Module1 Industrial Computing
Uploaded by
yayoburinyuyModule1 Industrial Computing
Uploaded by
yayoburinyuyModule 1 — Introduction to Industrial Computing (Form 5)
Learning Objectives
By the end of this lesson, students should be able to:
- Define Industrial Computing, open-loop and closed-loop systems.
- Explain the role of computers in modern manufacturing and automated processes.
- Give examples of industrial computing applications.
- Choose a suitable type of computer for a simple industrial task and justify the choice.
1. What is Industrial Computing?
Industrial Computing is the use of computers, controllers and software to run, monitor and control
industrial machines and processes.
In factories and production lines, computers collect data, control motors and valves, and make
decisions automatically. It includes devices like PLCs (Programmable Logic Controllers), industrial
PCs, embedded microcontrollers and SCADA systems.
2. Open-loop vs Closed-loop systems
Open-loop system: A system that acts on the input without checking the output. There is no feedback
to correct the process.
Example: A simple irrigation pump that runs for 10 minutes each day regardless of soil moisture.
Closed-loop system: A system that measures its output and uses the measurement to adjust the input
— this uses feedback.
Example: An automatic water tank controller that turns the pump on/off based on the water level
sensor reading.
Diagram suggestion:
- Open-loop: Input → Controller → Actuator → Output
- Closed-loop: Input → Controller → Actuator → Output → Sensor → (feedback to) Controller
3. Role of Computers in Modern Manufacturing
- Control machines (start/stop motors, set speeds, position tools).
- Collect data from sensors (temperature, pressure, speed).
- Make decisions quickly (turns devices on/off based on sensor readings).
- Display information for operators on screens (HMI).
- Record production data for quality control and maintenance.
- Communicate with other devices and with central systems (via networks).
4. Applications of Industrial Computing
- Automated assembly lines (robot arms, conveyors).
- CNC machines and machine tools.
- Process control in factories (chemical, food, textile).
- Building management systems (lighting, HVAC).
- Packaging and sorting systems.
- Monitoring and remote control (SCADA).
5. How to Choose a Computer for an Industrial System
- Ruggedness: Can it work in heat, dust, vibration? (industrial grade)
- Real-time response: Does it react quickly enough for the task?
- Input/Output (I/O): Does it have needed ports (digital I/O, analog inputs, serial, Ethernet)?
- Communication: Supports industrial protocols (Modbus, RS232/485, Ethernet).
- Power & Safety: Tolerant to power changes; has protections.
- Operating system / software support: Can it run required control software or code?
- Maintenance & spare parts: Easy to repair and available locally.
- Cost: Affordable and gives good value for the task.
Example: If you need to control 8 sensors and 6 motors in a dusty factory, choose a PLC or rugged
industrial PC with many I/O and dust protection — not a regular office laptop.
6. Importance / Benefits of Industrial Computing
- Improves accuracy and product quality.
- Increases production speed and output.
- Reduces human error and improves safety.
- Allows monitoring and logging for maintenance.
- Makes production flexible (quick change of settings).
7. Suggested Diagrams to Draw
Students should draw and label:
1. Block diagram of a closed-loop control system.
2. Simple factory automation line with PLC and HMI.
3. Comparison sketch of an office PC vs an industrial PC.
8. Short Exercises
1. Define Industrial Computing in one sentence.
2. Give one example each of an open-loop and a closed-loop system.
3. List three roles a computer can play on a production line.
4. A small bakery needs to automate oven temperature control. Should you use open-loop or closed-
loop control? Explain.
5. Name four important features to check when choosing an industrial computer.
6. You must choose a computer to control a conveyor with a photo-sensor that counts items. Write
two reasons why a PLC might be a good choice.
9. Teacher’s Quick Answer Key
1. Industrial Computing is the use of computers and controllers to run and monitor industrial
machines/processes.
2. Open-loop: a timed street light system; Closed-loop: thermostat-controlled heater.
3. Control machines; collect data from sensors; display status to operators.
4. Closed-loop — because oven temperature must be measured and adjusted to keep it at the set point.
5. Ruggedness, I/O availability, real-time response, communication protocols.
6. PLCs are rugged, offer many digital I/O and are easy to program for simple control tasks.
10. Short Exam Tips for Students
- Learn the definitions clearly (open vs closed loop).
- Practice drawing the block diagram and labelling sensors/actuators.
- Be ready to give simple examples from everyday life and from factories.
- For 'choose a computer' questions, explain at least two practical reasons for your choice.
