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Industrial Automation Lecture 4

The document discusses industrial automation, focusing on control systems, safety monitoring, error detection, and recovery. It outlines closed-loop and open-loop control systems, emphasizing the importance of feedback and sensor usage for safety and error management. Additionally, it covers principles and strategies for automation, including understanding and simplifying processes, and introduces various levels of automation.

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8 views13 pages

Industrial Automation Lecture 4

The document discusses industrial automation, focusing on control systems, safety monitoring, error detection, and recovery. It outlines closed-loop and open-loop control systems, emphasizing the importance of feedback and sensor usage for safety and error management. Additionally, it covers principles and strategies for automation, including understanding and simplifying processes, and introduces various levels of automation.

Uploaded by

Assta king
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 4
Eng. Hazza’a Al-faqih
Industrial Control Systems
Outline
❑Control System.
❑Safety Monitoring.
❑Error Detection.
❑Error Recovery.
❑Automation Principles and Strategies.
❑Levels of Automation.
Control System
▪ The control system causes the process to accomplish its defined function, which is to perform
some manufacturing operation.
▪ The control element of the automated system executes the program of instructions.
1. Closed-loop (feedback) control system – a system in which the output variable is compared
with an input parameter, and any difference between the two is used to drive the output into
agreement with the input
2. Open-loop control system – operates without the feedback loop, so no comparison is made
between the actual value of the output and the desired input parameter.
▪ Simpler and less expensive
▪ Risk that the actuator will not have the intended effect
Closed-loop (Feedback) Control System
1. The input parameter (i.e., set point) represents the desired value of the output.

2. The process is the operation or function being controlled.

3. The output variable (process variable) that is being controlled in the loop, perhaps a critical performance measure in the process, such as temperature or force or flow rate.

4. A sensor is used to measure the output variable and close the loop between input and output. Sensors perform the feedback function in a closed-loop control system.

5. The controller compares the output with the input and makes the required adjustment in the process to reduce the difference between them.

6. The adjustment is accomplished using one or more actuators, which are the hardware devices that physically carry out the control actions, such as electric motors or flow valves.
Open-Loop Control System
 In this case, the controls operate without measuring the output variable.

 The controller relies on an accurate model of the effect of its actuator on the process variable.

 With an open-loop system, there is always the risk that the actuator will not have the intended effect on the process, and that is the disadvantage of an open-loop system. Its
advantage is that it is generally simpler and less expensive than a closed-loop system.

Open-loop systems are usually appropriate when the following conditions apply:

 Actions performed by the control system are simple

 Actuating function is very reliable

 Any reaction forces opposing the actuation are small enough as to have no effect on the actuation

 If these conditions do not apply, then a closed-loop control system should be used
Safety Monitoring
Use of sensors to track the system's operation and identify conditions that are unsafe or
potentially unsafe
▪ Reasons for safety monitoring
◦ To protect workers and equipment

▪ Possible responses to hazards:


◦ Complete stoppage of the system
◦ Sounding an alarm
◦ Reducing operating speed of process
◦ Taking corrective action to recover from the safety violation

Example: Emergency stop buttons, Limit switches, photoelectric sensors,


temperature sensors, heat or smoke detectors, pressure-sensitive floor pads
Error Detection
 Error detection – in analyzing a given production operation, the possible errors can be classified into one of
three general categories:
1. Random errors, occur when the process is in statistical control. Large variations in part dimensions, even when
the production process is in statistical control, can cause problems in downstream operations.
2. Systematic errors, are those that result from some assignable cause such as a change in raw material or drift in
an equipment setting.
3. Aberrations errors that results from either an equipment failure or a human mistake
 Functions:
 Use the system’s available sensors to determine when a deviation or malfunction has occurred
 Correctly interpret the sensor signal
 Classify the error
The two main design problems in error detection are (1) anticipating all of the possible errors that can occur in a
given process, and (2) specifying the appropriate sensor systems and associated interpretive software so that the
system is capable of recognizing each error
Error Recovery
 Error recovery – is concerned with applying the necessary corrective action
to overcome the error and bring the system back to normal operation.
 Possible strategies:
 Make adjustments at end of work cycle
 Make adjustments during current work cycle
 Stop the process to invoke corrective action
 Stop the process and call for help
Automation Principles and Strategies
1. The USA Principle
2. Ten Strategies for Automation and Process Improvement
3. Automation Migration Strategy
Automation Principles and Strategies
1. Understand the existing process:
 Input/output analysis: What are the inputs? What are the outputs? What exactly
happens to the work unit between input and output? What is the function of the process?
 Value chain analysis: How does it add value to the product? What are the
upstream and downstream operations in the production sequence, and can they be
combined with the process under consideration?
 Charting techniques(such as the operation chart and the flow process chart) and
mathematical modeling
2. Simplify the process: Reduce unnecessary steps and moves
3. Automate the process:
 Ten strategies for automation and production systems
 Automation migration strategy
Levels of Automation
Levels of Automation
Any Question?

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