Industrial Automation

Contents of todays discussion:

Need of Automation.
Elements of Automation system.
Types of Automation.
Power sources in Automation.
Introduction to Pneumatic Automation.
Some examples on Automation.

Automation and its need

Consider the following Situations in Industrial
Environment:

To perform repetitive tasks with consistency.

To store large amount of data.
Reliable retrieval of the stored data.
To perform multiple tasks at the same time.
To apply high power and forces.
To Perform computations quickly.
To make quick routine decisions.

Human assistance in the above circumstances is

subjected to limitations.
This necessitates Automation.

Reasons for Automation

To increase the productivity.
To reduce labor cost.
To eliminate or minimize routine manual and
clerical tasks.
To improve the industrial safety.
To improve product quality.
To reduce the manufacturing lead time.
To accomplish the processes that cant be done
manually.
To avoid the high cost of not automating.

Automation and its History:

Automation is a technology by which a process is carried
out without human assistance.
History of automation can be traced to the development
of basic mechanical devices like wheels, cams, screws
and gears. These devices are used to generate POWER
Use of governors for the speed control of the steam
engine was done by James watt and his partner Mathew
Bolton in 1765.This was the first example of CONTROL
SYSTEM.
Jacquored used for the first time the PROGRAM OF
INSTRUCTIONS in 1800 for his loom to determine the
weaving pattern of the cloths.

Basic Elements of Automated

System
POWER

PROGRAM OF
INSTRUCTIONS

CONTROL
SYSTEMS

PROCESS

Types of Automation
Fixed Automation.
Programmable Automation.
Flexible Automation.

Automation Types Vs Product

Quantity and Variety
Programmable
Automation
Flexible
Automation

Product
Variety
Manual
Production

Fixed
Automation

Production Quantity

Power sources ( Working media) in

Automation

Electrical.
Pneumatic.
Hydraulic.
Combination of the above.

Pneumatics Versus Hydraulics

Pneumatics

Hydraulics

1. Higher speed. Usually 1.5 to 3

meters/sec.

1. Slow speed. Usually up to 0.5

meters/sec.

2. Forces available up to 5x103 N.

2. Forces available up to 5x107 N.

3. Pneumatics is not suited for

temperatures beyond 200C

3. Hydraulics is not suited for

temperatures beyond 100C.

4. Well suited for delicate handling

jobs.

4. Not suited for delicate handling

jobs.

5. Cylinder position is not predictable

under dynamic loads. Hence
smooth movement cannot be
guaranteed.

5. Cylinder position is highly

predictable for all kinds of loads.
Movement is therefore very
smooth.

6. Positioning of pneumatic cylinders

can be done with a moderate level
of accuracy. Usually 1 2 mm.

6. Positioning of hydraulic cylinders

can be done with much better
accuracy. Usually better than 0.25
mm.

7. Not well suited to handle high

starting loads.

7. Very well suited to handle high

starting loads.

Media Selection Criteria

Speed of Operation.
Reliability.
Service Life.
Sensitivity to Environment.
Ease of Maintenance.
Available Expertise.

Introduction to Pneumatics
Why choose Pneumatics ?
High Speed.
Inexpensive and mature technology.
Easily available, Low on cost.
Reliability.
Long service life.
Storage.
Transportable - No loss of power during storage.
Safety - Can be used in hazardous areas.
Coal Mines.
Petroleum Refining.
LPG Bottling.
Can be used in clean room areas.
Medicine & Pharma.

Applications in Industry
Automobile Production.
Petroleum Refining.
Petrochemicals.
Food & Confectionery.
Packaging & Handling.
Machine Tools.
Robotics.
Electronics - Pick and place.

Nature of Practical classes

You will perform the training on:
Basic Pneumatics.
Electro-Pneumatics.

Electro-Pneumatics using Programmable Logic Controllers.

Draw the circuit diagram according to the

situation given.
Check its correctness. You can use the demo
versions which will be kept on ftp.
Connect the different components according to
the diagram Carefully.
Check the working of the circuit.

An example

Pres
sct

In The Next Class We Shall

Discuss About The Principle of
Operations of Pneumatic circuits.