Presented by:

LOBE REBECCA FENDE (HT19A129)

NGASSAM SANDJON LARISSA (HT1A131)

INTRODUCTION TO AUTOMATION SYSTEM

General Objectives

1. Understand and learn about automation control systems and types of automation control

systems.

2. Learn about the types of control system pneumatic control systems, hydraulic control systems

and electrical control system.

Specific Objectives;

At the end of this chapter, student should be able to:

1. Define the Automation Control System

2. States the need of Automation Control System in the industry

3. States of the Fixed Automation / Hard-Wire Control System

4. Differentiate between Fixed Automation with Programmable Automation.

5. State the basic concepts of pneumatic control systems, hydraulic control systems and electrical

control systems

6. Classification of pneumatic control systems, hydraulic control systems and electrical control

systems.

7. Distinguish between the pneumatic control system, hydraulic control system and electrical

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control systems

1.0 Introduction:

In today’s fast-moving, highly competitive industrial world, a company must be flexible, cost

effective and efficient if it wishes to survive. In the process and manufacturing industries, this

has resulted in a great demand for industrial control systems/ automation in order to

streamline operations in terms of speed, reliability and product output. Automation plays an

increasingly important role in the world economy and in daily experience.

Automation is the use of control systems and information technologies to reduce the need for

human work in the production of goods and services. In the scope of industrialization,

automation is a step beyond mechanization. Whereas mechanization provided human

operators with machinery to assist them with the muscular requirements of work, automation

greatly decreases the need for human sensory and mental requirements as well.

What is Automation Control System?

Automation Control System - system that is able to control a process with minimal human

assistance or without manual and have the ability to initiate, adjust, action show or measures

the variables in the process and stop the process in order to obtain the desired output.

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1.1.2 Comparison Between Fixed and Flexible Automation System

Figure 1 Comparison Between Fixed and Flexible Automation System

Figure 2 fixed automation

Figure 3 programmed automation

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1.1.3 There Are Three (3) Types of The Control System Based On Supply:

a) Pneumatic Control Systems

b) Hydraulic Control System

c) Electrical Control System

a) Pneumatic Control System

Pneumatic control system is a system that uses compressed air to produce power /

energy to perform any task

Pneumatic systems found in many industrial systems such as food industry,

petrochemical and industrial involves robotics.

Pneumatic systems require:

i. Compressed air supply

ii. Control valve

iii. Connecting tube

iv. Transducer

Pneumatic control system can be controlled manually and automatically.

Basic

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 Figure 4

b) Hydraulic Control System

Hydraulic control system is a system that uses fluid to generate power/energy.

The hydraulic system used in the automobile industry such as power systems, braking
systems,

cranes, car jack, satellite and others.

The fluid used is oil.

The hydraulic system requires:

a) Hydraulic fluid supply

b) Control Valve

c) Cylinder

Hydraulic control system can be controlled manually and automatically

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 Figure 5 Basic block diagram of an automatic hydraulic control system by Manual /PLC

Electrical Control System

A control system that uses an electric current; either direct current (DC) or current

shuttle (AC) as a source of supply.

Electrical Control Systems Generally requires:

a) Electricity (DC) or (AC)

b) Input elements (switches, sensors, transducer, valves, electronic components,

etc.)

c) Output elements (motor, lights, etc.)

d) Extension cable

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 Figure 6

COMPARISON BETWEEN PNEUMATIC CONTROL SYSTEMS,

HYDRAULIC

CONTROL SYSTEM AND ELECTRIC CONTROL SYSTEM

i. PNEUMATIC CONTROL SYSTEM

a) Easy installation

b) Simple design

c) Use compressed air as a supply source to perform task.

ii. HYDRAULIC CONTROL SYSTEM

a) Complex to assemble

b) Use fluid like oil as a supply source to perform task.

c) Potential leakage will lead to pollution.

iii. ELECTRIC CONTROL SYSTEM

a) Simple system

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b) Use electricity as a supply source to perform task.

c) Widely use either for home user or in industrial.

Chapter 1

GENERALITIES OF AUTOMATION
1.1 The Industrial Control System

Every industrial production process consists of a series of simple or complicated machines

that, through the combination of raw materials, undergo a sequential transformation and

integration in order to produce a final product. The term “machine” denotes every kind of

electromechanical device on the industrial floor, e.g., from a simple motor (such as a drilling

or a cutting machine) up to a complicated chemical machine (e.g., a chemical combustion

machine). The whole set of machines (namely non-homogeneous machines), which are being

integrated and combined in an industrial production process, will be referred to as an “integrated

machine”.

Figure 7 SIMPLIFIED VISUALIZATION OF A PULP PROCESSING STAGE

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Before analyzing the procedures needed for automating an industrial production line, it is of

paramount importance to initially define in detail the various components that the automation

and their specific functionalities and properties consist of. In an industrial production line, the

“movement” is the fundamental and generalized characteristic of the overall process, since it is

impossible to consider an industrial process without the existence of a linear, circular, or any other

form of movement. Even in the case of a chemical reaction, where the existence of motion is not

obvious, the movement also exists in this case and more specifically in the form of an electro valve

control, which opens in order to supply the reactor with the necessary amount of the reacted

components. Furthermore, the existence of the need for movement is significantly evident, either
in

the cases where the product should be transferred to the various process points of the production

line, or in the cases of integrated machines, where parts of the machines should be moved in order

to produce the desired processing of the developing product.

Figure 8 BASIC KIND OF INDUSRIAL TYPE EQUIPMENT COMPOSING AN INDUTRIAL

SYSTEM

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usually we refer to them as “the motor is in operation”, “the motor is not operating”, “the electro
valve

is energized”, “the electro valve is not energized”, “the coil is under voltage”, and “the coil is not
under

voltage”. In general, there are two states of operation that can be defined as the ON and the OFF

operation, which can be further associated directly with the digital logic symbols of 1 and 0.

If one motor has, for example, two rotation directions or two rotational speeds and thus two

states of operation, ON1 and ON2, then this consideration is not in conflict with the previous

association. Actually, it can be considered as the case of having two motors, where one motor

has the two states OFF-ON1 and the other one has the states OFF-ON2. The operation of the

two motors, and more specifically the supply of the motors with the required electrical power, is

achieved by the power relays that also have two states of operation, the ON and the OFF state.

The control of the motors is achieved through the proper control of the relays, and thus the

desired control system is applied on the corresponding relays controlling the electrical supply to

the motors and it is not applied directly on the motors.

Figure 9 MULTI STATE ELECTRIC MOTORS ARE CONTROLLED BY TWO

POWER RELAYS

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switch (knob), etc. In the case that the operation of the integrated machine is set in the “manual”

mode, the operator is utilizing the operation devices for turning on the desired motors or the

actuators and in the proper sequence. In the case that the integrated machine is set in the “auto”

mode, the operator is again utilizing the operation devices, either for initiating the operation

mode, or for instructing the integrating machine to change the operational state. As an example,

in an integrating machine for chocolate production, the operator is capable, by the press of a button,

to order the control system to alter the current recipe production for another one. In this

case, the control system should allow the integrated machine to complete the current operation

and afterwards, ensuring the prerequisite quantities for executing the ordered recipe change, to

command the integrated machine in executing it. In most cases, the automation system of an
integrated

machine provides both the functionalities of an automatic or manual mode of operation,

especially for dealing with the emergency fault situations, where direct manual control of all the

provided automatic functionalities of the integrated machine is needed.

Figure 10 MANUALLY OPERATED DEVICE THAT HAVE TWO OPERATIONAL

STATES

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Figure 11 SHEMATIC OF A SIMPLIFIED BATCH DYEING PROCESS FOR TEXTILE
MATERIAL

continuous control of a physical analog variable through the utilization of any kind of actuators,

while industrial automation refers to the sequential or digital ON-OFF control of the two-state

devices. As has been presented in Figure 1.3, among the discrete devices, a continuous time control

device has also been included in the industrial system, in order to present the overall concept

that in an industrial control system, multiple continuous time control units can be integrated and

act in a cooperative way with the rest of the automation control units.

In the case of industrial control processes (batch processes), there are multiple process variables

that, although we would like to have them set at constant values, show random variations,

mainly due to multiple external disturbances during the production phases. The reduction and

elimination of these variations can be achieved through the proper application of automatic

control principles. In many cases, it is also desirable for a process variable to alter the set value

from an existing converged one into another operating point, while certain specifications usually

are amended to achieve this transition, e.g., a fast or slow transition time, a minimum control

effort change, a low overshoot during the alteration of the set point, a fast convergence, etc.

In Figure 1.6, a simple process of controlling the level of a liquid in a tank is presented. In this

process, it is assumed that the supply of the liquid in the tank is provided by an uncontrollable

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variable, while a valve is controlling the liquid’s output flow from the tank. In the described setup,

it is desired that the level of the tank be kept at a specific height h0, independent of the liquid

supply. To solve this problem, after the initial achievement of the specified height h0, the output

flow should be equal to the input flow.

Figure 12 EXAMPLE OF AN AUTOMATIC CONTROL SYSTEM

level of the liquid in the tank by a level sensor and, subsequently, appropriately tune the outflow

valve. In this case, the outflow valve has not only two states “Fully Open—Qmax flow” and “Fully

Closed—0 flow”, but it can take any kind of desired state value, thus allowing for a flow within

the (0, Qmax) continuous space. In the era of classical industrial automation, this control scheme

would have been implemented by analog circuits, whereas now it is commonly implemented by

the utilization of computers and, more specifically, programmable logic controllers (PLCs), which

are computational devices designed and configured for operating in industrial environments.

In Figure 1.7, a lead screw setup is presented, where the worktable can be translated by the

proper connection and rotation of the lead screw into two directions (left and right). For this reason,

the motor generating the rotation of the lead screw has two directions of rotation. Moreover,

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the motor has two rotation speeds, which means that the worktable can be translated in two speeds

profiles. With the help of the indicated position sensors (limit switches) and the provided motor,

we can design an industrial automation with the following desired operation.

After defining that, in an industrial system, both continuous and sequential control setups

exist, the term “industrial automation” now has a wider meaning, which includes every kind of

system being designed for implementing an automatic operation of an industrial process.

Figure 13 EXAMPLE OF AN AUTOMATIC SYSTEM

The industrial era was initiated by the efforts to automate existing industrial setups as a way to

improve the quality of the produced products and the overall production volumes. Contrary to

what is generally understood, industrial automation is not a discovery of the recent past, but it

is rather as old as industry itself. From the beginning, the designer of an industrial production

system has attempted to achieve an operation as autonomous as possible, always based on the

available instrumental tools.

Figure 14 BASIC ELEMENT OF AN AUTOMATED SYSTEM

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 CHAPTER 2

HARDWARE COMPONENTS FOR AUTOMATION AND

PROCESS CONTROL

2.1 ACTUATORS.

An actuator is a device that uses some type of energy and produces the required force, either
providing motion to an object or actuating something. Actuators (independently of their shape,
form, and size) produce the mechanical movements required in any physical process in a factory.
It should be highlighted that in any industrial production line, if the actuators are removed, what
will remain are only the “passive” metallic and plastic components, while the whole automation
will lose its ability to alter or produce something meaningful.

Figure 15 Various types of actuators in industrial automation, (a) servo motor, (b) DC motor,
(c) stepper motor, (d) linear motor, (e) pneumatic cylinder, (f) solenoid actuator.

Figure 16 Internal view of an AC motor (a) and step motor (b).

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copper or aluminum bars. Since these conductors are directly shorted by an end ring, they form

the rotor winding, which cuts the stator rotating magnetic field, causing the flow of electric current

through them. The attraction and repulsion between these two magnetic fields, according to

Lenz’s law, causes the rotation of the rotor.

In both types of motors, the rotational movement of the rotor is transferred to a shaft and,

subsequently, to a series of spindles, gears, pulleys, and smaller shafts in order to increase the

output torque or to transform the rotary motion to a linear or reciprocating one. For example,

Figure 17 Forward-reverse rotation of a three-phase motor

rotary motion of an electric motor can be converted to a linear one by using a ball screw pair and

guide rails. The AC induction motors are the most widely used motors in the automation industry

compared with the DC ones, mainly because of their efficiency and less maintenance required. It

is the simpler solution in applications such as machine tools, fans, pumps, compressors,
conveyors?

extruders, and various other complex machines.

MICRO ELECTRO MECHANICAL ACTUATOR

Micro-electro-mechanical systems (MEMS) are a process technology based on techniques of

microfabrication, and are used to create devices that have the ability to sense, control, and actuate

on the micro scale, while generating effects on the macro scale. Over the past few decades various

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micromechanical actuators (or micro actuators) began appearing in numerous industrial products

and applications.

Figure 18 The pneumatic cylinder as linear motion actuator

Since electric motors are supplied with electric power through the utilization of relays or
contactors,

their operational principles and characteristics are presented in this chapter as a specific kind

of actuator. Another reason for describing relays in this chapter is the need to know their structure

and operation in order to utilize them in designing and synthesizing automation circuits.

Relay`s operation principles

Relays consist of two parts; a first one containing the various main or auxiliary electric
contacts,
and a second one containing the electromagnet-based mechanism that creates the motion
required
for the operation of the electric contacts. Figure 5 shows a simplified form of a relay,
including
the coil-core electromagnet, the movable arm, the electric contact consisting of two parts
(the
fixed and the movable one), and the return spring. The relay’s contacts are electrically
conductive

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 Figure 19 simplified structure of a relay.
General purpose relay: General purpose relays are usually miniature relays, used either
as auxiliary components for the
Implementation of automation circuits, or as switches for supplying very small electric
loads, such
As electric valves, micromotors, small fans, alarm sirens, etc.

POWER RELAY

Power relays are made in order to feed the various kinds of electric motors with the required

electric power. In proportion to the typical motors’ powers, these power relays are made in several

sizes, from the smallest of nominal power 5.5 KW, to the largest of 500 KW under 660 V,

while it is obvious that the power relays and particularly their electric contacts must withstand a

“Switching under load”. This means simply that an electric contact of a power relay should have

the mechanical strength required in order to open while the nominal current is passing through

it. The reason that causes damage to the contact material is that an electric arc is created during

the opening or closing of the electric contact.

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 Figure 20 Typical internal structure of power relay.
to the mechanical one because the contact life is application-dependent, such as when a set of

contacts switch a load of less than rated value.

The power relays, except for their three main power-contacts (one for each phase of the three
phases

network), may be equipped with one or more pairs of auxiliary contacts, which are used in

the implementation of the automation circuit.

Figure 21 Typical external view of a power relay by Siemens

GENERAL PURPOSE RELAYS

General purpose relays are usually miniature relays, used either as auxiliary components for the

implementation of automation circuits, or as switches for supplying very small electric loads, such

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as electric valves, micromotors, small fans, alarm sirens, etc. Their use as auxiliary relays or as
auxiliary

contacts of a power relay mean they are necessary components for the implementation of

the Boolean logic functions described in the automation circuit.

Figure 22 Typical form of a general-purpose relay without (a) and with (b) a mounting
base.
A latching relay, after its activation, maintains its contact position although the coil power supply

has been removed, and therefore has two relaxed states as an electronic, bistable flip-flop. As we
have

seen from the description above, the classical relay should have a coil voltage applied to it at all
times

that it is required to stay energized. Such a situation is not necessary in latching relays, where them

contacts are mechanically or magnetically locked in the ON state until the relay is reset manually

or electrically. Mechanical latching relays use a locking mechanism to hold their contacts in them

last set position until commanded to change state, usually by means of energizing a second coil.

Figure 2.11 shows a simplified schematic of a latching relay operated by two coils, each one with
a

corresponding control button.

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 1) COMPUTER BASE INDUSTRAL CONTTROL AND AUTOMATION

The task of controlling an industrial process has evolved a lot over recent years, starting from a

complete manual operation, continuing in the analog control and low-level automation era, and

recently reaching a totally computer-based control and automation approach. Prior to the
introduction

of solid-state electronics, the designer of an industrial production process was attempting

to make the automation operate as automatically as possible, based on the various instrumental

tools. To enable the vision of a full automation technology and after the appearance of various

digital processors, a rapid increase in process control computers and minicomputers took place,

especially in small plants, which changed radically the situation in the field of industrial process

control and automation.

1.1.4 Advantages and Disadvantages of Automation Control in Industry

The main advantages of automation are:

Replacing human operators in tasks that involve hard physical work.

Replacing humans in tasks done in dangerous environments (i.e., fire, space, volcanoes,

nuclear facilities, underwater, etc.)

Performing tasks that are beyond human capabilities of size, weight, speed, endurance,

etc.

Economy improvement: Automation may improve in economy of enterprises, society or

most of humanity. For example, when an enterprise invests in automation, technology

recovers its investment; or when a state or country increases its income due to

automation like Germany or Japan in the 20th Century.

Reduces operation time and work handling time significantly.

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The main disadvantages of automation are:

Unemployment rate increases due to machines replacing humans and putting those

humans out of their jobs.

Technical Limitation: Current technology is unable to automate all the desired tasks.
Security Threats/Vulnerability: An automated system may have limited level of

intelligence, hence it is most likely susceptible to commit error.

Unpredictable development costs: The research and development cost of automating a

process may exceed the cost saved by the automation itself.

High initial cost: The automation of a new product or plant requires a huge initial

investment in comparison with the unit cost of the product, although the cost of

automation is spread in many product batches of things

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