Introduction to Industrial

Automation
- ETIA 31413 -
Faculty of Computing and
Technology

M r. M . M . S h e ya n U d aya n ga S i l va
B.ET(Hon.s) Specialization in Industrial Automation and Robotics
Te m p o r a r y L e c t u r e r
Control System Development FR

The development of the control system solution requires that the

problem is defined clearly. There are many ways of representing
the problem in a descriptive or graphical form.
• The methods of representing the control problem include:
• Positional sketch
• Motion diagram:
• - Displacement-Step Diagram.
• - Displacement-Time Diagram.
• Control chart
• Function diagram
• Function chart
• Circuit diagram
Department of Applied Computing 2
Control System Development FR
Po s i t i o n a l s ke tc h

The positional sketch shows the relationship between the

actuators and the machine fixture. The actuators are
shown in the correct orientation.
The positional sketch is not normally to scale and should
not be too detailed. The diagram will be used in
conjunction with the description of the machine operation
and the motion diagrams

Department of Applied Computing 3

Control System Development FR
Po s i t i o n a l s ke tc h

Department of Applied Computing 4

Control System Development FR
M o t i o n d i a g ra m :
The displacement-step diagram and the displacement-time
diagram are used for motion sequences.
Displacement-Step Diagram
The displacement-step diagram represents the operating
sequence of the actuators; the displacement is recorded in
relation to the sequence step. If a control system incorporates a
number of actuators, they are shown in the same way and are
drawn one below the other. Their interrelation can be seen by
comparing the steps.

Department of Applied Computing 5

Control System Development FR
M o t i o n d i a g ra m : D i s p l a c e m e nt - S te p D i a g ra m

Department of Applied Computing 6

Control System Development FR
M o t i o n d i a g ra m : D i s p l a c e m e nt - S te p D i a g ra m

• In this case there are two cylinders 1A and 2A. In

step 1 cylinder 1A extends and then cylinder 2A
extends in step 2. In step 3 cylinder 1A retracts
and in step 4 cylinder 2A retracts. Step number 5
is equivalent to step 1.

Department of Applied Computing 7

Control System Development FR
M o t i o n d i a g ra m : D i s p l a c e m e nt - t i m e d i a g ra m

• In the case of a displacement-time diagram, the

displacement is plotted in relation to the time.

Department of Applied Computing 8

Control System Development FR
C o nt ro l c h a r t
• In the control chart, the switching status of the
control element is represented in relation to the
steps or the time. The switching time is not taken
into account.
• The control diagram in the following figure shows
the statuses of the control components (1V for
cylinder 1A and 2V for cylinder 2A) and the status
of the limit switch 1S1 fitted at the front end
position of the cylinder 1A.
Department of Applied Computing 9
Control System Development FR
C o nt ro l c h a r t

Department of Applied Computing 10

Control System Development FR
F u n c t i o n d i a g ra m

• The function diagram is a combination of the

motion diagram and the control chart.
• The lines representing the individual states
are referred to as function lines.

Department of Applied Computing 11

Control System Development FR
F u n c t i o n d i a g ra m

Department of Applied Computing 12

Control System Development FR
F u n c t i o n d i a g ra m
Apart from the function lines, signal lines can also be
entered in the function diagram. The signal line
output is at the signal element and the end at the
point, where a change in status occurs, dependent
on this signal.
• Arrows on the signal lines indicate the direction of
signal flow.
• Signal branching are denoted by a dot at the point of
branching.
Department of Applied Computing 13
Control System Development FR
F u n c t i o n d i a g ra m
• Several changes in status of components are
introduced by a signal output. In the case of the OR
condition, a dot is placed at the point of conjunction of
the signal lines.
• Several signal outputs effect the same change in status
irrespective of one another. The AND condition is
designated by means of an oblique stroke at the point
of conjunction of the signal lines.
• A change in status only occurs, if all signal outputs are
present.
Department of Applied Computing 14
Control System Development FR
F u n c t i o n d i a g ra m

Department of Applied Computing 15

Control System Development FR
F u n c t i o n d i a g ra m

Department of Applied Computing 16

Control System Development FR
F u n c t i o n d i a g ra m

Department of Applied Computing 17

Control System Development FR
F u n c t i o n d i a g ra m
The diagram illustrates the following sequence:
• If the limit switch 2S1 is actuated and the push button 1S1 is pressed by the operator,
the piston rod of cylinder 1A extends.
• When the cylinder 1A reaches its forward end position, the limit switch 1S3 is
actuated and the piston rod of cylinder 2A advances.
• When the cylinder 2A reaches its forward end position, the limit switch 2S2 is
actuated and the piston rod of cylinder 1A retracts.
• When the cylinder When the cylinder 1A reaches its retracted end position A reaches
its retracted end position, the limit switch 1S2 is actuated and the piston rod of
cylinder 2A retracts.
• When cylinder 2A reaches its retracted end position, the limit switch 2S1 is actuated
and the initial position is reached again.
Department of Applied Computing 18
Control System Development FR

Department of Applied Computing 19

Control System Development FR
Function chart

Department of Applied Computing 20

Control System Development FR
Function chart

Department of Applied Computing 21

Control System Development FR
C i rc u i t d i a g ra m
The circuit diagram shows signal flow and the relationship between
components and the air connections. There is no mechanical layout
representation with the circuit diagram.
The circuit is drawn with the energy flow from the bottom to the
top. The various levels of a circuit include the energy source, signal
inputs, signal processing, control elements and the actuators. The
position of the limit valves are marked at the actuator. Components
and lines are identified by the component numbering system and
the port (way) connection numbers. These allow cross reference to
the components on the actual machine and make the circuit
readable.

Department of Applied Computing 22

Control System Development FR
C i rc u i t d i a g ra m

Department of Applied Computing 23

Examples FR

• A single-acting cylinder of 25 mm diameter is to clamp a

component when a pushbutton is pressed. As long as the push
button is activated, the cylinder is to remain in the clamped
position. If the push button is released, the clamp is to retract.

Department of Applied Computing 24

Examples FR

Try to draw the following:

• Motion diagram:
• - Displacement-Step Diagram.
• - Displacement-Time Diagram.
• Control chart
• Function diagram

Department of Applied Computing 25

Examples FR

A double-acting cylinder is to advance when a push button is

operated. Upon release of the push button the cylinder is to retract.
The cylinder is 250 mm diameter and consumes a large volume of
air. The push button connected with a pneumatic actuated valve.

Department of Applied Computing 26

Examples FR

The piston rod of the cylinder 1A is to advance only p if a workpiece

is inserted in the workpiece retainer, a guard has been lowered and
the operator presses the push button valve. Upon the release of the
push button or if the guard is no longer in its button or if the guard
is no longer in its lower position, the cylinder 1A is to retract to the
initial position.

Department of Applied Computing 27