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EMBEDDED CONTROL SYSTEMS
LECTURE -2-
INDUSTRIAL AUTOMATION
1 زينب محمود عمر.د
2021
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Industrial Automation is a discipline that
includes knowledge and expertise from various
branches of engineering including electrical,
electronics, chemical, mechanical,
communications and more recently computer and
software engineering. Automation & Control by
its very nature demands a cross fertilization of
these faculties.
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Automation engineering is a cross sectional
discipline that requires proportional knowledge
in hardware and software development and their
applications.
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In the past, automation engineering was mainly
understood as control engineering dealing with a
number of electrical and electronic components.
This picture has changed since computers and
software have made their way into every
component and element of communications and
automation.
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Industrial Automation Engineers have always
drawn new technologies and implemented
original or enhanced versions to meet their
requirements. As the range of technology
diversifies the demand on the innovative ability
of these Engineers has increased.
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Automatic mode: When the controller
generates an output signal based on the
relationship of process variable (PV) to the
setpoint (SP).
Manual mode: When the controller’s decision-
making ability is bypassed to let a human
operator directly determine the output signal
sent to the final control element. 6
INDUSTRY
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In a general sense the term “Industry” is defined
as follows.
Definition: Systematic Economic Activity that
could be related to Manufacture/Service/ Trade.
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AUTOMATION
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The word ‘Automation’ is derived from greek words
“Auto”(self) and “Matos” (moving). Automation
therefore is the mechanism for systems that “move by
itself”. However, apart from this original sense of the
word, automated systems also achieve significantly
superior performance than what is possible with
manual systems, in terms of power, precision and
speed of operation.
Definition: Automation is a set of technologies that
results in operation of machines and systems without
significant human intervention and achieves
performance superior to manual operation 8
CONTROL
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Definition: Control is a set of technologies that
achieves desired patterns of variations of
operational parameters and sequences for
machines and systems by providing the input
signals necessary.
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AUTOMATION AND CONTROL
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It is important to understand some of the differences
in the senses that these two terms are generally
interpreted in technical contexts and specifically in
this course. These are given below.
1. Automation Systems may include Control Systems
but the reverse is not true. Control Systems may be
parts of Automation Systems.
2. The main function of control systems is to ensure
that outputs follow the set points. However,
Automation Systems may have much more
functionality, such as computing set points for control
systems, monitoring system performance, plant
startup or shutdown, job and equipment scheduling
etc. 10
ROLE OF AUTOMATION IN INDUSTRY
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The fundamental objective of any industry is to
make profit.
profit can be maximized by producing good
quality products, which may sell at higher price,
in larger volumes with less production cost and
time
Systems such as Automated Guided Vehicles,
Industrial Robots, Automated Crane and
Conveyor Systems reduce material handling
time.
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Automation also reduces cost of production
significantly by efficient usage of energy,
manpower and material.
The product quality that can be achieved with
automated precision machines and processes
cannot be achieved with manual operations.
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COMPUTER NUMERICALLY CONTROLLED (CNC)
MACHINE
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THE FUNCTIONAL ELEMENTS OF
INDUSTRIAL AUTOMATION
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An Industrial Automation System consists of
numerous elements that perform a variety of
functions related to Instrumentation, Control,
Supervision and Operations Management related
to the industrial process.
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These elements may also communicate with one
another to exchange information necessary for
overall coordination and optimized operation of
the plant/factory/process.
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The first step, naturally, is measurement. If we can’t
measure something, it is really pointless to try to
control it. This “something” usually takes one of the
following forms in industry:
• Fluid pressure
• Fluid flow rate
• The temperature of an object
• Fluid volume stored in a vessel
• Chemical concentration
• Machine position, motion, or acceleration
• Physical dimension(s) of an object
• Count (inventory) of objects
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• Electrical voltage, current, or resistance
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Once we measure the quantity we are interested
in, we usually transmit a signal representing this
quantity to an indicating or computing device
where either human or automated action then
takes place.
If the controlling action is automated, the
computer sends a signal to a final controlling
device which then influences the quantity being
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measured.
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Industrial measurement and control systems
have their own unique terms and standards.
Which are:
Process: The physical system we are attempting
to control or measure. Examples: water filtration
system, molten metal casting system, steam
boiler, oil refinery unit, power generation unit.
Process Variable, or PV: The specific quantity
we are measuring in a process. Examples:
pressure, level, temperature, flow, electrical
conductivity, pH, position, speed, vibration.
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FUNCTIONAL CONFIGURATION OF A TYPICAL
SENSOR SYSTEM
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Controller: A device that receives a process variable
(PV) signal from a primary sensing element
(PSE) or transmitter, compares that signal to the
desired value for that process variable (called the set
point), and calculates an appropriate output signal
value to be sent to a final control element (FCE) such
as an electric motor or control valve.
Final Control Element, or FCE: A device that
receives the signal from a controller to directly
influence the process. Examples: variable-speed
electric motor, control valve, electric heater.
Manipulated Variable, or MV: Another term to
describe the output signal generated by a controller.
This is the signal commanding (“manipulating”) the 25
final control element to influence the process.
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THE END
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