Industrial Automation

1 What is Industrial Automation?

2 Automation Device Systems and Structures

3 Process Periphery
4 Real-time Programming
5 Real-time Operating Systems
6 Programming Languages for Industrial Automation
7 Reliability and Safety of Industrial Automation Systems

IAS, Universitt Stuttgart 1

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.1.1 Technical Process
1.1.2 Industrial Automation
1.1.3 Real-time System

1.1.4 Automation Computer

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment
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1.1.1 Technical process

Definition #1:
A technical process is a process during which material, energy or
information is altered in its state. This modification of state can imply
the transition of an initial state to a final state.

process, procedure, event

TECHNICAL
initial state of final state of
PROCESS
material, energy material, energy
or information or information
in a technical system

transformation
transport storage

refers to: flow of material, energy or information

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1.1.1 Technical process

Examples

Initial State Technical Process Final State

in a technical system
Low ambient Thermal process regarding Higher ambient temperature
temperature house heating with an oil-fueled
heating system
Dirty laundry Washing process in a washing Fresh laundry
machine
Unsorted parcels Transportation and distribution Parcels sorted by destinations
process in a parcel distribution
system
Energy of fossil or Enegry transformation and Electric energy
nuclear fuels energy generation processes in
a power plant
Parts to be stored Storage process in a high bay Parts compiled for commissions
warehouse
Train at location A Traffic process of a train journey Train at location B
Monomere substance Process in a chemical reactor Polymeric substance
Untested device Test process in a test laboratory Tested device
Parts without a drill- Drilling process of a drilling Parts with drill-hole
hole machine
Pollutants Process in a system for pollution Information on pollution
monitoring concentrations are indicated in
monitoring center

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1.1.1 Technical process

Definition #2: DIN 66201

A process is the entirety of all interacting processes within a system
that transforms and stores material, energy or information.
A technical process is a process in which its physical parameters
are recorded and influenced by technical means.
affectuating output
variables quantities

material,
material, energy
energy or
or information
information
TECHNICAL PROCESS outflow
inflow

in a technical system

from simple to highly complex washing machine, power plant

different partial processes are combined to an overall process
car with automotive electronics

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1.1.1 Technical process

Technical system with technical process

actuating measured
signals signals

material, energy or material, energy or

information inflow Technical System information outflow

(device, machine
or technical plant)

process-
influencing process
information outcome
information
process
input the technical
variables
process process runs on
Technical Process output technical system
variables

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1.1.1 Technical process

Example for a technical plant with technical process

actuating signals measured signals
Technical Plant

substance A
substance B

substance
C

Technical Process

feed outflow
substance A reac- reaction
fill empty
tion product
feed
substance C
substance B

technical plant: chemical reactor

technical process: 3 sub-processes (fill, reaction, empty)

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.1.1 Technical Process
1.1.2 Industrial Automation
1.1.3 Real-time System

1.1.4 Automation Computer

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment
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1.1.2 Industrial Automation

Industrial automation
= process + automation

automat = independently
cigarette vending machine operating
technical systems
ticket vending machine

automation = to enable machines,

office automation, installations and facilities
to operate independently
traffic automation,
railway automation,
industrial automation

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1.1.2 Industrial Automation

industrial automation

= the automation of a technical process

industrial automation system

= technical system with technical process

+ computer and communication system
+ process operators

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1.1.2 Industrial Automation

Structure of an industrial automation system

people
(process operators)
for managing and
operating the technical
process as well as
intervening in
exceptional situations

process process
influence outcome

computer and communication system

consisting of e.g., programmable logic
controllers (PLC), industrial PCs, micro
controllers, bus systems, etc.

control signals
signals from the
to the
technical process
technical process

technical system
(technical product or technical plant ), in
which a technical process takes place

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1.1.2 Industrial Automation

industrial automation system

goal is the automation of operations in the technical process with the

help of appropriate information processing units

human operators only places requests on the operating results

automation of the technical
process in the foreground

process control system

goal is the management of the procedure of the technical process by
human operators, supported by the automation of individual
operations
operation in the
managing refers to controlling and regulating
foreground
process computer sciences
goal is an automation software system
real-time system computer and communication
system in the foreground

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.1.1 Technical Process
1.1.2 Industrial Automation
1.1.3 Real-time System

1.1.4 Automation Computer

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment
IAS, Universitt Stuttgart 13

1.1.3 Real-time System

Definition: DIN 44300

Real-time operation is the operation of a computer system, in which
programs required for the handling of arising data are in constant
operation so that the processing results are available within a given period
of time.
This data may appear according to a random time distribution or at regular
intervals.

Features of a real-time system

hardware/software system

data reception, data processing, data delivery to the process within a

given time limit

external events
processing priority

Real-time system allows real-time operation

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1.1.3 Real-time System

Requirements on real-time systems

timeliness
reaction right on time

not too soon, not too late

simultaneousness
simultaneous reaction to various events
parallel processes

dependability
reliable, safe, available

important reason for purchase

predictability
all reactions must be planable and deterministic

comprehensible in case errors occur

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1.1.3 Real-time System

Industrial automation system are real-time systems

people external
influences
time time

sensor signals
computer and technical process
communication in a
system control signals technical plant

operating personnel

computer and communication

system
technical process

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.1.1 Technical Process
1.1.2 Industrial Automation
1.1.3 Real-time System

1.1.4 Automation Computer

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment
IAS, Universitt Stuttgart 17

1.1.4 Automation Computer

Features

Processors applicable in a process automation system are free

programmable digital processors (computers) that have to show
mainly 3 features:

Compliance of real-time operation requirements, that is recording,

processing and output of process data in a timely manner

Possibilities for input/output of process signals (directly or via a

communication system) for process connection

Processing of numbers, characters and bits

In 60th and 70th years specific process computers

- Term antiquated, because differences disappeared

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1.1.4 Automation Computer

Different forms of automation computers

programmable logic controller (PLC)

micro controller

personal computer (PC)

process control system

IAS, Universitt Stuttgart 19

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment

1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

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1.2 Degree of Automation and Computer Deployment

Degree of automation:

The sense and benefit of an automation depends of the technical process

(accessible / inaccessible) and the general conditions (economically
reasonable / senseless). The degree of automation describes the extend of
the processes included in the automation.
bandwidth: from zero up to fully automated operation

Caution! - Also with fully automated operation the human being can
make interventions (set point default or malfunction)!

Types of operation:

off-line operation (operation with indirect process connection) with the

lowest degree of automation
on-line / open-loop operation (open on-line operation) for a medium
degree of automation
on-line / closed-loop operation (closed on-line operation) for a high degree
of automation

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1.2 Degree of Automation and Computer Deployment

Operation without computer use

general management
orders

operation
accounting

operation
protocol applications for
the process
management

process
personnel
no automation
control and
regulation
devices display device
and graphical
recorder

manual
device

technical plant

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 1.2 Degree of Automation and Computer Deployment

Off-line operation (indirectly connected operation)

input,
operation modes,
instructions

general management orders

input of the
operation
protocol operation
protocol
off-line-
computer instruc-tions
for the
process
manage-ment
process
personnel
control and
regulation low degree of
devices display device
and graphical automation, no
recorder
connection to
the technical
manual process
device

technical plant

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1.2 Degree of Automation and Computer Deployment

On-line/ open-loop operation

general management orders

operation
monitoring operation
protocol

control board instructions

medium degree
open- of automation,
loop data acquisition
control and from the
regulation process
devices personnel technical process
computer
system

on-line
manual
device

technical plant

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 1.2 Degree of Automation and Computer Deployment

On-line-/ closed-loop operation

operation management
and control
orders

on-line und
closed-loop operation
protocol
high degree of
automation, data
computer and communication system recording and
emergency influence of the
emergency instruments technical process
control

technical plant

IAS, Universitt Stuttgart 25

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.3.1 Types of automation systems
1.3.2 Product automation
1.3.3 Plant automation
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

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1.3.1 Types of automation systems

product automation

industrial automation systems, in which the technical process takes place

within a device or within a single machine

large quantities

plant automation

industrial automation systems, in which the technical process is composed of

single partial processes that take place on greater, often geographically wide
spread plants

unique systems

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1.3.1 Types of automation systems

Examples for the two types of industrial automation systems

Examples of products in product Examples of technical plants

automation In plant automation
heating systems power plants (steam generator,
washing machines turbines, generators)
sewing machines energy grid
kitchen tools (e.g., dish washer, high bay warehouse
microwave, etc.) parcel distribution installations
TVs, radios chemical reactors
cameras process engineering installations
alarm systems steal production plants
toys milling installations
navigation systems railway traffic system ( long distance
answering machines trains, commuter railways, metros)
musical instruments traffic light installations
machine tools gas supply installations
measuring devices purification and water plants
automobiles with sub-systems: building system installations
motor control, ABS, distance laboratories and test fields
warning system, route planing, etc. environmental measurement
installations
etc.

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.3.1 Types of automation systems
1.3.2 Product automation
1.3.3 Plant automation
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions

1.6 Technical Systems

1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

IAS, Universitt Stuttgart 29

1.3.2 Product automation

Characteristic criteria regarding product automation

technical process in a device or machine (embedded systems)

dedicated automation functions simple

automation computer in the form of a micro controller or PLC

few sensors and actuators

degree of automation 100%, on-line/closed-loop operation

high quantities (serial or mass products)

engineering and software costs of inferior importance since they are

distributed among large unit numbers

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1.3.2 Product automation

Structure with simple product automation

user
or
operator

set values

display
example:
manipulated variables

micro controller kitchen tool

process results
technical product

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1.3.2 Product automation

Structure with complex product automation

user
or
operator

micro-
controller

bus system

example:
automotive
micro- micro- micro-
controller controller controller electronics
1 2 n

subsystem subsystem subsystem

1 2 n

technical product

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.3.1 Types of automation systems
1.3.2 Product automation
1.3.3 Plant automation
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions

1.6 Technical Systems

1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

IAS, Universitt Stuttgart 33

1.3.3 Plant automation

Characteristic criteria regarding plant automation

technical process in an industrial plant, often geographically wide

spread

extensive and complex automation functions

PLCs, PCs and process control systems are used as automation

computer systems

large number of sensors and actuators

medium to high degree of automation

unique system

engineering and software costs are critical for overall costs

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1.3.3 Plant automation

Structure for a larger technical plant

factory bus

observation, level 3
operating,
master protocolling
computer PC PC

plant bus
level2

PLC PLC PLC

field bus field bus

level1

sub- sub- sub-

system system system
technical plant

IAS, Universitt Stuttgart 35

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.4.1 Technical components
1.4.2 Sensors and actuators
1.4.3 Communication system
1.4.4 Automation computer system
1.4.5 Automation software system
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

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1.4.1 Technical components

technical components of an
industrial automation system

technical system to be facilities necessary for

automated (automation object) automation (automation system)

facilities for
technical technical user - process
product plant communication

hardwired individual
interface to the
devices
technical process:
sensors and actuators

communication system automation computer

system
communication bus system for the
system close to communication hardware system automation software
the process between (device system) system
(field bus) automation computers

computer process user system

hardware periphery software software

IAS, Universitt Stuttgart 37

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.4.1 Technical components
1.4.2 Sensors and actuators
1.4.3 Communication system
1.4.4 Automation computer system
1.4.5 Automation software system
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

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1.4.2 Sensors and actuators

Sensors

acquisition of information on the progression of process variables

sensors, detection devices, measuring devices
conversion into electrical or optical signals
examples: temperature,
pressure ,
velocity

Actuators

conversion of control information in order to influence process variables

actuators (correcting element)
examples : relays,
magnets,
servomotors

IAS, Universitt Stuttgart 39

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.4.1 Technical components
1.4.2 Sensors and actuators
1.4.3 Communication system
1.4.4 Automation computer system
1.4.5 Automation software system
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

IAS, Universitt Stuttgart 40

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1.4.3 Communication system

Communication system in product automation

simple products user

or
operator

set values
few sensors and actuators

display
manipulated variables
short line distances micro controller

process results
technical product

complex products

communication between subsystems via bus system

examples: CAN bus, Interbus-S user
or
operator

micro-
controller

bus system

micro- micro- micro-

controller controller controller
1 2 n

subsystem subsystem subsystem

1 2 n

technical product

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1.4.3 Communication system

Communication system in plant automation

many sensors and actuators, geographically distributed

many automation computers, geographically distributed

Communication tasks on several levels

factory bus

factory bus observation, level 3

operating,
master protocolling
computer PC PC

plant bus
plant bus (process bus) level2

PLC PLC PLC

field bus field bus

field bus level1

sub- sub- sub-

system system system
technical plant

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.4.1 Technical components
1.4.2 Sensors and actuators
1.4.3 Communication system
1.4.4 Automation computer system
1.4.5 Automation software system
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

IAS, Universitt Stuttgart 43

1.4.4 Automation computer system

Programmable Logic Controller (PLC)

originally replacement for relay and contactor control (1-bit-computer)

today wide range of service up to the operation of big machine
compounds
programming through specific programming devices with the aid of
ladder diagram or function diagram

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1.4.4 Automation computer system

Micro controller (One-chip-computer)

highly integrated components

employment for mass products

composition of

standard Micro processor

data memory / program memory
bus interfaces
process signal interfaces

programming with development system

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1.4.4 Automation computer system

Personal Computer (PC) resp. Industrial PC (IPC)

for adverse environment deployment of industrial PCs

plugable circuit boards for connection of

electrical process
signals
optical process
signals
bus systems

programming in high-level language

use of real-time operating systems

as single operating system

in addition to standard operating systems

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1.4.4 Automation computer system

Process control system - PCS (1)

distributed computer systems, connected via bus systems

usage of prefabricated program modules developed by the

manufacturer of the PCS

configuration by operator

interconnection with PLC computers

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1.4.4 Automation computer system

Process control system (2)

operation
master
computer
factory
bus

display and display and

engineering
operation operation
station
component component

redundant manufacturer-specific system bus

field level field level field level

component component component

sensors and actuators field bus field device

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.4.1 Technical components
1.4.2 Sensors and actuators
1.4.3 Communication system
1.4.4 Automation computer system
1.4.5 Automation software system
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

IAS, Universitt Stuttgart 49

1.4.5 Automation software system

Automation software system

set of all programs necessary for the execution of automation tasks,

including their documentation

differentiation between executive and organizational/administrational

tasks

executive programs organizing and administrating

(application software) programs (operating software
or system software)
input measured values
software device drivers
calculation of control
variables operating system

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1.4.5 Automation software system

Application software System software

programs for organizing

programs for acquisition of
execution of application
process variables
programs

operating system
programs for process programs for managing
monitoring peripheral devices

programs for organizing

programs for process control data traffic with external
memories

programs for the dialogue

programs for process between human and
regulation computer

programs for process

optimization und compilation programs
management

programs for process safety

run-time programs
and security

IAS, Universitt Stuttgart 51

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

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1.5 Levels of Process Management and Automation Functions

Model of levels in the management of a technical process

levels of hierarchy levels in distribution levels of a company

long-term business management

strategic distribution policy level
level

dispositive production
distribution planning
level management level

tactical level distribution tactic process control level

level of measuring
operative level controlling and regulat
sales
ing process variables
(process variable level)

field of action market technical process in a

technical system

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1.5 Levels of Process Management and Automation Functions

Time requirements on the different levels

business management level: Effects ranging between

months-years

operation / production management level: Effects ranging between

days-weeks-months

process control level:

Effects ranging between
minutes-hours

process variable level: Effects ranging between

microseconds-seconds

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1.5 Levels of Process Management and Automation Functions

Automation functions
Levels of a company Automation functions

business cost analysis,

management level statistical evaluations

production and work sequence planning,

operation capacity optimization,
management level evaluation of process results

process monitoring,
process control start-up and shut-down,
level malfunction handling, process
guidance, process security

measuring, controlling,
manipulating, regulating
process variable
interlocking, emergency
level
handling of process
variables,shut-down, protection

recording and influencing

field level process variables with sensors
and actuators

IAS, Universitt Stuttgart 55

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.6.1 Process variables in technical systems
1.6.2 Processes in technical systems
1.6.3 Classification of technical systems
1.6.4 Assignment of technical production processes to
process types
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

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1.6.1 Process variables in technical systems

Types of occurring process variables

Process variables, that are allocated to the course of physical

state-variables with a continuous or piecewise continuous range of values
example: temperatures in a heating system

Process variables, that are allocated to certain discrete process states

physical variables with a continuous range of values that characterize
the process states
binary process variables that are allocated to state transitions i.E., To
events that cause the change of state

example: switch setting: 0/off - 1/on

IAS, Universitt Stuttgart 57

1.6.1 Process variables in technical systems

Types of occurring process variables

process variables that are allocated to individually identifiable objects

physical variables with a continuous range of values
example: temperature of a slab in a clogging mill,
size of a part in a store
identification numbers i.e., non-physical variables
example: type, design, application, depot number

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.6.1 Process variables in technical systems
1.6.2 Processes in technical systems
1.6.3 Classification of technical systems
1.6.4 Assignment of technical production processes to
process types
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

IAS, Universitt Stuttgart 59

1.6.2 Processes in technical systems

Definition of three process types in technical systems

continuous processes

sequential processes, discrete event type processes

object-oriented processes

Caution! - a clear distinction is not always possible !

example: transportation as a continuous and object-oriented process

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1.6.2 Processes in technical systems

Continuous processes in technical systems

Characteristics processes containing timedependent continuous

process variables

Process variable physical variables with a (at least piece-wise)

continuous range of values
Examples generation processes,
transformation processes,
movements, etc.
Mathematic differential equations (time as an independent
models variable), transfer functions

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1.6.2 Processes in technical systems

Sequential processes in technical systems

Characteristics processes containing sequences of

different, distinguishable process states
Process variables binary signals that cause or indicate
discrete process states as well as
continuous physical variables allocated to
process states
Examples sequences of process states during start-
up or shut-down of a turbine,
sequence of states during the operation of
an elevator, sequence of states during
production using a machine tool
Models flow charts, state models, Petri nets,
function plans according to DIN 40719

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1.6.2 Processes in technical systems

Object-oriented processes in technical systems

Characteristics processes during which individually

identifiable objects are transformed,
transported or stored
Process physical variables with a continuous
variables range of values or non-physical
variables (e.g., type, design,
application, bay number) that are
allocated to the objects, as well as
binary variables, that cause or indicate
state changes of objects
Examples processes during the manufacturing of
parts, traffic processes, storage
processes, information processes in
computers
Models simulation models, queue-models, state
models, Petri nets

IAS, Universitt Stuttgart 63

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.6.1 Process variables in technical systems
1.6.2 Processes in technical systems
1.6.3 Classification of technical systems
1.6.4 Assignment of technical production processes to
process types
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

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1.6.3 Classification of technical systems

Classification methods

Classification according to the kind of...

transformed or transported medium
material related processes, energy related processes,
information related processes

effect
generation processes, distribution processes, storage processes

material-related transformation
chemical processes, production processes

dominating process type

flow processes (continuous), successive processes (sequential),
piece-related processes (object-related)

IAS, Universitt Stuttgart 65

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.6.1 Process variables in technical systems
1.6.2 Processes in technical systems
1.6.3 Classification of technical systems
1.6.4 Assignment of technical production processes to
process types
1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

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1.6.4 Assignment of technical production processes to process types

Assignment of technical production processes to process

types
Technical production Process types
processes
Energy-related continuous processes,
processes sequential processes
chemical processes continuous processes,
sequential processes
production processes continuous processes,
sequential processes,
object-related processes
material-handling continuous processes,
processes sequential processes,
object-related processes

Technical processes can contain processes of different types,

on the other hand a process in turn can be a technical process.

IAS, Universitt Stuttgart 67

1.6.4 Assignment of technical production processes to process types

Examples:

generation of electric energy in a turbo generator

continuous process
sequential process (start-up sequence of plant)
energy-related processes

batch processes
single process steps are continuous processes
sequence of steps is a sequential process

Chemical processes
manufacturing a turned part
transportation of the sleeve is an object-related process
manufacturing process consists of a sequence of steps (mount part,
drive drilling machine to position etc.), thus it is a sequential process
machine-cutting process is a continuous process

production process

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34
Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems

1.7 Graphical representation of technical processes

1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and Environment

IAS, Universitt Stuttgart 69

1.7 Graphical representation of technical processes

Flowchart
similar to block diagrams used in control engineering
processes and process steps are represented as rectangles
arrows represent the information or material flow
bundles of connections are shown as double lines with arrow

Example:

additive
crush
additive solvent
chrused

raw material

dissolve reaction separate

inter- final product
material
mediate
solvent dissolved product

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1.7 Graphical representation of technical processes

Information/material-oriented representation

information/materials as circles
processes/functions as linking arrows

Example

additive crus
h
additive
crushed
rea
ctio ion solvent
n rat
epa
s
inter-
material diss mediate
olve
product sep
n ara
ctio tion
material rea final
dissolved product

olve
diss
solvent

IAS, Universitt Stuttgart 71

1.7 Graphical representation of technical processes

Phase model representation

mixture of flowchart and information/material-oriented representation

Example

sub
additive
additive process solvent
crushed
"crush"

inter-
reaction mediate separate
raw product
material
sub
material
process final
dis-
"dis product
solved
solving"
solvent

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1.7 Graphical representation of technical processes

Examples for the flowchart representation

additive
crushing
raw material
final product
solvent dissolving reaction separation

solvent

simple flow chart

additive solvent

heating steam
350 kg/h 700 kg/h

3 bar
x z1
M1 M2
raw material M
800 kg/h M W1

solvent
1000 kg/h heating 1 bar
steam 108 C
B1 B2
1 bar 1 bar final product
20 C 20 C 1450 kg/h

depot

P1 P2

process flow chart

IAS, Universitt Stuttgart 73

1.7 Graphical representation of technical processes

heating steam
solvent
5 bar
700 kg/h

V301
F1
additive
350 kg/h V302 V304
V206
V303

raw material
FRC
1.01
M
3h
M1 Z1 X TRC
1.02
800 kg/h
M2 M W1
V101 V102 V103 3h
V201 V202 V203 V105 V112 LRC
V111 1.04
K1
solvent FRC
V305
1000 kg/h M
2.01
V204 3h
B1 B2 A1
TRC
1.02
W3
LRC LRC
1.03 1.04 V306
V301
M
3h
M M LRC+
W2 V302 V116
3h 3h 1.04

P1 P2 V303

V106 V107 V106 V110

final product
1450 kg/h
condensate

Pipes and instrumentation flow diagram

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions

1.6 Technical Systems

1.7 Graphical representation of technical processes

1.8 Examples of Industrial Automation Systems

1.8.1 Product automation
1.8.2 Plant automation
1.9 Effects of Industrial Automation on People, Society and Environment

IAS, Universitt Stuttgart 75

1.8.1 Product automation

Automation system of an industrial washing machine

PI-flowchart

A B C
tank
drawer
soft cold

soft hot

hard cold

steam or electrical
drum
heating

waterpump

drain
dosage pump

filter M

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1.8.1 Product automation

Simplified block diagram

user

automation system

input and display

chip card interface
modul
human-process-communication

micro computer

program system 1: evolution & operating

program system 2: control and monitoring

door position
temperature

tank valve
unbalance

heating
valve 1

valve n
level

motor

pump
sensors actuators

technical process in technical system

"washing machine"

IAS, Universitt Stuttgart 77

Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Basic Process Types in Technical Systems

1.7 Graphical representation of technical processes

1.8 Examples of Industrial Automation Systems

1.8.1 Product automation
1.8.2 Plant automation
1.9 Effects of Industrial Automation on People, Society and Environment

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1.8.2 Plant automation

Automation system of a heating and industrial water system

PI-flowchart radiator im room 1 radiator in room n

exhaust gas flap

circulation
smokestack pump

low-
forced-air temperature
burner boiler load pump

cold
fuel-oil feed-water industrial
feed water industrial water
reservoir

IAS, Universitt Stuttgart 79

1.8.2 Plant automation

Simplified block diagram

prozess automation system

residents

automation system

equipment for human-process communication

computer 1 (PLC) computer 2 (PLC)

program system 1 "control and program system 2 "evalution and

monitoring" operating"

hardware 1 hardware 2
industrial water temp.

smoke stack pressure

outdoor temperature

inlet-air temperature

room temperature n
room temperature 1

forced-air burner
circulation pump
exhaust gas temp.

exhaust gas flap

CO 2 in exhaust gas
boilertemperature

inlet temperature

load pump
oil level

"sensors" "actuators"

detection devices for measurment of correcting element to influence the

process variables technical process

TECHNICAL PROCESS consists of the thermal process

in the building and of the process in the low-temperature heating system

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Industrial Automation

1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions

1.6 Technical Systems

1.7 Graphical representation of technical processes
1.8 Examples of Industrial Automation Systems
1.9 Effects of Industrial Automation on People, Society and
Environment

IAS, Universitt Stuttgart 81

1.9 Effects of Industrial Automation on People, Society and Environment

Intentional (positive) effects of industrial automation

simplified and more convenient operation

automation of a washing machine
automation of a heating system

production of better, cheaper products of even quality with lowered

production costs
automation of chemical production processes

reduction of of the endangerment of people

ABS system
traffic system automation (like inductive train security, automatic
barrier close)

better, more humane working conditions

automation of painting or foundry work

Securing jobs through higher competitiveness

use of robots in automobile manufacturing

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1.9 Effects of Industrial Automation on People, Society and Environment

Unintentional (negative) effects of industrial automation

redundancy of workers may lead to unemployment

use of robots in manufacturing

restructuring of jobs due to changes in work flow and fields of work

lower/ higher qualified jobs
drop of ancillary tasks
increase of jobs in the service sector

reduction of human relationships

introduction of ticket vending machines and information systems

increase of stress and reduction of relaxing tasks

automation of testing systems

overtaxing in difficult situations

safety-critical decision in a nuclear power plant

IAS, Universitt Stuttgart 83

1.9 Effects of Industrial Automation on People, Society and Environment

industrial automation has effects on:

people
society
environment
energy and resources

The automation engineer is responsible for the effects of

industrial automation

Dilemma: trade-off between benefits and damage

direct, immediate responsibility

damages in industrial automation systems designed by him
violations of generally accepted guidelines and regulations
(regulations of the VDE, etc.)
safety of automation systems

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1.9 Effects of Industrial Automation on People, Society and Environment

indirect, oblique responsibility

unintentional side effects

important: sense of responsibility

of the automation engineer

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