Computer Integrated Manufacturing

Enterprise Manufacturing
Manufacturing
Level Support
SupportSystems
Systems
Automation and Control Quality
Quality
Control
Control
Technologies Factory Systems
Systems
Level Manufacturing
Manufacturing
Systems
Systems
Lecture 2
Automation
Automation Material
Material
Engineering 475 and
andControl
Control Handling
Handling
Technologies
Technologies Technologies
Technologies
Automated Production Systems
Groover, Fig. 3.1

Automation and Control Process Industries Versus

in Manufacturing Discrete Manufacturing
Level Enterprise Corporate Information
5 Level System
Typical Unit Operations Typical Unit Operations in
Flow of data in the Process Industries Discrete Manufacturing
4 Plant Level Production System
Chemical Reactions Casting
Deposition Forging
Cell or Distillation Extrusion
Manufacturing system
3 – groups of machines Heating Machining
System Level
Mixing and Blending Assembly
Separation of Ingredients Plastic Molding
2 Machine Level Individual Machines Sheet Metal Stamping

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onautomation
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Sensors, Actuators, other
1 Device Level hardware elements found
foundininthe
themanufacture
manufactureofofdiscrete
discretecomponents.
components.
Groover, Fig. 3.6
Groover, Table 4.1

Discrete Manufacturing Control Systems

Automation and Control Technologies
Definition – A control system is a group of components
There are three primary automation and control technologies that maintains a desired result by manipulating the value
used in discrete component manufacturing plants. of another variable in the system.

G Programmable Logic Controllers (PLC’s)

Input Control Output
G Robotics
Signal System Signal
G Computer Numerical Control (CNC)

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1
 Block Diagrams Transfer Function
A block diagram consists of a block representing
each component in a control system connected by Transfer Function – Ratio of the output signal
lines that represent signal paths. divided by the input signal.
Electrical
Temperature Voltage
Thermocouple Input Signal
Control Output Signal
System
I(s) Component O(s)
Armature
Motor Speed
O(s )
Voltage

H (s ) =
DC Motor
I(s )
Stem Position Flow Rate
The transfer function is usually written in
Valve
terms of the Laplace transform variable, s.

Gain and Phase Shift Block Diagram of a Control System

The transfer function of a component describes the size and
Controller
timing relationship between the output signal and the input Error Detector
Manipulating Process
Element
signal. Input
Error
Output amplitude E=Sp-Cm V M
Gain = Sp + V M C
Output
Input amplitude Σ Gc = Gm = Gp = C
_ E V M
Phase shift = output phase angle - input phase angle

Cm
H=
C
Measured value of
controlled variable C m Measuring
Transmitter

Bateson, Fig. 1.7

Bateson, Fig. 1.4

Operations Performed Continuous Versus Discrete

by a Control System Control
Continuous Control – the variables and parameters are
Measurement: Measure the value of the controlled variable
continuous and analog
Decision: Compute the error and use the error to form a
control action Discrete Control – variables and parameters are
discrete, mostly binary
Manipulation: Use the control action to manipulate some variable
in the process in a way that will tend to reduce the G Continuous control is the topic of the Control
error Systems course.

G This class will focus primarily on discrete control.

G Many industrial automation systems are based on

discrete input and output signals.

2
 Types of Discrete Control Examples of Event-
Event-Driven Control
A robot loads a part into a fixture, and the part is sensed
Event-
Event-driven change is executed by the controller by a limit switch. Sensing the part’s presence is the event
in response to some event that has caused the state that alters the system state. The event-driven change is
of the system to be changed. that the automatic machining cycle can now commence.

The diminishing level of plastic molding compound in

Time-
Time-driven change is executed by the controller the hopper of an injection molding machine triggers a
either at a specific point in time or after a certain low-level switch, which in turn triggers a valve to open
time lapse has occurred. that starts the flow of new plastic into the hopper. When
the level of the plastic reaches the high-level switch, this
triggers the valve to close, thus stopping the flow of
Many industrial control systems include a
pellets into the hopper.
combination of event-driven and time-driven
elements.

Examples of Time-
Time-Driven Control

Heat treating operations must be carried out for a certain

length of time. An automated heat treating cycle consists of
automatic loading of parts into the furnace (perhaps by a
robot) and then unloading after the parts have been heated
for the specified length of time.

In the operation of a washing machine, once the laundry tub

has been filled to the preset level, the agitation cycle
continues for a length of time set on the controls. When this
time is up, the timer stops the agitation and initiates draining
of the tub.