Industrial Automation T Rajendran. Industrial Automation Control Systems Process Control ...
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Transcript of Industrial Automation T Rajendran. Industrial Automation Control Systems Process Control ...
Industrial AutomationIndustrial Automation
Control SystemsControl Systems Process ControlProcess Control Industrial ControlIndustrial Control Computer Integrated ManufacturingComputer Integrated Manufacturing Systems ModelingSystems Modeling Systems EngineeringSystems Engineering Real Time ProgrammingReal Time Programming Software toolsSoftware tools
Expectation of AutomationExpectation of Automation
High ReliabilityHigh Reliability Fast Trouble shootingFast Trouble shooting Simple OperationSimple Operation Easily ConfigurableEasily Configurable High AccuracyHigh Accuracy Optimization functions and Optimization functions and
processing of operating dataprocessing of operating data FlexibilityFlexibility
Process ControlsProcess Controls
PC
IS
IntegratedControl &
Management systems
1960-70 1970-80 1980…
MIS
HistoryHistory
Pioneering period – 60 – Electronic Pioneering period – 60 – Electronic devicesdevices
Direct Digital controlDirect Digital control MicrocomputerMicrocomputer Computer controlled Process plantsComputer controlled Process plants
– CentralizedCentralized– DistributedDistributed– Process ModelsProcess Models– Advanced Control (AI)Advanced Control (AI)
Basic principles of controller loopBasic principles of controller loop
Memory - Set PointMemory - Set Point Comparator for set point (measured Comparator for set point (measured
value MV) as reported by transmittervalue MV) as reported by transmitter Deviation = errorDeviation = error Amplifier – amplifies the control Amplifier – amplifies the control
deviations – output of the controllerdeviations – output of the controller
Process ControlProcess Control
Open Loop ControlOpen Loop Control Closed Loop controlClosed Loop control
Process ControlProcess Control
Two position controlTwo position control Multi position controlMulti position control PID Proportional control PID Proportional control
(proportional, integral or derivative)(proportional, integral or derivative) Ratio controlRatio control Cascade control Cascade control
Controller OperationController Operation
controller-
Set point
error Control signal
Control element
sensorprocess
Measured value
Auto/manual
InstrumentationInstrumentation
PressurePressure FlowFlow liquid levelliquid level TemperatureTemperature Pneumatic and control valvesPneumatic and control valves
TransducersTransducers
To measure / senseTo measure / sense to convert measured value to a to convert measured value to a
useful outputuseful output
TransducersTransducers
MeasurementMeasurement– Type of measurandType of measurand– Number of measurementsNumber of measurements– Sensing measurementSensing measurement– Transduction elementTransduction element– Range of measurementRange of measurement
ConversionConversion– Specific formatSpecific format– AmplifiedAmplified– Conversion of AC to DCConversion of AC to DC
TransducersTransducers
ConventionalConventional SiliconSilicon Fiber OpticFiber Optic
Displacement / motion transducersDisplacement / motion transducers Temperature TransducersTemperature Transducers Pressure TransducersPressure Transducers Liquid level TransducersLiquid level Transducers Liquid FlowLiquid Flow
Intelligent SensorsIntelligent Sensors
On-chip signal processingOn-chip signal processing MEMS (Micro Electro Mechanical MEMS (Micro Electro Mechanical
Systems) sensorsSystems) sensors BIOSENSORSBIOSENSORS NANOSENSORSNANOSENSORS
NANOSENSORS & future trendsNANOSENSORS & future trends
1 nm = 1 millionth of a mm1 nm = 1 millionth of a mm
Building blocksBuilding blocks
The Processor The Processor Analog & Digital I/O modulesAnalog & Digital I/O modules interrupts, Timers/countersinterrupts, Timers/counters Display controlsDisplay controls SCADA (Supervisory control and SCADA (Supervisory control and
data acquisition systems)data acquisition systems)
Processing SystemProcessing System
The use of Microprocessors The use of Microprocessors (calculator chips & Mini computers)(calculator chips & Mini computers)
ArchitectureArchitecture– Input, Memory, Output, MicrpPInput, Memory, Output, MicrpP
Address bus, Data bus, control busAddress bus, Data bus, control bus 8 , 16, 32, 64 bits8 , 16, 32, 64 bits Microprocessors & microcontrollersMicroprocessors & microcontrollers
Analog & Digital I/O modulesAnalog & Digital I/O modules
Basic signalsBasic signals
Analog inputs
Digital inputs
Interrupt inputsTimer / counter inputs
Control outputs
Display outputs
Analog & Digital I/O modulesAnalog & Digital I/O modules
Basic signalsBasic signals
Analog inputs
Digital inputs
Interrupt inputsTimer / counter inputs
Control outputs
Display outputs
Inside look of a real time sysytemInside look of a real time sysytem
Processor & memory
module
Analog inputs
Digital inputs
Interrupt inputsTimer / counter inputs
Control outputs
Display outputs
Interruptcontroller Timer /
counter
Analo
g inpu
t m
odule
I/O modulesI/O modules
Analog input Analog input – From SensorsFrom Sensors– Measurand like flow, position, Measurand like flow, position,
temperature …temperature …– Signal may be amplified, filtered or/and Signal may be amplified, filtered or/and
isolatedisolated Digital inputDigital input
– Refer to ON-OFF status of valves, linit Refer to ON-OFF status of valves, linit switches.. (1 bit )switches.. (1 bit )
I/O modulesI/O modules
Interrupt input Interrupt input – Draw attention of real time system towards Draw attention of real time system towards
abnormal situationsabnormal situations– Attends to interrupt and resumes normal Attends to interrupt and resumes normal
workwork Timer / CounterTimer / Counter
– Clock input or Gate input to enable/ disable Clock input or Gate input to enable/ disable timer/counterstimer/counters
– Output of timer/counter can be used as Output of timer/counter can be used as interruptsinterrupts
I/O signalsI/O signals
Display output signalsDisplay output signals– LED, LCD, VDU, alarmsLED, LCD, VDU, alarms– Status of process, limits setsStatus of process, limits sets– May control or operator assistedMay control or operator assisted
Control output signalControl output signal– Required to drive the control valves, motors Required to drive the control valves, motors
etcetc– May be simple ON/OFF or fine control of May be simple ON/OFF or fine control of
motor speed, position, displacement, flow..motor speed, position, displacement, flow..– Analog signals / digital actuatorsAnalog signals / digital actuators
Analog inputAnalog input
The module continuously scans the The module continuously scans the analog input signals in the pre analog input signals in the pre defined order and frequencydefined order and frequency
Amplifies -> converts to digital -> Amplifies -> converts to digital -> processor and memory module for processor and memory module for processingprocessing
EPROM or switchesEPROM or switches Local intelligenceLocal intelligence
Digital InputDigital Input
Directly accepted by processorDirectly accepted by processor N bits in parallelN bits in parallel Local intelligenceLocal intelligence
Analog OutputAnalog Output
Digital multiplexerDigital multiplexer Digital to Analog converterDigital to Analog converter Master processor executes two I/O Master processor executes two I/O
instructionsinstructions– Write Data byte/word in digital output Write Data byte/word in digital output
portport– Write address byte/word in address port Write address byte/word in address port
Interrupt controlInterrupt control
Interface between no. of interrupting Interface between no. of interrupting devices and master processordevices and master processor
Priorities allocation- static or Priorities allocation- static or dynamic.dynamic.
Timer / CounterTimer / Counter
Number of timers and counters which Number of timers and counters which may be cascaded or used may be cascaded or used independentlyindependently
Count in the form of data byte/wordCount in the form of data byte/word Clock from the processor or externalClock from the processor or external
Display Control moduleDisplay Control module
Manual entry sub moduleManual entry sub module CRT controller sub moduleCRT controller sub module LED / LCD control sub moduleLED / LCD control sub module Alarm annunciator sub moduleAlarm annunciator sub module Printer controller sub modulePrinter controller sub module
SCADASCADA
Supervisory Control And Data Supervisory Control And Data Acquisition SystemsAcquisition Systems– Channel scanningChannel scanning– Conversion into engineering unitsConversion into engineering units– Data processingData processing
CIMCIM
cim
Process planning
drafting
MeM
fe
CNC
Robots
Schedudle
Prodplan
cad
Tool design
fms
simulation
ERP
Shop floor data
CAD / CAM / CIMCAD / CAM / CIM
CIM, Concurrent EngineeringCIM, Concurrent Engineering Product Life Cycle ManagementProduct Life Cycle Management Engineering ModelingEngineering Modeling CIM databasesCIM databases Computer aided process planningComputer aided process planning IT & ERPIT & ERP Manufacturing automation – PLC, Manufacturing automation – PLC,
CNC, RobotsCNC, Robots
CAD/CAM/CIMCAD/CAM/CIM
Flexible ManufacturingFlexible Manufacturing Shop Floor Data CollectionShop Floor Data Collection SimulationSimulation
Concurrent EngineeringConcurrent Engineering
DESIGN softwareDESIGN software– Solid ModelingSolid Modeling– Assembly modelingAssembly modeling– Sheet metal designSheet metal design– DraftingDrafting– Tolerance analysisTolerance analysis– Mechanism DesignMechanism Design– Mould DesignMould Design– Thermal AnalysisThermal Analysis– Piping DesignPiping Design– OptimizationOptimization– Tool DesignTool Design
Concurrent EngineeringConcurrent Engineering
Process PlanningProcess Planning ERPERP Shop Floor Data CollectionShop Floor Data Collection PLMPLM EDMEDM