20ei217-Ia Module I

SRI RAMAKRISHNA ENGINEERING COLLEGE
VATTAMALAIPALAYAM, N.G.G.O. COLONY POST, COIMBATORE – 641 022.
DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING
20EI217
INDUSTRIAL AUTOMATION
Module 1
INDUSTRIAL PROCESS AUTOMATION
05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 1

COs, POs, PEO and PSO
On successful completion of the course, the students will be able to
CO1: Interpret the concepts of process automation, safety monitoring and error diagnostics
CO2: Utilize the functions of PLC, ladder programming languages to implement the
different processes in industry
Course Outcomes CO3: Illustrate about block and structured program in plc to control the different process
CO4: Outline the operations of the distributed control and supervisory control in industrial
automation
CO5: Make use of the automation controllers for measurement and control of
different controllers
PO1: Engineering knowledge: Apply the knowledge of mathematics, science,
engineering fundamentals, and an engineering specialization to the solution of
complex engineering problems.
PO2: Problem analysis: Identify, formulate, review research literature, and analyze
POs Mapping with complex engineering problems reaching substantiated conclusions using first
the COs principles of mathematics, natural sciences, and engineering sciences.
PO3: Design/development of solutions: Design solutions for complex engineering
problems and design system components or processes that meet the specified needs
with appropriate consideration for the public health and safety, and the cultural,
societal, and environmental considerations.
The graduates of this program after four to five years will,
PEOs Mapping PEO I: Engage in design of systems, tools and applications in the field of electronics and
with the Course instrumentation engineering and allied engineering industries.
PSO Mapping with PSO 2: Understand, Specify and verify the principles of measuring instruments
the course using the state of art equipment.
Syllabus
INDUSTRIAL PROCESS AUTOMATION 15
Process Automation: Necessity and evolution, automation in process industry, architecture of
industrial automation network, Types of automation systems - Levels of automation - Elements of
automated systems: Power to accomplish the automated process - Safety monitoring -
Maintenance and repair diagnostics - Error detection and recovery.
CONTROLLERS FOR AUTOMATION 20
Programmable Logic Controller: Architecture of PLC system - Input and output modules -
Programming languages - Ladder diagram instruction: Logic functions, timers, counters, jump and
call, PID - Batch process using PLC - Design of conveyor belt control system using PLC - Design
of mixing of two liquids in a single tank – Functional block diagram(FBD) - Structured text
Programming: Conditional instructions, Iteration instructions.
Distributed Control System: Architecture of computer based industrial automation system: Server,
client, standalone - Direct digital control (DDC) - Computer Supervisory Control - Operation,
monitoring, control and data acquisition in DCS - Integration of DCS with PLC and SCADA -
Comparison on PLC, DCS and SCADA
APPLICATIONS OF AUTOMATION 10
Automation on condition monitoring and predictive maintenance - Industrial safety automation - AI
based autonomous guided vehicle: Motion control, system control - IoT solutions to monitor
beverage bottling assets on the production line - HVAC and building management system in oil
industries - Robot Process Automation

Syllabus
CASE STUDIES
1.Automation on vision based live object monitoring system.
2.Oil Pump jack monitoring and control system
3.Smart bus fleet management system
TEXT BOOKS
1.Chanchal Dey, Sunit Kumar Chen, "Industrial Automation Technologies", 1 Edition,
CRC Press, 2020.
2.W.Bolton, "Programmable Logic Controller", 6th Edition, Newnes-Elsevier Ltd., 2015.
REFERENCES
1.Petruzella F.D., "Programmable Logic Controllers", 5 th Edition, McGraw Hill
Publications, 2016.
2.Mikel P.Groover, "Automation, Production Systems and Computer-Integrated
Manufacturing", 4th Edition, Pearson Education Ltd., 2016.
3.Frank Lamb, "Industrial Automation-Hands on", 1st Edition, McGraw Hill Publications,
2013

Syllabus
WEB REFERENCES
1. https://www.ti.com/applications/industrial/factory-automation/overview.html
2. https://www.britannica.com/technology/automation/Advantages-and disadvantages –
of - automation.
3. https://www.st.com/en/applications/factory-automation.html
4.https://www.advantech.in/resources/case-study/hvac-and-building-management-
systems
5.https://www.advantech.in/resources/case-study/utilizing-iot-solutions-to-monitor -
beverage-bottling-assets on-the-production-line

Industrial Automation

Automation
What is Automation ?
Automation is basically the delegation of human control function to technical equipment for
 Increasing Productivity
 Increasing Quality
 Reducing Cost
 Increasing Safety in working conditions
A Historical Background of Automation
Programmable Logic Controller
Electronic Control using Logic Gates
Hard wired logic Control

Pneumatic Control
Manual Control
Process Automation
 An industrial production process consists of series of
machines, through which a combination of raw materials
goes through and transform into the final product.
 Here, the term “machine” can be anything like a motor, drill,

conveyor belt, etc. which come under electromechanical
devices or chemical machines like ovens, dryers, chemical
combustion systems etc.
 There are several factors that lead to the implementation of

automation system in industrial production like requirement
of high-quality products, high expectations in product
reliability, high-volume production etc.

Process Automation
 Industrial Automation is a process of operating machines and

other industrial equipment with the help of digital logical
programming and reducing human intervention in decision
making and manual command process with the help of
mechanized equipment.
 The above definition is definitely not a simple one to

understand but let us try to understand what an industrial
automation is with the help of a small example.

Process Automation
 The dictionary defines automation as “the technique of

making an apparatus, a process, or a system operate
automatically.”
 We define automation as "the creation and application of

technology to monitor and control the production and
delivery of products and services.”

Automation in Process Industry
 Consider a manual industrial production process, where an

operator is observing the temperature of an oven. Assume
the task is to reach a certain temperature and maintain that
temperature for about 30 minutes.
 So, the operator has to first adjust the amount of fuel to the oven
by controlling a valve to rise the temperature to the desired
amount.
 Once the necessary temperature is achieved, it has to be

maintained by constantly adjusting the valve i.e. either increase
or decrease the fuel depending on the temperature for the next
30 minutes.
 Now, with industrial automation, the whole process is taken
care of without the help of an operator. First, there is a
temperature sensor placed near the oven which reports the
temperature to a computer.
 Now, there is motorized valve, which is also controlled by the

computer, for the fuel to be supplied to the oven. Based on the
temperature readings from the sensor, the computer will open
the valve to allow more fuel in the beginning. Once the
desired temperature is achieved, the valve is shutoff.
 Based on the temperature readings. The timer in the computer

will indicate once 30 minutes is up and the computer can
completely shut off the system.
Figure-1: Block diagram of Automation in process industry

Process Automation

MCQ
1. Sensors and control relays can’t generate or interpret protocol communication, _______ is needed
to provide an interface between the sensors and the SCADA network.
a) Field instruments b) Optical fibers
c) HMI d) RTU’s
ANS: D) RTU’s
2. _______the operator interface must allow the operator to observe current status, and interact to
initiate new steps or halt the sequence.
a) Batch Process b) Continuous Process
c) Continuous & Sequential Process d) Sequential Process
ANS: A) Batch Process
3. The HART protocol is a typical smart instrumentation field bus that can operate in a _______ digital
fashion.
a) 0-5V b) 3-15 psi
c) hybrid 4-20mA d) 0-24V
ANS: C) hybrid 4-20mA

Types of Industrial Automation Systems
Different Types of Industrial Automation Systems
Fixed Automation. Also referred to as hard automation,

fixed automation systems carry out a single set of tasks
without deviation.
Programmable Automation.
Flexible Automation.
Integrated Automation.

Fixed Automation
Also referred to as hard automation, fixed automation systems

carry out a single set of tasks without deviation. Because of
its function, this type of system would typically be used for
discrete mass production and continuous flow systems.
An example of a fixed automation equipment would be an

automated conveyer belt system designed to increase
efficiency by moving objects from point A to B without
minimal efforts.
Just like all other fixed automation system equipment,

automated conveyer belts perform fixed and repetitive
operations to achieve high production volumes.

Programmable Automation
 As the names suggests, programmable automation runs
through commands delivered by a computer program.
 This means that the resulting processes can vary widely with
changing instructions given to the computer through a
series of code. However, as the programming efforts are
non-trivial, the processes hence the tasks do not change
much.
 This type of automation is common in mass production

settings which produce similar types of products that utilize
many of the same steps and tools like in paper mills or steel
rolling mills.

Flexible Automation
 Also referred to as soft automation, this type of automation is

utilized in computer-controlled flexible manufacturing systems
and allows for a more flexible production.
 Every equipment receives instructions from a human-operated

computer which means that the tasks can vary widely with
changing code delivered to the computer.
 This type of automation would typically be used in batch

processes and job shops with high product varieties and low-to-
medium job volume, such as in textile manufacturing.

Integrated Automation
 Integrated automation involves the total automation of

manufacturing plants as it is entirely handled by computers
and control processes with minimal human involvement.
 Computers can design the necessary parts, test the designs,

and fabricate the parts. Integrated automation, like flexible
automation, is compatible with both batch process
manufacturing and continuous process manufacturing.

Levels of Industrial Automation
Three level representation of a typical Industrial Automation

Application are
Supervisor Level
Control Level
Field Level

Levels of Automation
Figure-2: Levels of Automation in process industry

Supervisor Level
Sitting at the top of hierarchy, the supervisor level usually

consists of an Industrial PC, which is usually available as a
desktop PC or a Panel PC or a Rack-mounted PC.
These PCs run on standard operating systems with a special

software, usually provided by the supplier for industrial
process control.
The main purpose of the software is process visualization

and parameterization. A special industrial ethernet is used for
communication, which can be Gigabit LAN or any wireless
topology (WLAN).

Control Level
The Control Level is the mid-level in the hierarchy and this is

the level where all the automation related programs are
executed.
For this purpose, generally, Programmable Logic
Controllers or PLCs are used, which provide real-time
computing capability.
PLCs are usually implemented using 16-bit or 32-bit
microcontrollers and run on a proprietary operating system
to meet the real-time requirements.
PLCs are also capable of being interfaced with several I/O
devices and can communicate through various
communication protocols like CAN.

Field Level
The terminal equipment like Sensors and Actuators are

categorized into Field Level in the hierarchy.
The sensors like temperature, optical, pressure etc. and

actuators like motors, valves, switches etc. are interfaced
to a PLC through a field bus and the communication
between a Field Level device and its corresponding PLC is
usually based on a point-to-point connection.
Both wired and wireless networks are used for

communication and using this communication, the PLC can
also diagnose and parameterize various components

Figure-3: Levels of Automation in process industry


MCQ
1. Operator interface must allow the operator to have rapid access to all continuous and logic
sequences is one the basic requirement for
a) Process record keeping b) Process diagnostics
c) Process control d) Process monitoring
ANS: C) Process control
2. The HART protocol is a typical smart instrumentation field bus that can operate in a _______
digital fashion.
a) 0-5V b) 3-15 psi
3. Foundation Fieldbus consists of _______layers.
a) Six b) Five
c) Four d) Three
ANS: A) Four

Continuous Versus Discrete Control
 Industrial control systems used in the process industries tend to
emphasize the control of continuous variables and parameters.
 By contrast, the manufacturing industries produce discrete parts

and products, and their controllers tend to emphasize discrete
variables and parameters.
 Just as there are two basic types of variables and parameters that
characterize production operations, there are also two basic types of
control:
(1) Continuous control, in which the variables and parameters are
continuous and analog; and
(2) Discrete control, in which the variables and parameters are discrete,
mostly binary discrete.

Hardware Components for Automation
 To implement automation and process control, the control

computer must collect data from and transmit signals to the
process. Process variables and parameters were classified as
continuous or discrete, with several subcategories in the
discrete class.
 The digital computer operates on digital (binary) data, whereas

at least some of the data from the physical process are
continuous and analog.
 Accommodations for this difference must be made in the

computer–process interface.

The components required to implement this interface are the

following:
Sensors to measure continuous and discrete process variables.

Actuators to drive continuous and discrete process parameters.
Devices to convert continuous analog signals into digital data
and digital data into analog signals.
Input/output devices for discrete data.

Comparison Between Continuous Control and
Discrete Control

Continuous Control Systems
• In continuous control, the usual objective is to maintain the

value of an output variable at a desired level, similar to
the operation of a feedback control system.
• However, most continuous processes in the practical world

consist of many separate feedback loops, all of which
have to be controlled and coordinated to maintain the
output variable at the desired value.

Continuous Control Systems
There are several ways to achieve the control objective in a

continuous process-control system. In the following, the
most prominent categories are surveyed.
 Regulatory Control.
 Feedforward Control.
 Steady-State Optimization.
 Adaptive Control

Discrete Control Systems
• In discrete control, the parameters and variables of the system

are changed at discrete moments in time, and the changes
involve variables and parameters that are also discrete,
typically binary (ON/OFF).
• The changes are defined in advance by means of a program of
instructions, for example, a work cycle program.
• The changes are executed either because the state of the
system has changed or because a certain amount of time has
elapsed. These two cases can be distinguished as
(1) Event-driven changes
(2) Time-driven changes

Figure-5: The computer process control system, showing the various types of
components required to interface the process with the computer

Sensors and its applications
Figure 6: Basic Sensors

Sensors
• The era of automation has begun already. Most of the things that we use now
can be automated.
• To design automated devices first we need to know about the sensors, these are
the modules/devices which are helpful in making things done without human
intervention.
• Even the mobiles or smart phones which we daily use will have some sensors
like hall sensor, proximity sensor, accelerometer, touch screen, microphone
etc.
• These sensor acts as eyes, ears, nose of any electrical equipment which senses
the parameters in outside world and give readings to devices or Microcontroller.

Sensors
• A sensor is a device that detects and responds to some type

of input from the physical environment.
• The input can be light, heat, motion, moisture, pressure or

any number of other environmental phenomena.
• The output is generally a signal that is converted to a

human-readable display at the sensor location or
transmitted electronically over a network for reading or
further processing.

Sensors
• The sensor can be defined as a device which can be used to

sense/detect the physical quantity like force, pressure,
strain, light etc and then convert it into desired output like
the electrical signal to measure the applied physical
quantity.
• In few cases, a sensor alone may not be sufficient to analyze

the obtained signal. In those cases, a signal conditioning
unit is used in order to maintain sensor’s output voltage
levels in the desired range with respect to the end device
that we use.

Signal Conditioning
• In signal conditioning unit, the output of the sensor may be

amplified, filtered or modified to the desired output voltage.
• For example, if we consider a microphone it detects the audio

signal and converts to the output voltage (is in terms of mill
volts) which becomes hard to drive an output circuit.
• So, a signal conditioning unit (an amplifier) is used to increase

the signal strength. But the signal conditioning may not be
necessary for all the sensors like photodiode, LDR etc.

Signal Conditioning
Figure 7: Sensor with Signal Conditioning

Sensors in IOT
• Sensors play a pivotal role in

the internet of things (IoT).
• They make it possible to

create an ecosystem for
collecting and processing
data about a specific
environment so it can be
monitored, managed and
controlled more easily and Figure 3: Sensors in IoT
efficiently.

Sensors in IoT
• IoT sensors are used in homes, out in the field, in

automobiles, on airplanes, in industrial settings and in
other environments.
• Sensors bridge the gap between the physical world and

logical world, acting as the eyes and ears for a computing
infrastructure that analyzes and acts upon the data collected
from the sensors.

Types of sensors
• Sensors can be categorized in multiple ways. One common

approach is to classify them as either active or passive.
Figure 8: Active sensor VS Passive sensor in Remote Sensing

Active Sensor
• An active sensor is one that requires an external power

source to be able to respond to environmental input and
generate output.
• For example, sensors used in weather satellites often require

some source of energy to provide meteorological data about
the Earth's atmosphere.

Passive Sensor
 A passive sensor, on the other hand, doesn't require an

external power source to detect environmental input. It
relies on the environment itself for its power, using sources
such as light or thermal energy.
 A good example is the mercury-based glass thermometer.

The mercury expands and contracts in response to
fluctuating temperatures, causing the level to be higher or
lower in the glass tube.
 External markings provide a human-readable gauge for

viewing the temperature.

Analog Sensors
 Another way in which sensors can be classified is by whether
they're analog or digital, based on the type of output the
sensors produce.
 Analog sensors convert the environmental input into output

analog signals, which are continuous and varying.
Thermocouples that are used in gas hot water heaters offer a
good example of analog sensors.
 The water heater's pilot light continuously heats the

thermocouple. If the pilot light goes out, the thermocouple
cools, sending a different analog signal that indicates the gas
should be shut off.


Analog Sensor Output
Figure 9: Analog Sensor Output

Digital Sensors
 In contrast to analog sensors, digital sensors convert the

environmental input into discrete digital signals that are
transmitted in a binary format (1s and 0s).
 Digital sensors have become quite common across all

industries, replacing analog sensors in many situations. For
example, digital sensors are now used to measure
humidity, temperature, atmospheric pressure, air quality
and many other types of environmental phenomena.

Digital Sensor Output
 As with active and passive

sensors, some types of sensors
such as thermal or pressure
sensors are available in both
analog and digital forms.
 In this case, too, the environment

in which the sensor will operate
Figure 10: Digital Sensor Output
typically determines which is the
best option

Sensors & Types of Sensors

MCQ
1. Sensors and control relays can’t generate or interpret protocol communication, _______ is needed
to provide an interface between the sensors and the SCADA network.
a) Field instruments b) Optical fibers
c) HMI d) RTU’s
ANS: D) RTU’s
2. _______the operator interface must allow the operator to observe current status, and interact to
initiate new steps or halt the sequence.
a) Batch Process b) Continuous Process
c) Continuous & Sequential Process d) Sequential Process
ANS: A) Batch Process
3. The HART protocol is a typical smart instrumentation field bus that can operate in a _______ digital
fashion.
a) 0-5V b) 3-15 psi

Types of sensors
• Let us see the various different types of sensors that are

available in the market and discuss their functionality,
working, applications etc. We will discuss various sensors
like:
• Light Sensor
IR Sensor (IR Transmitter / IR LED)

Photodiode (IR Receiver)
Light Dependent Resistor

Types of sensors
• Tilt Sensor
 Accelerometer
• Weight Sensor
 Load Cells (Weight Sensor)
• Humidity Sensor
• Rainfall Sensor
• Motion Sensor
• Ultrasonic Sensor
IR Sensor
• It is also called as IR Transmitter. It is
used to emit Infrared rays.
• The range of these frequencies are

greater than the microwave
frequencies (i.e. >300GHz to few
hundreds of THz).
• The rays generated by an infrared

Figure 11: IR Sensor
LED can be sensed by Photodiode
explained below. The pair of IR LED
and photodiode is called IR Sensor.

Photodiode
• A photodiode is constructed such that light

rays should fall on the PN junction which
makes the leakage current increase based
on the intensity of the light that we have
applied. So, in this way, a photodiode can
be used to sense the light rays and
maintain the current through the circuit.
• Using a photodiode we can build a basic

automatic street lamp which glows when
the sunlight intensity decreases.
Figure 12: Photodiode

LDR (Light Dependent Resistor):
• As the name itself specifies that the

resistor that depends upon the light
intensity.
• It works on the principle of

photoconductivity which means the
conduction due to the light.
• When light falls on the LDR, its resistance

Figure 13: LDR Sensor
decreases and acts similar to a conductor
and when no light falls on it, its resistance
is almost in the range of MΩ or ideally it
acts as an open circuit.

Accelerometer
• This type of sensor detects changes

in gravitational acceleration,
making it possible to measure tilt,
vibration and, of course,
acceleration.
• Accelerometer sensors are used in

a wide range of industries, from
consumer electronics to
professional sports to aerospace Figure 14: Acceleration
and aviation. Sensor

Accelerometer Application

Load Cell (Weight Sensor)
• Load cells are similar to strain
gauges which measure the physical
quantity like force and give the
output in form of electrical signals.
• When some tension is applied on the

load cell it structure varies causing
the change in resistance and finally,
its value can be calibrated using
Figure 15: Load Cell
a Wheatstone bridge.

Load Cell Application

Humidity Sensor
• These sensors can detect the level of water
vapors in the air to determine the relative
humidity.
• Humidity sensors often include
temperature readings because relative
humidity is dependent on the air
temperature.
• The sensors are used in a wide range of
industries and settings, including
agriculture, manufacturing, data centres,
Figure 16: Humidity Sensor
meteorology, and heating, ventilation and
air conditioning

Rainfall Sensor
• When it rains, the wet glass

causes the light to scatter and
lesser amount of light gets
reflected back to the sensor
Applications
• Smart Irrigation System

• Automatic Car Wiper System
Figure 17: Rainfall Sensor

Motion Measurement Sensor
• A motion sensor, or motion detector, is
an electronic device that uses a sensor
to detect nearby people or objects.
• Motion sensors are an important
component of any security system.
• When a sensor detects motion, it will
send an alert to your security system,
and with newer systems, right to your
mobile phone.
• Active ultrasonic sensors and passive
infrared sensors are the two most
common motion sensor technologies, Figure 18 : Ultrasonic sensor and
both of which are known for their PIR sensor for motion detection
accuracy and reliability.

ULTRASONIC SENSOR
• The ultrasonic sensor emits high-frequency sound waves towards
the target object, and a timer is started
• Target object reflects the sound waves back towards the sensor
• The receiver picks up the reflected wave and stops the timer
• The time taken for the wave’s return is calculated against the
speed of sound to determine the distance travelled
Figure 19 : Ultrasonic sensor

Application of Ultrasonic Sensor
There are many applications with the

ultrasonic sensor. We can make use of
it avoid obstacles for the automated
cars, moving robots etc.
The same principle will be used in the

RADAR for detecting the intruder
missiles and airplanes. A mosquito can
sense the ultrasonic sounds. So,
ultrasonic waves can be used as
mosquito repellent. Figure 20 : Ultrasonic sensor

ACTUATORS
 One of the important components of a mechatronic

control system is the actuator.
 Actuators are the devices that accept a control command

and produce a change in the physical system by
generating force, motion, heat, flow, etc.
 It is a device that makes something to move. Normally,

the actuators are used in conjunction with the power
supply and a coupling mechanism.

ACTUATORS
• Actuators are the device used for converting hydraulic,

pneumatic, and electrical energy into mechanical energy.
• The mechanical energy used to get the work done. Actuators

perform functions just opposite to that of the pump.
• They can be used for lifting, tilting, clamping opening,

closing, metering, mixing and turning, and for many other
operations.

Functions of actuation
1. Transformation of rotary motion into a translating motion as

in the case of the cam and follower mechanism where the
rotational motion of the cam is changed into the
translational movement of the follower.
2. Transformation of rotary motion for a long distance which

is not possible by using gears, as in the case of belt drives.
3. Transformation of rotary motion for a medium distance

without slipping which is not possible by using belt drives, as
in the case of belt drives.

Functions of actuation
4. Transformation of linear motion into rotational motion as in

the case of rack and pinion mechanism.
5. Locking of rotating elements as in the case of ratchet and

pawl mechanism.

Types of Actuators
Actuators are basically classified into the following two types

based on their movement.
Translational
Rotational
It is possible to convert one form of actuation to another.

For example, translational motion is converted into
rotational and vice versa by suitably designing the interfacing
components around the actuator.
Rack and pinion, gears, pulleys, lead screw and nut, and cams
can be used as interfacing components.

Classification of Actuators
Actuators can be classified into the following types based on

the type of energy.
1.Electrical
2.Electromechanical
3.Electromagnetic
4.Hydraulic
5.Pneumatic

Electrical Actuators
 An actuator obtaining electrical energy from the

mechanical system is called electric actuators.
 Electric actuators are generally referred to ad being those
where an electric motor drives the robot links through
some mechanical transmission i.e. gears.
Electrical actuators comprise the following :

1. Drive system: DC motor, AC motor, Stepper motor
2. Switching Device:
a. Mechanical switch: Solenoids, Relays
b. Solid-state switch: Diodes, Thyristor, Transistors

Electro-mechanical actuators
• Electromechanical actuators are electrical motors that

convert electrical energy into mechanical motion.
• Motors are the principal means of converting electrical

energy into mechanical energy in industry.
• Broadly, they are classified into DC motors, AC motors, and

stepper motors.

Electro-magnetic actuators
• An electromagnetic actuator is a device that provides working

motion due to an internal electromagnetic field.
• The solenoid is the most common electromagnetic actuator. A

solenoid consists of a static, hollow-centered wire coil and a
movable ferrous metal plunger.
• When the wire coil is energized, a magnetic field establishes

that provides the force to push or pull the metal plunger.

Input/Output Devices for Discrete Data
 Discrete data can be processed by a digital computer

without the kinds of conversion procedures required for
continuous analog signals. As indicated earlier, discrete
data divide into three categories:
(a) binary data,

(b) discrete data other than binary
(c) pulse data.

Contact Input/Output Interfaces
 Contact interfaces are of two types, input and output.
 These interfaces read binary data from the process into the
computer and send binary signals from the computer to
the process, respectively. The terms input and output are
relative to the computer.
 A contact input interface is a device by which binary data

are read into the computer from some external source
(e.g., a process).

Contact Input/Output Interfaces
 It consists of a series of simple contacts that can be either

closed or open (on or off) to indicate the status of binary
devices connected to the process such as limit switches
(contact or no contact), valves (open or closed), or motor
pushbuttons (on or off).
 The computer periodically scans the actual status of the

contacts to update the values stored in memory.

Elements of Automated System
An automated system consists of three basic elements:
(1) Power to accomplish the process and operate the

system.
(2) A program of instructions to direct the process.
(3) A control system to actuate the instructions.

An automated system is used to operate some process, and

power is required to drive the process as well as the controls.
The principal source of power in automated systems is

electricity. Electric power has many advantages in
automated as well as non automated processes:
Electric power is widely available at moderate cost. It is an

important part of the industrial infrastructure.

Electric power can be readily converted to alternative

energy forms: mechanical, thermal, light, acoustic,
hydraulic, and pneumatic.
Electric power at low levels can be used to accomplish

functions such as signal transmission, information
processing, and data storage and communication.
Electric energy can be stored in long-life batteries for use

in locations where an external source of electrical power is
not conveniently available


Power to accomplish the Automated
System
Figure-4: Power to accomplish the Automated System

Safety monitoring
Safety monitoring solutions automatically transmit a safety

alert when an employee becomes incapacitated or otherwise
unable to request help manually using the monitoring device.
Such automation often comes in two forms:
(1) fall detection that determines when an employee has fallen
using accelerometers & gyroscopes.
(2) man-down alerting that causes the device to automatically
trigger an alarm when a total lack of motion is detected for a
configurable period of time.
Automation ensures that any injured employee will receive
aid promptly through a pin-point response rather than
waiting for an alarm to sound at the next missed check-in
perhaps one or two hours later.

Safety monitoring
Automated safety monitoring has applications in nearly

every industry and organization that manages the safety of
its personnel.
These solutions establish a new best practice in delivering

precise, prompt help to employees in distress.
Between this and the time and cost-efficiency benefits, all

organizations should examine if the move to an automated
employee safety monitoring is of value to them.

Safety monitoring
Automated safety monitoring is easy to implement, making

it an ideal successor to current methods.
Such safety monitoring systems are predominantly web-

based, providing the greatest level of compatibility on
computers and mobile devices and ensuring that critical
information can be accessed from any location by any
authorized personnel.
These solutions are designed to facilitate rapid adoption by

management and employees alike and include an option for
central monitoring of emergency alerts to reduce the
internal burden of monitoring upon current personnel.

Maintenance and Repair Diagnostics
Automated production systems are becoming increasingly
complex and sophisticated, thus complicating the problem
of maintaining and repairing them.
Maintenance and repair diagnostics refers to the capabilities

of an automated system to assist in the identification of
the source of potential or actual malfunctions and failures
of the system.
Three modes of operation are typical of a modern

maintenance and repair diagnostics subsystem

Status Monitoring
In the status monitoring mode, the diagnostic subsystem

monitoring and records the status of key sensors and
parameters of the system during normal operation.
On request, the diagnostics subsystem can display any of

these values and provide an interpretation of current
system status, perhaps warning of an imminent failure

Failure diagnostics
The failure diagnostics mode is invoked when a

malfunction or failure occurs.
Its purpose is to interpret the current values of the

monitored variables and to analyze the recorded values
preceding the failure so that the cause of the failure can be
identified

Recommendation of repair procedure
The third mode of operation the subsystem provides a

recommended procedure to the repair crew as to the steps
that should be taken to effect repairs.
Methods for developing the recommendations are

sometimes based on the use of expert systems in which the
collective judgments of many repair experts arc pooled
and incorporated into a computer program that uses
artificial intelligence techniques.

Error Detection and Recovery
In the operation of any automated system, there are hardware
malfunctions and unexpected events that occur during
operation.
These events can result in costly delays and loss of
production until the problem has been corrected and regular
operation is restored.
Traditionally equipment malfunctions are corrected by human
workers, perhaps with the aid of a maintenance and repair
diagnostics subroutine.
With the increased use of computer control for manufacturing
processes, there is a trend toward using the control computer
not only to diagnose the malfunctions but also to
automatically take the necessary corrective action to restore the
system to normal operation.

Error Detection
 Indicated by the term. error detection blind recovery consists

of two steps:
(1) Error detection and
(2) Error recovery.
The error detection step uses the automated systems available
sensor systems to determine when a deviation or
malfunction has occurred, correctly interpret the sensor
signal(s), and classify the error.
Design of the error detection subsystem must begin with 11
classification of the possible errors that can occur during
system operation.

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SRI RAMAKRISHNA ENGINEERING COLLEGE

VATTAMALAIPALAYAM, N.G.G.O. COLONY POST, COIMBATORE – 641 022.

DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 1

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 3

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 4

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 5

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 6

Programmable Logic Controller

Electronic Control using Logic Gates

Hard wired logic Control

 Here, the term “machine” can be anything like a motor, drill,

 There are several factors that lead to the implementation of

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 8

 Industrial Automation is a process of operating machines and

 The above definition is definitely not a simple one to

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 9

 The dictionary defines automation as “the technique of

 We define automation as "the creation and application of

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 10

 Consider a manual industrial production process, where an

 Once the necessary temperature is achieved, it has to be

 Now, there is motorized valve, which is also controlled by the

 Based on the temperature readings. The timer in the computer

Figure-1: Block diagram of Automation in process industry

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 13

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 14

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 15

Different Types of Industrial Automation Systems

Fixed Automation. Also referred to as hard automation,

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 16

Also referred to as hard automation, fixed automation systems

An example of a fixed automation equipment would be an

Just like all other fixed automation system equipment,

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 17

 This type of automation is common in mass production

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 18

 Also referred to as soft automation, this type of automation is

 Every equipment receives instructions from a human-operated

 This type of automation would typically be used in batch

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 19

 Integrated automation involves the total automation of

 Computers can design the necessary parts, test the designs,

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 20

Three level representation of a typical Industrial Automation

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 21

Figure-2: Levels of Automation in process industry

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 22

Sitting at the top of hierarchy, the supervisor level usually

These PCs run on standard operating systems with a special

The main purpose of the software is process visualization

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 23

The Control Level is the mid-level in the hierarchy and this is

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 24

The terminal equipment like Sensors and Actuators are

The sensors like temperature, optical, pressure etc. and

Both wired and wireless networks are used for

05/21/24 Mr.I.Aravindaguru,Asst.Prof/EIE- Module 1 25

Figure-3: Levels of Automation in process industry