than 6 relays then a PLC is already lesser expensive
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