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Mechatronic System

Fundamentals of industrial automation

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92 views2 pages

Mechatronic System

Fundamentals of industrial automation

Uploaded by

Sandeep Tiwari
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Mechatronic System (BME054)

Unit-1 Mechatronics and Its Scope

Fundamentals of Industrial Automation


Industrial automation refers to the use of control systems, such as computers, robots, and
information technologies, to handle different industrial processes and machinery with minimal
human intervention. It enhances productivity, efficiency, and reliability while reducing errors
and labor costs. Understanding the fundamentals of industrial automation requires grasping
key concepts, systems, and technologies. Here's an overview of the main elements:
1. Automation Systems
• Fixed Automation: This involves using machinery and systems designed to perform
a specific set of tasks. It is best for mass production where the process remains
unchanged for a long time (e.g., assembly lines in car manufacturing).
• Programmable Automation: Machines and equipment in this system can be
reprogrammed for different tasks. It’s used in batch production where the system
needs to adapt to varying product specifications.
• Flexible Automation: Highly adaptable systems where equipment and machinery
can easily switch between tasks without manual reconfiguration, ideal for processes
that need to handle a wide range of products.
2. Key Components
• Sensors: Devices that detect changes in the environment (temperature,
pressure, light, etc.) and provide feedback to the control systems.
• Controllers: These include devices like Programmable Logic Controllers
(PLCs) or Distributed Control Systems (DCS) that execute control actions
based on inputs from sensors.
• Actuators: Components that perform physical actions, such as motors, valves,
or relays, based on signals from the controllers.
• Human-Machine Interface (HMI): Interface devices that allow operators to
monitor and control the automation systems.
3. Control Systems
• Open-Loop Control: A system where the control action is independent of the
output (no feedback). Examples include simple timers or manually set operations.
• Closed-Loop Control: A system that continuously monitors and adjusts its
operations based on feedback from the output. Examples include temperature
control systems.
PID Control (Proportional-Integral-Derivative) is one of the most commonly used
closed-loop control systems.
4. Communication Networks
Industrial automation systems rely on networks to connect various components:
• Fieldbus: A real-time network used for communication between field devices
like sensors and controllers.
• Ethernet/IP: An industrial protocol used for automation applications,
providing a high-speed communication network for various control devices.
• SCADA (Supervisory Control and Data Acquisition): A system that gathers
and processes real-time data to allow high-level supervision and control of
industrial processes.
5. Robotics in Automation
Robots are a crucial part of industrial automation:
• Articulated Robots: Robots with rotary joints (e.g., robotic arms) commonly
used in assembly, welding, and packaging.
• Collaborative Robots (Cobots): Designed to work alongside humans,
increasing efficiency in tasks that require both human and machine input.
6. Automation and Control Software
• PLC Programming Languages: Common languages include Ladder Logic,
Function Block Diagram (FBD), and Structured Text (ST), used to develop
control logic in industrial automation systems.
• SCADA Software: Used to monitor and control large-scale industrial processes
and equipment. This software gathers data from sensors and controls machinery
in real-time.
7. Industrial Internet of Things (IIoT)
The IIoT involves connecting industrial machines and devices to the internet to enable
real-time monitoring, data analysis, and predictive maintenance. It enhances
automation by enabling smart, data-driven decision-making.
8. Benefits of Industrial Automation
• Increased Productivity: Automation speeds up processes and allows 24/7
operation.
• Enhanced Quality: Reduces human error and ensures consistent product
quality.
• Cost Efficiency: Reduces labor costs and waste while optimizing resource
usage.
• Improved Safety: Machines can handle dangerous tasks, reducing risks for
human workers.
9. Challenges in Industrial Automation
• High Initial Costs: Automation systems require significant investment in
machinery, software, and infrastructure.
• Complex Maintenance: While automated systems can reduce manual labor,
they require skilled technicians to maintain and troubleshoot.
• Cybersecurity Risks: As more systems become connected through IIoT, they
are vulnerable to cyberattacks.

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