Course Name: Industrial Automation and Drives

Week No.: 03 Lecture No: 07

Topic Name: Needs and Benefits of Industrial Automation
1. Objectives:
● Students will be able to understand the industrial automation along
with its Types, Needs and Benefits.
● Students will be able to learn the Challenges and Future Trends
associated with Industrial Automation
● Students will be able to explain the Real-World Applications and
limitations of Industrial Automation

Lecture Content:

Industrial Automation
In order to understand industrial automation and its
specific applications, let’s define automation as a concept
first.

Automation: Definition and Meaning

Automation refers to a broad range of technologies,
techniques, and tools designed to minimize human
intervention in processes, thereby making them more
efficient, faster, more productive, and less prone to errors.
Automation is present in nearly every aspect of daily life,
from consumer tools and household appliances to complex
systems in modern transportation, manufacturing, and
banking.

Various scientific techniques and approaches—mainly

mechanical, hydraulic, electrical and electronic, pneumatic,
and computer-based—are commonly used in combination
to achieve automation.

Industrial Automation
Industrial automation focuses on the automation of
industrial processes and machinery. This is accomplished
through the integration of

information technologies, specialized equipment like logic

controllers and various modules, and robots to improve
manufacturing, quality control, and material handling
processes.

Today, industrial automation is pervasive across industries

and supply chains. It is challenging to envision a factory or
production line without any form of industrial automation
technology and tools.

The applications of industrial automation solutions are

rapidly expanding due to advancements in technology.
Modern software tools, machines, and robots are
increasingly performing tasks that were traditionally done
manually or required human supervision.

Industrial automation involves the use of control systems

such as computers, robots, and information technologies to
handle different processes and machinery in an industry to
replace a human being. Industrial automation refers to the
use of control systems such as computers, robots, and
information technologies to manage and control industrial
processes, reducing the need for human intervention. This
comprehensive approach encompasses a wide range of
technologies and systems designed to improve efficiency,
accuracy, and safety in industrial operations.

Historically, we’ve seen a significant evolution from manual

labor to mechanization during the Industrial Revolution,
and now to sophisticated automation systems. This shift is
not just about replacing human labor; it’s about enhancing
efficiency, precision, and safety across industrial
operations.
History of Industrial Automation

Although automation as a distinct field emerged in the

twentieth century, its roots trace back much further.
Automation has been foundational in the quest to increase
manufacturing efficiencies since the beginning of human
civilization. For centuries before the Industrial Revolution,
 major manufacturers developed specialized machinery to
enhance productivity and precision beyond human
capabilities. Modern industrial automation technologies,
which operate continuously with minimal human
intervention for maximum efficiency, are the pinnacle of this
long-standing drive to automate

Key Components of Industrial Automation:

1. Control Systems:
o Programmable Logic Controllers (PLCs): PLCs are
specialized
computers used to control machinery and processes in
 an industrial setting. They are designed for real-time
use and can handle a wide variety of input and output
arrangements.

o Distributed Control Systems (DCS): DCS involves

distributing control throughout a system, rather than
centralizing it. This approach allows for greater
flexibility, reliability, and performance in managing
complex industrial processes.

o Supervisory Control and Data Acquisition (SCADA):

SCADA systems are used for high-level process
supervisory management. These systems monitor and
control industrial processes across multiple sites and
large distances, providing real-time data collection and
analysis.

2. Robotics:
o Industrial Robots: These are programmable machines
capable of performing a variety of tasks such as
welding, painting, assembly, pick and place, product
inspection, and testing. Robots are used to enhance
productivity and quality while minimizing human error.

o Automated Guided Vehicles (AGVs): AGVs are mobile

 robots used for material handling and transportation in
manufacturing plants,warehouses, and distribution
centers. They follow predetermined paths or navigate
autonomously using various guidance systems.

3. Information Technologies:
o Human-Machine Interfaces (HMIs): HMIs allow
operators to interact with automated systems through
graphical displays, making it easier to monitor and
control processes.

o Manufacturing Execution Systems (MES): MES

software monitors and controls production on the
factory floor, providing data on performance, quality,
and other key metrics.

o Enterprise Resource Planning (ERP): ERP systems

integrate all facets of an operation, including
development, manufacturing, sales, and marketing,
facilitating seamless information flow across the
organization.
 Types of Automation

There are three types of automation, each suited to

different applications:
1) Fixed Automation
2) Programmable Automation
3) Flexible Automation

1) Fixed Automation:

Also known as Hard Automation, Fixed Automation involves

the employment of specific-purpose equipment to automate a
repetitive sequence of tasks, processing or assembly
operations. Generally, the operational
sequence is not complex, involves fundamental
functionalities like rotational or plain linear motion, or an
amalgamation of both. The advantages of fixed automation
are improved rate of production, low cost of the unit, and the
automation of the material handling process. If the
automation repeats the same tasks with identical units, it is
Fixed Automation. The most notable limitation, here, is that
Hard Automation units must be replaced when new tasks
need to be completed.
Typical features of fixed automation are:

 High initial investment for custom-engineered

equipment.
 High production rates
 Relatively inflexible in accommodating product
variety

Figure 2. Types of
Automation(https://medium.com/aiautomation/a-look-
into-automation-its-different-types-f4266049f54d)
2) Programmable Automation:

Programmable Automation allows for fresh programs to be

designed and deployed to the system to implement new
processes. Both traditional thermostats and traditional
cruise control are examples of programmable automation
— you set a speed or temperature and the mechanisms
consistently produce the programmed outcome. Whereas
with fixed automation, automation is designed with only
one set of operation sequences, Programmable Automation
allows for reprogramming for different tasks after a batch
of one type is complete. The main advantage of the
programmable automation is greater flexibility to deal with
the
variation of designs. While it is the best-fit for batch
production of a variety of designs, it produces fewer units
than both Fixed and Flexible Automation because of the
changeover-time between functions.

Some of the features that characterize programmable

automation include:

 high investment in general purpose equipment

 lower production rates than fixed automation
  flexibility to deal with variations and changes in
product configuration.
 most suitable for batch production.

3) Flexible Automation:
This automation type is an extension of programmable
automation that has the capacity to produce a spectrum
of products with next-to-zero downtime and no
complicated change-over manual procedure, which
means greater production rate. Because there is no need
for complex reprogramming, Flexible Automation can
switch between tasks. Think to our thermostat and
cruise control examples. Modern adaptive cruise control
and self-learning thermostats are examples of Flexible

Automation — users don’t need to reprogram the

mechanisms to change their outcomes. In
manufacturing, because there is no need for batch
production, tasks can be completed on demand. Flexible
Automation enables automatic and rapid changes to
programmed sequences, such as production of design
variations, with virtually no down-time. In short, Flexible
Automation allows for a variety of procedure
outcomes and high output.
 The features of flexible automation are:

 High investment for a custom-engineered system

 Continuous production of variable mixtures of product
 Medium production rate
 Flexibility to deal with product design variations

Need for industrial automation:

a. Efficiency and Productivity

b. Quality Improvement
c. Cost Reduction
d. Safety and Ergonomics
e. Market Demands

a. Efficiency and Productivity:

Automated systems can operate continuously without
breaks, unlike human workers. This capability
significantly reduces cycle times and increases
throughput.

For instance, assembly lines in automotive plants can

produce vehicles faster and with more consistent quality
compared to manual processes.
 b.Quality Improvement:

Automation ensures high precision and consistency in

manufacturing. Automated systems can maintain tight
tolerances and reduce variations in product quality.

Consider the semiconductor industry, where precision is

paramount. Automated systems produce components
with microscopic accuracy, minimizing defects.

c. Cost Reduction:
Automation helps lower direct labor costs as fewer human
workers are needed for repetitive tasks.
It also reduces operational costs by optimizing resource
usage and minimizing waste.

For example, automated material handling systems in

warehouses can significantly cut down storage and
retrieval times, saving costs.

d. Safety and Ergonomics:

Automation reduces the need for human intervention in
hazardous environments, such as chemical plants or
mining operations. This not only protects workers but also
ensures operations can continue in dangerous conditions.
 In addition, it improves workplace ergonomics by taking
over repetitive and physically demanding tasks, reducing
the risk of musculoskeletal disorders.
e. Market Demands:
With globalization, there’s a need to meet high demand
with scalable production. Automation allows industries to
ramp up production quickly and efficiently.

Moreover, the growing trend towards personalized and

customizable products requires flexible manufacturing
systems that can adapt to different product specifications
on the fly.

Several key drivers push industries towards automation:

Technological Advances: Innovations in robotics, artificial

intelligence (AI), and the Internet of Things (IoT) are making
automation more capable and accessible.

Economic Factors: To stay competitive, companies need to

reduce costs
and improve efficiency. Automation provides a clear path to
achieve these goals.
Regulatory Requirements: Compliance with
safety, environmental, and quality standards often
necessitates automated processes that can consistently
meet these stringent criteria.

Workforce Trends: Addressing labor shortages and filling

skill gaps is another critical driver. Automation helps
bridge these gaps by performing tasks that are hard to
staff or require specialized skill
Benefits of Industrial Automation

1. Operational Benefits of Industrial Automation

2. Financial Benefits of Industrial Automation
3. Strategic Benefits of Industrial Automation
1. Operational Benefits of Industrial Automation
 Increased Throughput:
Automated systems can work around the clock,
significantly boosting production volumes. They’re
designed to operate at high speeds without the fatigue
or errors that can affect human workers. In industries
like electronics manufacturing, automation enables the
rapid assembly of complex devices, keeping up with
market demand.
 Improved Product Quality:
Automation ensures precision and consistency, which
are critical for maintaining high-quality standards.
Automated processes reduce the
risk of defects and variations in product output.
For example, in the pharmaceutical industry,
automated systems ensure that each batch of
medication meets exact specifications, reducing the risk
of errors that could affect patient safety.

 Enhanced Flexibility and Agility:

Modern automated systems are highly adaptable. They
can switch between tasks or products with minimal
downtime, allowing companies to respond quickly to
market changes or customer demands.
This flexibility is particularly valuable in sectors like
consumer goods, where product lifecycles are short,
 and customization is key.
 Energy Efficiency:
Automation can lead to more efficient use of energy and
resources. Automated systems are often designed to
optimize power consumption and reduce waste.

For instance, automated lighting and climate control

systems in smart factories adjust based on real-time
conditions, saving energy and reducing costs.”
2. Financial Benefits of Industrial Automation
Cost Savings:
Automation reduces direct labor costs by replacing manual
tasks with automated processes. This shift not only cuts
wages but also reduces associated costs like training and
benefits.

Additionally, automated systems minimize material

wastage through precise control and monitoring, leading to
cost savings in raw materials and supplies.
Return on Investment (ROI):
While the initial investment in automation technology can
be high, the long-term benefits often justify the cost.
Many companies see a quick
return on investment through improved efficiency, higher
output, and lower operational costs.
For example, a manufacturing company investing in
automated assembly lines might recoup the investment
within a few years through increased production capacity
and reduced labor expenses.
Reduced Downtime:
Automated systems are typically more reliable and require
less frequent maintenance than manual operations. When
they do need maintenance, advanced systems can often
predict issues before they cause downtime, enabling
preventive measures.

This reliability means fewer interruptions in production,

leading to consistent output and better use of resources.”

3.Strategic Benefits of Industrial Automation

Competitive Advantage:
Automation enables faster time-to-market by streamlining
production processes and reducing lead times.
Companies can produce and deliver products more
quickly than those relying on manual processes.

It also allows for greater customization and flexibility in

meeting customer demands, giving companies an edge in
markets where consumer preferences are constantly
evolving.
Scalability:
Automated systems are designed to scale. Whether a
company needs to increase production volume or
expand operations to new locations, automation
provides the flexibility to grow without significant
retooling.

For instance, an automated warehouse system can

handle an increased volume of goods with minimal
adjustments, supporting business growth.

Data-Driven Decision Making:

Automation systems generate vast amounts of data that
can be analyzed
to improve processes and make informed decisions.
Integration with data analytics and enterprise resource
planning (ERP) systems provides insights into every aspect
of operations.

This capability is crucial for optimizing performance,

reducing costs, and identifying opportunities for
innovation and improvement.”
Real-World Examples of Industrial Automation

1. Automotive Industry: The automotive industry has

been a pioneer in adopting automation. Robots are
extensively used in assembly lines for tasks like welding,
painting, and assembling parts.

This automation has significantly increased production

speed and consistency. For instance, modern automotive
plants can produce a car every few minutes, with robots
ensuring each vehicle meets stringent quality standards.

2. Pharmaceutical Industry:
Automation in the pharmaceutical industry covers various
stages, from drug formulation to packaging. Automated
systems ensure precise dosing, accurate labeling, and
compliance with regulatory standards.

This precision is critical in producing safe and effective

medications. Automated processes also enable rapid
production of large volumes, essential during times of high
demand, such as during a pandemic.

3. Food and Beverage Industry:

In the food and beverage sector, automation is used in
processing, packaging, and quality control. Automated
systems handle tasks like sorting, bottling, and sealing,
ensuring products are hygienic and safe for consumption.

For example, automated bottling lines in beverage plants

can fill and cap thousands of bottles per hour, maintaining
high hygiene standards and reducing the risk of
contamination.”

Challenges and Future Trends in Industrial Automation

While automation offers numerous benefits, it also

presents certain challenges which are listed below:

Initial Capital Investment: Implementing automation

requires significant upfront investment in technology,
training, and infrastructure. For small and medium-sized
enterprises, this cost can be a barrier.

Skill Requirements: Operating and maintaining

automated systems demand specialized skills. There’s a
growing need for a workforce trained in robotics,
programming, and system integration.
Integration with Existing Systems: Integrating new
automated systems with existing infrastructure can be
complex and costly. Companies must ensure compatibility
and smooth transitions to avoid disruptions.
Future Trends in Industrial Automation:

Advances in AI and Machine Learning: AI and machine

learning are driving the next wave of automation. These
technologies enable systems to learn from data, adapt to
new tasks, and optimize performance without human
intervention.

Growth of IoT and Smart Manufacturing: The Internet of

Things connects machines and devices, allowing for
seamless Smart manufacturing systems use IoT to
monitor and control processes in real-time, enhancing
efficiency and responsiveness.

Increased Focus on Sustainability: There’s a growing

emphasis on sustainable and green manufacturing.
Automation can contribute by reducing energy
consumption, minimizing waste, and supporting the use
of eco-friendly materials.”

Limitations of Industrial Automation

While industrial automation offers numerous
advantages, it also comes with certain challenges and
drawbacks. Here are some key disadvantages to
consider:
1. High Initial Costs
2. Job Displacement
3. Complexity and Dependence on Technology
4. Cybersecurity Risks
5. Loss of Flexibility
6. Environmental Impact
7. Reduced Innovation and Workforce Creativity
8. Limited Human Touch and Customer Experience
9. Implementation and Technical Challenges
10. Ethical and Social Concerns

1. High Initial Costs

Investment in Technology:
Implementing automation requires a significant upfront
investment in equipment, software, and infrastructure.
This cost can be prohibitive, especially for small and
medium-sized enterprises (SMEs).

Ongoing Maintenance and Upgrades: Automation

systems require regular maintenance and periodic
upgrades to keep up with technological advancements,
adding to the ongoing costs.
2.Job Displacement
Reduction in Low-Skilled Jobs:
Automation often leads to the displacement of low-
skilled jobs, as machines and robots take over repetitive
and manual tasks.

Need for Skilled Workforce:

While automation creates new job opportunities, they
often require higher technical skills, leading to a skills
gap for the existing workforce.

3.Complexity and Dependence on Technology

Complex System Integration:
Integrating automation into existing systems can be
complex and time-consuming. It often requires
specialized expertise to ensure seamless operation and
compatibility.

Dependence on Technology:
Companies become heavily reliant on their automated
systems. Any failure or technical issue can disrupt
operations and lead to significant downtime and losses.
4. Cyber Security Risks

Increased Vulnerability to Cyber Attacks: Automated

systems
connected to networks are vulnerable to cyber security
threats, which can compromise data integrity, operational
continuity, and safety.

Need for Robust Security Measures: Protecting

automated systems requires robust cybersecurity
measures, which can be complex and costly to
implement and maintain.
5. Loss of Flexibility
Difficulty in Handling Customization:
Automated systems are excellent at handling repetitive
tasks but can struggle with customization or adapting to
new processes without significant reprogramming or
reconfiguration.

Resistance to Change:
Once automated systems are in place, making changes to
the processes can be difficult and costly, reducing
operational flexibility.
 6.Environmental Impact
Resource and Energy Consumption:
Automation systems, especially large-scale industrial
robots and machines, can consume significant amounts
of energy and resources, potentially increasing the
environmental footprint of a company.
E-Waste Generation:
The reliance on sophisticated electronic systems and devices
means that obsolete or broken components contribute to
electronic waste (e- waste), which is challenging to dispose
of responsibly.

7. Reduced Innovation and Workforce Creativity

Routine Tasks Limiting Human Involvement:
By automating repetitive and routine tasks, companies may
inadvertently
limit opportunities for employees to engage in creative
problem-solving
and process innovation.

8. Limited Human Touch and Customer Experience Lack

of Personalization:
Automated systems may lack the ability to provide the
personalized service and human touch that can be crucial in
customer-facing roles or industries.
Decreased Employee Morale:
Workers might feel undervalued or disconnected if they
perceive that machines are replacing their roles or if their
jobs become monotonous due to automation.

9.Implementation and Technical Challenges

Complex Setup and Integration:

Setting up automated systems requires careful planning,
expert knowledge, and often, a reconfiguration of existing
processes, which can be technically challenging and
disruptive

Risk of Technical Glitches an Downtime:

Automated systems are not immune to technical glitches.
Malfunctions can cause significant downtime and require
specialized technicians to resolve, leading to operational
delays.

10.Ethical and Social Concerns

Impact on Employment:
Automation can lead to ethical and social concerns
regarding job displacement and the widening gap between
high-skilled and low- skilled workers.
Summary:

In our 7th lecture on “'Needs and Benefits of Industrial Automation”,

we covered:
2. Understanding Industrial Automation with its Types, Needs and
Benefits.
3. Key Drivers and Benefits of Industrial Automation.
4. Real-World Applications and Challenges of Industrial Automation.

References:

 "Industrial Automation: Hands-On" by Frank Lamb, 2nd Edition,

Publisher: McGraw-Hill Education, Year: 2020.

 "Industrial Automation and Control System Security Principles" by Ronald

Krutz and Russell Dean Vines, 2nd Edition, Publisher: Wiley-IEEE Press,
Year: 2017.

 "Industrial Automation: Circuit Design and Integration" by James H.

Craddock, 1st Edition, Publisher: CRC Press, Year: 2019.
Course Name: Industrial Automation and Drives

Week No.: 03 Lecture No: 08

Topic Name: Needs and Benefits of Industrial Automation
1. Objectives:

● Students will be able to understand Automation Hierarchy of Industrial

Automation
● Students will be able to describe the Basic component of automation
system.
● Students will be able to learn the Role of Sensors and Actuators in
Automation Systems.

Automation Hierarchy

Automation Hierarchy refers to the structured levels at

which various automation components operate within an
industrial system. It’s like the organizational chart of an
automated system, defining how each level interacts and
contributes to overall operation.

The automation hierarchy in industrial automation

represents the various levels of control and management
within an industrial system, from field devices to enterprise-
level decision-making systems. Each level has distinct
functions and responsibilities, ensuring efficient operation
and integration of the entire automation process.

1. Field Level

Field Level is the lowest level in the automation hierarchy

and involves the physical components that directly interact
 with the production process.

 Sensors: Devices that detect and measure physical

quantities such as temperature, pressure, flow, level, and
presence. They convert these

physical quantities into electrical signals that can be used

by the control systems.

Figure 1. Automation Hierarchy Pyramid(realpars.com)

 Actuators: Devices that convert control signals into

physical action. Common actuators include electric
motors, pneumatic or hydraulic cylinders, and solenoids.

 Transmitters: Devices that send sensor data to

 controllers. They ensure that the data is accurately
conveyed for further processing.

2. Control Level

Control Level focuses on the real-time control of industrial

processes. It involves the use of specialized controllers to
manage operations and ensure that processes run smoothly.

 Programmable Logic Controllers (PLCs): PLCs are

industrial computers used to automate electromechanical
processes. They are known for their robustness and
reliability in industrial environments.

 Distributed Control Systems (DCS): DCS consists of

multiple controllers distributed throughout a plant. Each
controller manages a specific section of the process, with
centralized monitoring and control

 Human-Machine Interfaces (HMIs): HMIs provide

operators with a user-friendly interface to monitor and
control processes. They display real-time data and allow
for manual intervention if necessary.

3. Supervisory Level

Supervisory Level involves the supervision and

coordination of the control systems to ensure optimal
performance and compliance with production goals.
 Supervisory Control and Data Acquisition (SCADA):
SCADA systems provide high-level supervision and control
over large-scale processes. They gather real-time data
from field devices and control systems, offering a
centralized platform for monitoring and control.

 Manufacturing Execution Systems (MES): MES bridge

the gap between control systems and enterprise-level
planning. They manage and monitor work-in-progress on
the factory floor, providing real-time data on production
performance and quality.

4. Planning Level

Planning Level is responsible for the overall planning and

optimization of production processes. It integrates data from
various sources to make informed decisions and enhance
operational efficiency.

 Enterprise Resource Planning (ERP): ERP systems

integrate all aspects of a business, including production,
inventory management, procurement, finance, and human
resources. They ensure that all departments work in
harmony to achieve organizational goals.

 Production Planning and Scheduling: These systems

optimize the use of resources, plan production schedules,
and ensure timely delivery of products. They take into
account factors like demand forecasts, inventory levels,
and production capacity.

5. Enterprise Level
 Enterprise Level focuses on strategic decision-making and
long-term planning. It encompasses the overall business
strategy and ensures that the automation systems align
with the organization’s objectives.

 Business Intelligence (BI): BI tools analyze data from

various sources to provide insights into business
performance. They help in identifying trends, making
forecasts, and supporting decision-making processes.

 Corporate Management Systems: These systems provide

a top-down approach to managing business operations.
They ensure that all levels of the automation hierarchy are
aligned with the company’s strategic goals and objectives.

Integration and Communication

For effective industrial automation, integration and

communication across all levels of the hierarchy are crucial.
This ensures seamless data flow and coordination,
enhancing overall efficiency and productivity.

 Industrial Communication Networks: Protocols like

Ethernet/IP, Modbus, PROFIBUS, and CAN bus facilitate
communication between devices and systems at different
levels of the hierarchy.

 Data Integration: Systems like OPC (OLE for Process

Control) standards enable interoperability between
different automation and control systems, allowing for
seamless data exchange and integration.
Role of Sensors in Automation Systems

Sensors are critical components in automation systems,

providing the necessary data for monitoring, controlling, and
optimizing industrial processes. They play a pivotal role in
ensuring the efficiency, accuracy, and safety of automated
systems. Here is an in-depth look at the various roles
sensors play in automation:

1. Data Acquisition
Sensors are the primary means of acquiring real-time data
from the physical environment. They measure various
physical quantities and convert them into electrical signals
that can be processed by control systems.
 Temperature Sensors: Measure the temperature of a
process or environment.
 Pressure Sensors: Measure the pressure of gases or
liquids.
 Flow Sensors: Measure the flow rate of liquids or gases
 Level Sensors: Measure the level of substances in tanks
or silos.
 Proximity Sensors: Detect the presence or absence of an
object within a specific range.
 Optical Sensors: Measure light intensity, detect color, or
count objects passing a point.

2. Process Control
The data provided by sensors is crucial for process control.
Control systems like PLCs and DCS use this data to make
real-time adjustments to maintain desired operating
conditions.
 Feedback Control: Sensors provide feedback to the
control system, which adjusts actuators to keep the
process variables within desired ranges.
 Feedforward Control: Sensors can anticipate changes in
process variables and make preemptive adjustments to
maintain stability and performance.

3. Quality Assurance
Sensors help maintain and improve product quality by
ensuring that processes remain within specified parameters.

 Dimensional Inspection: Optical and laser sensors are

used to measure dimensions and ensure products meet
specifications.

 Surface Inspection: Cameras and vision sensors detect

surface defects and ensure the quality of finished
products.

4. Safety and Protection

Sensors enhance the safety of automation systems by
monitoring conditions and triggering alarms or shutdowns
when unsafe conditions are detected.

 Gas Detectors: Monitor for the presence of hazardous

gases and trigger alarms or ventilation systems.

 Temperature Sensors: Prevent overheating by shutting

down equipment or activating cooling systems when
temperatures exceed safe limits.
 Pressure Sensors: Prevent overpressure conditions that
could lead to equipment failure or explosions.

5. Predictive Maintenance
Sensors enable predictive maintenance by monitoring the
condition of equipment and detecting signs of wear or
impending failure.

 Vibration Sensors: Monitor the vibration levels of rotating

machinery to detect imbalance or bearing wear.

 Temperature Sensors: Detect overheating in motors or

other equipment, indicating potential issues.

 Oil Quality Sensors: Monitor the condition of lubricants

to determine when they need to be replaced.

6. Energy Management
Sensors help optimize energy use by monitoring and
controlling energy-consuming processes.

 Energy Meters: Measure the energy consumption of

machines and processes.

 Environmental Sensors: Monitor conditions such as light

and temperature to control HVAC systems efficiently.

6. Automation Integration
Sensors play a crucial role in integrating various components
of an automation system, enabling seamless communication
and coordination.
 Communication Protocols: Sensors with built-in
communication capabilities, such as Ethernet, Modbus, or
CAN bus, facilitate integration with control systems.

 Smart Sensors: These sensors have embedded processing

capabilities, allowing them to perform preliminary data
analysis and communicate directly with higher-level
control systems.

Types and Terminology Used in Sensors

In automation and control systems, sensors play a crucial

role by detecting physical quantities and converting them
into electrical signals. These signals are then used for
monitoring, controlling, and optimizing various processes.
Here, we delve into the types and terminology associated
with sensors.

Terminology

1. Sensor:
o A device that detects and measures a physical
quantity (such as temperature, pressure, or motion)
and converts it into an electrical signal.

2. Transducer:
o A device that specifically converts a physical quantity
into an electrical signal. While the term "sensor" and
"transducer" are often used interchangeably, a
transducer typically emphasizes the conversion
aspect.
 o Example: A thermocouple that converts temperature
into a voltage signal.

3. Switch:
o A binary or digital sensor that provides a discrete
output signal, usually in the form of ON/OFF states.
o Example: A pressure switch that activates when
pressure exceeds a certain threshold

4. Digital Transducer:
o A transducer equipped with an analog-to-digital
converter (ADC) to provide digital signals directly
compatible with digital control systems.
o Example: A digital temperature sensor that outputs
temperature readings in a digital format.

Output Signal Types in Sensors

Understanding the types of output signals provided by

sensors is crucial for integrating them into automation
systems. Sensors generally produce either analog or
digital/discrete outputs, each serving different purposes in
monitoring and control.

1. Analog Output
Analog output signals provide a continuous range of values
that represent the measured variable. These signals can vary
smoothly over a specified range, allowing for precise
measurement and control.

 Current Output (4-20 mA): This is a common standard in

industrial applications. The current signal varies from 4
 mA to 20 mA in proportion to the measured parameter.
The 4 mA baseline helps detect issues like a broken wire
(which would result in a 0 mA signal).

Example:
o A pressure sensor might output a current range of 4-
20 mA, where 4 mA corresponds to 0 psi and 20 mA
corresponds to 725 psi. This allows for detailed
monitoring of pressure variations within this range.

 Voltage Output (0-10 V): Another common form of analog

signal where the voltage varies from 0 V to 10 V in
proportion to the measured variable.

Example:
o A temperature sensor might output a voltage range
of 0-10 V, where 0 V corresponds to the lowest
measurable temperature and 10 V to the highest.

2. Digital/Discrete Output
Digital or discrete outputs are binary signals that indicate
the presence or absence of a condition. These outputs are
typically in the form of ON/OFF states and are used for
simple decision-making processes in automation systems.

 ON/OFF Signal: Represents two states, such as

open/closed, presence/absence, or yes/no. This type of
signal is essential for operations that require a
straightforward indication of a condition being met.
Example:
o A proximity sensor outputs an ON signal when an
object is detected within its sensing range and an
OFF signal when the object is outside the range. This
allows the system to make simple decisions based on
the presence or absence of an object.

Thermal overload relays

Thermal overload relays are essential devices used to protect

electric motors from overcurrent conditions that could cause
damage. These relays are not traditional switches or relays;
instead, they function as sensors detecting excessive motor
current. Integrated with power relays, they form a unified
device within the motor's power circuit. This integration
allows the thermal overload relay to indirectly stop the motor
by interrupting the control circuit of the power relay when an
overcurrent condition is detected.
Thermal overload relays are protective devices used in
electrical systems, particularly to safeguard motors from
overheating due to overcurrent conditions. They operate on
the principle of thermal expansion and are
typically installed in motor control circuits. Here’s an in-
depth look at their function, types, and applications.
 Figure 2. Structure of Thermal Overload Relay (Utmel.com)

Function

1. Protection Against Overload:

o Primary Function: Thermal overload relays protect

motors from overheating by sensing excessive
current flow. When the current exceeds a predefined
limit, the relay activates to disconnect the motor
from the power supply.

o Mechanism: They consist of a bimetallic strip that

bends when heated by excessive current. The
bending of the strip triggers a
mechanical linkage that opens the contact, cutting
off the power supply to the motor.

2. Reset Mechanism:
o After tripping, thermal overload relays can be
manually or automatically reset once the motor cools
down and the overload condition is resolved.
Types

1. Bimetallic Overload Relays:

o Construction: These relays use a bimetallic strip

made from two metals with different thermal
expansion coefficients. When current flows through
the strip, it heats up and bends.

o Operation: The bending action trips the relay to

open the circuit if the current remains high for a
duration exceeding the thermal time constant of the
strip.

Figure 2. Working Principle of Bimetallic Stripe (Utmel.com)

2. Eutectic Alloy Overload Relays:

o Construction: These relays use a eutectic alloy that

melts at a specific temperature.

o Operation: When the motor overheats, the alloy

melts, triggering the relay to open the circuit. These
relays are generally more precise but require
 replacement of the alloy element after each
operation.

3. Electronic Overload Relays:

o Construction: Utilize electronic components to sense

current
and temperature, providing more accurate and
adjustable protection settings.
o Operation: They offer advanced features such as
phase loss

o protection, adjustable trip settings, and

communication capabilities with control systems.

Applications

1. Motor Protection:

o Primary Use: Widely used in motor control centers

(MCCs) to protect motors in various industrial
applications from damage due to overload conditions.
o Industries: Found in manufacturing plants, HVAC
systems, pumping stations, and any facility that
relies on motors for operation.

2. Industrial Automation:

o Integration: Integrated into automated systems to

enhance reliability and prevent downtime caused by
motor failure due to overheating.
3. Electrical Panels:
o Usage: Installed in electrical distribution panels for
safeguarding motors and other critical equipment.
o
Advantages

1. Reliable Protection:
o Provides dependable protection against overload
conditions, preventing motor damage and prolonging
equipment lifespan.

2. Cost-Effective:
o Generally, more affordable than other types of motor
protection devices, making them a popular choice for
many applications.

3. Easy to Use:
o Simple design and operation make them easy to
install, set, and reset after an overload condition.

Proximity switches

Proximity switches are sensors used in industrial

automation for detecting objects within their sensing range
without physical contact. This non-contact operation makes
them ideal for applications requiring durability and
precision.
 Figure 4. Proximity switches Circuit Diagram Operation
(https://instrumentationtools.com/)

Below are the primary types of proximity switches based on

their operating principles:

Types of Proximity Switches

1. Inductive Proximity Switches:

Figure5.
Inductive
proximity
sensor

(https://innovationdiscoveries.space/)
 o Operating Principle: Inductive proximity switches
operate based on electromagnetic induction. They
generate an electromagnetic field and detect changes
in this field caused by the presence of a metallic
object.
o Applications: These switches are primarily used to
detect metal objects. Common applications include
automated assembly lines, conveyor systems, and
machine tools.
o Advantages: Highly durable, resistant to dust and
dirt, and reliable in harsh environments.

2. Capacitive Proximity Switches:

o Operating Principle: Capacitive proximity switches

detect changes in capacitance caused by the
presence of an object. These switches can sense both
metallic and non-metallic objects.

o Applications: Suitable for detecting a wide range of

materials, including plastics, glass, and liquids. They
are often used in packaging, material handling, and
level detection in container
 o Advantages: Versatile, capable of detecting various
materials, and can operate through non-metallic
barriers like glass or plastic.

3. Magnetic Proximity Switches

o Operating Principle: Magnetic proximity switches

operate using a magnetic field. They detect the
presence of magnetic materials or a magnetic field,
typically from a magnet attached to a moving part.
o Applications: Commonly used in situations where
long sensing distances are required or where the
object being detected is a magnet. Applications
include door and window sensors, position sensing
in hydraulic cylinders, and security systems.

o Advantages: Capable of detecting through non-

ferromagnetic materials, reliable over long distances,
and immune to environmental contaminants like
dust and water.
Additional Types:

1. Ultrasonic Proximity Switches:

o Operating Principle: Emit ultrasonic sound waves

and measure the time it takes for the waves to reflect
back from an object. The presence and distance of
the object are determined based on the time delay.
o Applications: Used in level measurement, object
detection in harsh environments, and applications
where non-contact measurement is crucial.
o Advantages: Effective in dirty, dusty, or misty
environments, can measure distance accurately, and
can detect a wide range of materials.

2. Photoelectric Proximity Switches:

o Operating Principle: Use light (infrared, visible, or

laser) to detect the presence of an object. When an
object interrupts the light beam, the switch is
activated.
o Applications: Widely used in packaging, conveyor
systems, and safety applications where precise and
non-contact detection is required.
o Advantages: High precision, fast response time, and
can detect transparent objects.
Applications of Proximity Switches

1. Automated Assembly Lines:

o Proximity switches detect the presence and position
of parts, ensuring proper assembly and quality
control.

2. Conveyor Systems:
o Monitor the movement of objects on conveyors,
triggering actions such as sorting, counting, and
stopping the conveyor if an object is detected.

3. Safety Systems:
o Implemented in safety interlock systems to prevent
access to dangerous areas or to stop machinery if a
person or object is detected.

4. Level Sensing:
o Detect the level of materials in tanks, silos, and
hoppers, ensuring accurate level control and
preventing overflows.

5. Robotics:
o Used in robotic systems for object detection,
positioning, and collision avoidance.

Key parameters for selecting proximity switches include:

Detection Distance: The maximum range within which the

switch can sense an object.

Object Placement Distance: The distance between the

object and the switch’s sensing area, which should be less
than the detection distance for effective operation.

Power Supply: The voltage range within which the switch

operates.

Response Time: The time it takes for the switch to react to

the presence of
an object.

Operating Frequency: The maximum rate at which the

switch can toggle between on and off states.

Proximity switches are available in various forms, such as

cylindrical, rectangular, and slot types, each suited to
different application needs. Internally, they typically include
components like an LC oscillator, a Schmitt trigger unit, and
an amplifier-switching circuit.

Inductive switches create a high-frequency electromagnetic

field, and the presence of a metallic object reduces the
oscillation amplitude of the field, triggering the switch.

Capacitive switches generate an electrostatic field, and

changes in capacitance due to nearby objects trigger their
operation.

Magnetic switches work by detecting changes in magnetic

flow caused by the movement of ferrous materials through
the magnetic field.

These sensors are often connected to power supplies and

loads using either two-wire or three-wire configurations. The
presence of residual current in two-wire setups can be a
consideration when connecting to sensitive electronic
circuits.

Proximity switches are extensively used in industrial

settings for applications such as position detection, object
counting, and machine monitoring. They are also critical in
robotics for detecting proximity to objects and in safety
systems to monitor access points.

Limit switches

Limit switches are mechanical devices with electrical

contacts that detect the end or limit of a motion. They
operate through the rectilinear movement and force of a
plunger, which activates internal contacts. The plunger
movement returns to its original position with a return
spring. Limit switches are housed in aluminum or plastic for
protection and insulation. They are typically actuated
mechanically by moving objects like piston rods or shafts.
Here’s a detailed overview of limit switches:

Components of a Limit Switch

1. Actuator: The part of the switch that comes into contact

with the moving part of the machine. Various types
include:

o Lever Actuator: Uses a lever or arm to activate the

switch.
o Plunger Actuator: Uses a plunger that is pressed
down to activate the switch.
o Roller Actuator: A variation of the lever actuator
that includes a roller to reduce friction.

2. Head: Houses the actuator and connects it to the switch

body.

3. Body: The main part of the switch, containing the

electrical contacts and wiring.

4. Contacts: Electrical components that open or close

circuits when the actuator is engaged. They can be
 Normally Open (NO) or Normally Closed (NC).

5. Terminals: Connection points for the wires that integrate

the limit switch into the control circuit.

Working Principle

Limit switches operate by the mechanical movement of an

object or machine part which actuates the switch's actuator.
When the actuator is engaged, it moves the internal contacts
from their default state to the opposite state, either opening
or closing an electrical circuit. This change sends a signal to
the control system, indicating the position or presence of the
moving part.

Types of Limit Switches

1. Mechanical Limit Switches: Operate through direct

physical contact. Subtypes include:

o Snap Action: Provides rapid switching once the

actuator moves past a certain point.
o Slow Action: Gradually changes the state of the
contacts as the actuator moves.

2. Non-Contact Limit Switches: Operate without physical

contact, using technologies like:

o Inductive: Detects metal objects through

electromagnetic fields.
o Capacitive: Detects any material that can alter the
capacitance of a field.
o Photoelectric: Uses light beams to detect objects.
Applications

Limit switches are widely used in various applications,

including:

 Industrial Automation: To control the movement of

machinery and robotic arms.
 Conveyor Systems: To detect the presence and position
of items.
 Elevators: To ensure doors are closed and to detect the
position of the elevator car.
 Safety Interlocks: To shut down machines if a dangerous
condition is detected.

Advantages

1. Reliability: They provide consistent and repeatable

operation.
2. Durability: Designed to withstand harsh industrial
environments.
3. Simplicity: Easy to install and maintain.
4. Cost-Effectiveness: Generally inexpensive compared to
other types of sensors.

Limitations

1. Mechanical Wear: Physical contact leads to wear and tear

over time
2. Limited Range: Usually operates over short distances.
3. Environmental Sensitivity: Mechanical parts can be
affected by dust, moisture, and other contaminants.

Level switches or level sensors

Level sensors are essential devices used to monitor and
measure the height of liquids or granular materials within
tanks, silos, and other storage containers. They are designed
to ensure optimal operation, safety, and efficiency in various
industrial processes. The types of level sensors range from
fully electronic to purely mechanical, each suited to specific
applications and materials.

Here’s an in-depth look at different types of level sensors and

their applications:
Types of Level Sensors

1. Electronic Level Switches for Conductive Liquids

o Working Principle: These sensors use electrodes to

detect the presence of conductive liquids between
two predefined points. When the liquid level rises to
cover the electrodes, a change in electrical
conductivity is detected, triggering a response.
o Applications: Commonly used in industries dealing
with conductive liquids like water, juices, milk, and
other similar substances.

2. Capacitive Level Switches

o Working Principle: Capacitive sensors measure

changes in capacitance caused by the presence of a
liquid or solid material. When the sensor's probe is
immersed in the material, the dielectric constant
changes, altering the capacitance and indicating the
level.
o Applications: Suitable for detecting non-conductive
liquids (like oils) and various bulk solid materials
(such as grains, powders).

3. Ultrasonic Level Sensors

o Working Principle: Ultrasonic sensors emit

ultrasonic waves towards the surface of the material
and measure the time it takes for the echoes to
return. The level is determined based on the travel
time of the waves.
 o Applications: Effective for detecting levels of liquids,
sludge, and solids. They are used in wastewater
treatment, chemical
processing, and food and beverage industries,
providing digital or analog outputs for control
systems.

4. Radar-Type Level Sensors

o Working Principle: These sensors use radar signals

to measure the level of materials. The radar waves
are transmitted towards the material surface and
reflected back to the sensor. The time taken for the
signals to return is used to calculate the level.
o Applications: Ideal for precise measurements in
challenging conditions, such as high temperatures,
pressures, and varying chemical compositions. They
are widely used in oil and gas, petrochemical, and
heavy industrial applications.
5. Float Level Switches

o Working Principle: A float level switch consists of a

floating element (a magnet or metallic ball) that
moves with the liquid level. The movement opens or
closes an electrical contact, indicating the level.

o Applications: Cost-effective and widely used in water

treatment, sewage plants, and HVAC systems. They
are suitable for both simple and complex level

monitoring tasks.

6. Optical Level Switches

o Working Principle: Optical level switches detect the

level of liquids based on the refraction of infrared
light. When the sensor tip is immersed in a liquid,
the change in refractive index alters the light path,
triggering the switch.
 o Applications: Ideal for small devices and
transparent liquids. They are commonly used in
vending machines, medical equipment, and
applications requiring precise level detection in small

volumes

Flow switch

Flow switches are vital components in industrial systems,

designed to monitor the flow of liquids through pipes and
ensure proper operation. They play a crucial role in
applications such as cooling systems, lubrication systems,
and various process controls. Here’s a detailed overview of
flow switches, focusing on two common types: paddle-type
and thermal dispersion flow switches.

1.Paddle-Type Flow Switches

Working Principle
Paddle-type flow switches are mechanical devices that detect
flow using a paddle or vane that extends into the pipe. When
liquid flows through the
pipe, it moves the paddle, which in turn triggers an electrical
switch. The switch opens or closes an electrical circuit based
on the paddle’s position. When the flow stops or falls below a
certain threshold, the paddle returns to its original position,
changing the state of the switch.

Features and Applications

 Installation: These switches can be installed on both

horizontal and vertical pipes, making them versatile for
various piping configurations. Different paddle sizes are
available to accommodate various pipe diameters.
 Application: Commonly used in cooling systems,
lubrication systems, and water treatment plants. They are
ideal for applications where detecting the presence or
absence of flow is crucial to prevent equipment damage,
such as in machine cooling systems where monitoring
water flow is essential to avoid overheating.

2. Thermal Dispersion Flow Switches

Working Principle

Thermal dispersion flow switches utilize heat to detect flow.

They consist of two temperature sensors: one measures the
fluid’s ambient temperature, while the other is slightly
heated. The flow of the liquid affects the temperature of the
heated sensor. When the flow rate is high, the liquid cools
the heated sensor more effectively, reducing the temperature
difference between the two sensors. Conversely, when the
flow rate is low, the cooling effect is less, increasing the
temperature difference.
This change in temperature difference is converted into a
switch signal, indicating whether the flow rate is above or
below a predetermined threshold.
Features and Applications

 Precision: Thermal dispersion switches are highly precise

and sensitive, capable of detecting even low flow rates.
 Durability: With no moving parts, they offer high
reliability and require minimal maintenance.
 Application: These switches are used in applications
requiring precise flow detection, such as in chemical
processing, food and beverage industries, and HVAC
systems. They are particularly useful in detecting low flow
rates where traditional mechanical switches may not be
sensitive enough.

Temperature and Pressure Switches

In industrial processes, monitoring and controlling both

temperature and pressure are critical tasks to ensure safety,
efficiency, and quality. Automation engineers rely on various
types of switches and sensors to

keep these parameters within acceptable ranges, and to

initiate actions if they deviate. Here’s an overview of
temperature and pressure switches, their working principles,
and their applications.

o Temperature Switches

Temperature switches are devices that detect temperature

changes and trigger actions when a specific temperature
threshold is reached. They can be simple on-off switches or
more sophisticated devices providing continuous
temperature monitoring.

Types of Temperature Switches

1. Bimetallic Temperature Switches

o Working Principle: These switches use a bimetallic

strip composed of two metals with different
expansion rates. When the temperature changes, the
strip bends due to the differing expansion rates,
opening or closing an electrical contact.
o Applications: Commonly used in HVAC systems,
domestic appliances, and industrial equipment for
basic temperature control and safety.

2. Thermostatic Switches

o Working Principle: Similar to bimetallic switches,

but often more precise. They use a temperature-
sensitive element that expands or contracts with
temperature changes to activate a switch.
o Applications: Widely used in heating systems,
refrigerators, and automotive applications.

3. Electronic Temperature Switches

o Working Principle: These switches use electronic

temperature sensors like thermocouples or RTDs
(Resistance Temperature Detectors) to measure
temperature and trigger a switch. They offer high
precision and can be integrated into complex control
systems.
 o Applications: Suitable for industrial automation,
process control, and applications requiring precise
temperature monitoring.

o Pressure Switches

Pressure switches are devices that detect pressure changes

in a fluid or gas and activate an electrical contact when a
specific pressure threshold is reached. They are crucial in
maintaining safe and efficient operation in various systems.

Types of Pressure Switches

1. Mechanical Pressure Switches

o Working Principle: These switches use a diaphragm,
piston, or bellow that moves in response to pressure
changes. The movement activates an electrical
contact to signal a pressure change.
o Applications: Common in hydraulic and pneumatic
systems, HVAC systems, and water treatment plants.

2. Electromechanical Pressure Switches

o Working Principle: Similar to mechanical switches

but with an added electrical element for enhanced
functionality and reliability. They combine
mechanical components with electrical contacts for
better performance

o Applications: Used in industries requiring more

robust and reliable pressure monitoring, such as oil
and gas, chemical processing, and industrial
 automation.

3. Electronic Pressure Switches

o Working Principle: These switches use electronic

sensors (e.g., piezoelectric sensors) to measure
pressure and trigger a switch. They provide high
accuracy and can be programmed for complex
control tasks.
o Applications: Ideal for applications needing precise
pressure control and monitoring, such as in process
industries, aerospace, and medical equipment.

Applications and Importance

 Safety: Temperature and pressure switches are critical for

preventing equipment damage and ensuring safety. For
example, overheating can lead to machinery failure or fire
hazards, while excessive pressure can cause explosions.

 Process Control: Maintaining optimal temperature and

pressure is essential for product quality in processes like
plastic molding, food processing, and chemical
manufacturing.

 Energy Efficiency: Proper monitoring and control help in

optimizing energy usage, reducing costs, and minimizing
environmental impact.
 Summary:
In our 8th lecture on “Week 3_lecture 8_Automation Hierarchy &
Basic component of automation system” we covered:

1. Hierarchy of Automation system.

2. Overview of basic components of industrial automation.
3. Role of Sensors and Actuators in Industrial Automation.

References:

 "Industrial Automation: Hands-On" by Frank Lamb, 2nd Edition, Publisher:

McGraw-Hill Education, Year: 2020.

 "Industrial Automation and Control System Security Principles" by Ronald

Krutz and Russell Dean Vines, 2nd Edition, Publisher: Wiley-IEEE Press,
Year: 2017.

 "Industrial Automation: Circuit Design and Integration" by James H.

Craddock, 1st Edition, Publisher: CRC Press, Year: 2019.