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MCT312 Lecture1 PDF

The document provides an introduction to industrial automation, detailing its definition, evolution from Industry 1.0 to Industry 4.0, and its benefits such as reduced production costs and improved quality. It also outlines challenges like high capital expenditure and potential unemployment, and describes various automation strategies and types, including fixed, programmable, and flexible automation. Additionally, it explains the levels of industrial automation, from field level with sensors and actuators to control and supervisory levels with PLCs and SCADA systems.

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Abanoub Mouries
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19 views17 pages

MCT312 Lecture1 PDF

The document provides an introduction to industrial automation, detailing its definition, evolution from Industry 1.0 to Industry 4.0, and its benefits such as reduced production costs and improved quality. It also outlines challenges like high capital expenditure and potential unemployment, and describes various automation strategies and types, including fixed, programmable, and flexible automation. Additionally, it explains the levels of industrial automation, from field level with sensors and actuators to control and supervisory levels with PLCs and SCADA systems.

Uploaded by

Abanoub Mouries
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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Industrial Automation

Lecture 1
Introduction

Dr. Nancy Emad El-Hady


[email protected]
Automation
• Automation is the application of mechanical, electrical, and/or
computer technology to reduce the level of human participation in
task performance.

2
Evolution of Automation in Industry

Source: Dey, C., & Sen, S.K. (Eds.). (2020).


Industrial Automation Technologies (1st ed.).
CRC Press.

3
INDUSTRY 1.0 TO INDUSTRY 4.0

Source: DFKI, 2011


4
Benefits of Industrial Automation

1. Reduced production cost.


2. Decreased part cycle time.
3. Improved quality and reliability.
4. Better floor space utilization.
5. Reduced waste.
6. Safer worker environment.

5
Challenges of Industrial Process Automation
1. High capital expenditure.
2. Requires higher sophistication in maintenance.
3. Any automated production system usually has a lower degree of
flexibility in terms of possible products.
4. Higher unemployment.
5. With increasing use of motorized actuators as part of modern
automation, power demand and industrial waste will rise leading
to more pollution.

6
Automation Strategies
• Minimize manufacturing process steps
• Increase process flexibility
• Optimize material handling
• Automate inspection
• Implement process control

7
Types of Automation systems

8
Fixed Automation
• Fixed automation involves the use of specialized machinery and
equipment that is designed to perform specific tasks in a specific
sequence in a production process.

• Typical features:
o High initial investment for custom-engineered equipment.
o High production rate.
o Relatively inflexible in accommodating product alteration.

9
Programmable Automation
• There is flexibility to change the sequence of operations to
accommodate different product configurations via a set of
instructions.

• Typical features:
o High investment in general-purpose equipment.
o Low production rates relative to fixed automation.
o Flexibility to deal with product configuration.
o Mostly suitable for batch production.
o The system must be reprogrammed
and reorganized to correspond to the
new product.

10
Flexible Automation
• It is an extension of programmable automation.

• The essential features that distinguish flexible automation from


programmable automation are as follows: capacity to change part of
the programs or to change the physical setup with no loss in
production time.

• Typical features:
o High investment for a custom-engineered system.
o Flexibility to deal with product design variation.
o Continuous production of variable mix of products.
o Medium production rates.

11
Source: Dey, C., & Sen, S.K. (Eds.). (2020). Industrial Automation
Technologies (1st ed.). CRC Press.
12
Industrial Automation Levels

Source: Industrial Automation from Scratch A Hands-on Guide to Using Sensors, Actuators,
PLCs, HMIs, and SCADA to Automate Industrial Processes, Olushola Akande ·
13
Field level
• This is the lowest level in the hierarchy of industrial automation.

• Sensors convert physical characteristics into electrical signals.


Examples: proximity sensors, temperature sensors, pressure
sensors, level sensors, flow sensors, and limit switches.

• Actuators convert electrical signals into physical characteristics,


which can be in the form of motion.
Examples: AC/DC motors, servo motors, stepper motors, pumps,
control valves, solenoids, contactors, and relays

14
Control level
• This level consists of programmable logic controllers (PLCs) or other
forms of controllers.

• PLCs are the brains behind modern industrial automation. They are
used to carry out control functions in industries.

15
Supervisory and Production level
• This level consists of Supervisory Control And Data Acquisition
(SCADA) and Human Machine Interface (HMI), among others, for
monitoring and controlling various parameters and setting
production targets.

16
Textbooks:
• Stamatios Manesis, George Nikolakopoulos, “Introduction to Industrial Automation
”, 2018, by CRC Press.
• Frank Lamb, “Industrial Automation: Hands On”, 2013, by the McGraw-Hill.
• Frank Petruzella, “Programmable Logic Controllers (3rd. ed.)”,2004, by McGraw-
Hill.
17

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