Basics of Automation and Manufacturing Theory

Introduction to the course

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 Introduction to the course: Studying Materials
Course Materials:
Textbook
1. Hugh Jack. Automating Manufacturing Systems with PLCs. Lulu.com; 7th edition.
2010
2. SIEMENS. Sematic S7- Ladder Logic (LAD) for S7-300 and S7-400 Programming.
Manual Book. 4/2017 3.
References
1. Mikell P. Groover. Automation, Production Systems and Computer-integrated
Manufacturing. 2nd edition, Prentice Hall, 2001.
2. F. Ebel, S. Idler, G. Prede, D. Scholz., Fundamentals of automation technology, 2008.
Software (Required)
TIA Portal SP1 V16 (Contact me if you are not able to install)

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 Introduction to the course: Studying Materials

Note: Take installers from instructor

Install software's

- TIA PORTAL V14/V16

- PLCSIM
- WinCC

Requirement:

- RAM in your PC/Laptop AT LEAST 6GB - WIN10

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 Introduction to the course: Objective of the course

1. Understand current developments, trends, and basics of automation technology

2. Understand and apply Controlled Numerical Control (CNC) technology in industrial
manufacturing
3. Understanding Hardware construction, Communication, and Programming (LAD) with
the Programmable Logic Controllers (PLCs)
4. Know-how to apply the PLC technology to analyze and design automated
manufacturing systems

5. Understand basics and applications of industrial robots in industrial automation

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 Introduction to the course: Objective of the course

6. Know how to integrate PLCs and industrial robots for industrial automation

7. Know how to integrate computers, computer numerical control (CNC), and

industrial robots for industrial automation system.

8. Understand concepts of production systems and fundamentals of engineering

materials, its properties and manufacturing engineering.

9. Understand fundamentals of manufacturing processes and applications, also know

the trends in advanced manufacturing technology.

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 Introduction to the course: Review

- Data type

- Boolean Algebra

- Logic control

- Sensor/Actuator/Communication/interface devices….

- Drive technology

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 Q&A
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 Lecture 1: Introduction to the Automation Technology and Robotics

1. Terminologies and some concepts

2. Current trends in automation in manufacturing

3. Major roles of automation in manufacturing

4. Automation applications in manufacturing

5. Components of an automated systems in manufacturing

6. Hardware components for automation systems

7. Levels of Industrial Automations

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 1. Terminologies and some concepts

Manual work Mechanization Automation

Single Operation Manual Non-manual Non-manual

Complete Process Manual Manual Non-manual

Human is a part of Process without
Definition Handicraft
the process human being

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1. Terminologies Oil & Gas
Cars Airplanes

Vending machine Launch vehicles

Examples and Fields of

Automation Systems

Robots Traffic control

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Warehouses
 1. Terminologies

Packaging Material
Automation
Systems Separation
Machines

Example of Automation
Systems in
Supply Manufacturing Automated
Chain Assembly
Automation
Systems line

Thanh Tran, GPEM

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AUTOMATIC QUALITY CONTROL INSPECTION SYSTEM
 Lecture 1: Introduction to the Automation Technology and Robotics

1. Terminologies and some concepts

2. Current trends in automation in manufacturing

3. Major roles of automation in manufacturing

4. Automation applications in manufacturing

5. Components of an automated systems in manufacturing

6. Hardware components for automation systems

7. Levels of Industrial Automations

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 2. Current trends in automation in manufacturing
1. Improving accuracy with machine learning (a cornerstone of IoT, Big Data, and
Industry 4.0)
2. Digital twins and industrial automation (creation of a virtual copy of a machine or
system --- > efficient commissioning, optimized machine design, smooth operations
and short changeover time)

3. Advances in industrial cyber-security

4. Virtual reality (VR) and augmented reality (AR) (simulate a product or environment
digitally --- > allowing to interact and immerse with computer-generated experience
5. The rise of smart industrial robots (cutting-edge software and vision systems can be
programmed to perform a range of tasks)
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 2. Current trends in automation in manufacturing

Research Topics

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 Lecture 1: Introduction to the Automation Technology and Robotics

1. Terminologies and some concepts

2. Current trends in automation in manufacturing

3. Major roles of automation in manufacturing

4. Automation applications in manufacturing

5. Components of an automated systems in manufacturing

6. Hardware components for automation systems

7. Levels of Industrial Automations

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 3. Major roles of automation in manufacturing

Inaccessible
Environment
by workers Competitive
Prices
Improve
worker
safety Major roles of High quality
Automation in with high
Manufacturing productivity
Mitigate
Effect of labor
shortages Reduce
manufacturing
Reduce labor lead time
cost
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 Lecture 1: Introduction to the Automation Technology and Robotics

1. Terminologies and some concepts

2. Current trends in automation in manufacturing

3. Major roles of automation in manufacturing

4. Automation applications in manufacturing

5. Components of an automated systems in manufacturing

6. Hardware components for automation systems

7. Levels of Industrial Automations

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 4. Automation applications in manufacturing

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 4. Automation applications in manufacturing

Major Industry Segments: Focus Areas

• Manufacturing • DCS (Distributed Control Systems)

• Pharmaceutical Manufacturing • PLCs (programmable controller and I/O

modules)
• Consumables Manufacturing
• CNC (computer numerical control)
• Automotive Manufacturing
• Embedded computer board
• Material Handling
• Sensors / Measurement Equipment
• Process
• Motor control
• Refining • Motion control
• Chemical • Machine vision
• Food & Beverage and Pulp and PThaanph eTrarn, GPEM
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 Lecture 1: Introduction to the Automation Technology and Robotics

1. Terminologies and some concepts

2. Current trends in automation in manufacturing

3. Major roles of automation in manufacturing

4. Automation applications in manufacturing

5. Components of an automated systems in manufacturing

6. Hardware components for automation systems

7. Levels of Industrial Automations

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 5. Components of Automated Systems

(1) Power

(2) Program of (3) Control Process output

Process/Plant
Instructions Systems

Elements of Automated Systems

Controlled system
Three components of Automated Systems
• Wisely available
(1) Power: Electrics --------- >
• Ready to convert to other forms: Mechanical, thermal,
(2) Program of Instructions:
and hydraulic forms
(3) Control system:
• Very low power levels for functions such as signal
processing, data storage,..
• Stored in long-life batteries
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 5. Components of Automated Systems

(2) Program of Instructions:

• Simplest form: maintain a certain controlled variable at a specified level, such as
regulating the temperature in a heat treatment furnace
• Complex processes: a sequence of activities is required during the work cycle, and
the order and details of each activity are defined by the program of instructions

Example:
The numerical control (NC) part program specifies the individual sequence of steps
required to machine a given part, including worktable and cutter positions, cutting
speeds, feeds, and other details of the operation.

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 5. Components of Automated Systems

(3) Control system: The third basic component of an automated system. Two types of
control system can be distinguished: closed-loop and open-loop. A closed loop
system, also known as a feedback control system

(a) Closed loop

(b) open loop

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 5. Components of Automated Systems

Types of Automation
Automation Systems Systems

Fixed Programable Flexible Integrated

Features: Features: Features:

Features:
• High volume production • Computer controlled • Advanced optimization algorithm
• Changeable sequence of operation
• Dedicated equipment • Programmable Material • Computer computation
• Electronics controls
• Fixed effective operation Handling • Production/Management integration
Factory Type:
Factory Type: Factory Type:
Factory Type: • Batch process
• Continuous flaw • Job Shop • All types
• Mass production
• Discrete mass production • Batch process • Large
Example
Example Example
Example • NC Machine
• Process Automation • CNC Machining center • Chemical process automation
• Assembly Robots
• Conveyor • AGVS • Plant with CIM
• Transfer line

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 Lecture 1: Introduction to the Automation Technology and Robotics

1. Terminologies and some concepts

2. Current trends in automation in manufacturing

3. Major roles of automation in manufacturing

4. Automation applications in manufacturing

5. Components of an automated systems in manufacturing

6. Hardware components for automation systems

7. Levels of Industrial Automations

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 6. Hardware components for Automation

Hardware components
for automation system

(3) Interface Devices

(1) Sensor (2) Actuator (4) Process Controllers
and communication

A device which provides a usable output in response to a specified measurand

• Electric current or Potential or Magnetic or Radio sensors,
• Humidity sensor,
• Fluid velocity or Flow sensors,
• Pressure sensors,
• Thermal or Heat or Temperature sensors,
• Optical sensors,
• Position sensors,
• etc.

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 6. Hardware components for Automation

Hardware components
for automation system

(3) Interface Devices

(1) Sensor (2) Actuator (4) Process Controllers
and Communications

An actuator: A component of a machine that is responsible for moving and controlling a

mechanism or system
• Electrical Actuator: AC and DC electric motors, stepper motors, and solenoids
• Mechanical Actuator:
• Pneumatic Actuator:
• Hydraulic Actuator: Linear Actuator: Solenoid, Hydraulic/ Pneumatic
• New actuators Rotary Actuator: Motor, Hydraulic/Pneumatic
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 6. Hardware components for Automation

Hardware components for

automation system

(3) Interface (4) Process

(1) Sensor (2) Actuator
Devices Controllers

Interface devices
• Allow the process to be connected to the computer controller and vice versa.
• Sensor signals from the manufacturing process are fed into the computer, and
command signals are sent to actuators that operate the process.
• Communication between the process and the controller.
• The devices include analog-to-digital converters (ADC), digital-to-analog
converters (DAC), contact input/output interfaces, and pulse counters and
generators
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 6. Hardware components for Automation

Hardware components for

automation system

(3) Interface (4) Process

(1) Sensor (2) Actuator
Devices Controllers

• Most process control systems use some type of digital computer as the controller
✓ Two-point control
✓ PID control
✓ Feed forward control, and so on…
• A widely used process controllers that satisfy the preceding real-time controller
requirements is a Programmable Logic Controllers (PLCs)
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 Lecture 1: Introduction to the Automation Technology and Robotics

1. Terminologies and some concepts

2. Current trends in automation in manufacturing

3. Major roles of automation in manufacturing

4. Automation applications in manufacturing

5. Components of an automated systems in manufacturing

6. Hardware components for automation systems

7. Levels of Industrial Automations

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7. Levels of Industrial Automations

Operator Engineering
Supervision level 2

Control Bus

programmable
Control level controllers

Fieldbus
direct I/O microPLCs
Field level

Sensor-Actuator Bus

transducers / actors
 7. Levels of Industrial Automations

• These functionalities: overall

Information
Technology
Level 4 control of a factory
Enterprise
• Why it is a Pyramid?
Level 3 Production Control

Level 2 Supervisory Control

Automation
Industrial

Level 1 Automatic Control

Level 0 Sensor and Actuators

Process/Machine

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 7. Levels of Industrial Automations
Information

Offline Enterpri
Technology

se

Offline Production Control

Spatial/Time Scale
- Online, soft-real time
- General Purpose Supervisory Control
Automation
Industrial

- Real-time S/W,
Automatic Control
- Special H/W

- Embedded H/W and

S/W Sensor and Actuators

Process/Machine
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 7. Levels of Industrial Automations

Level 0: Sensor and actuator

• Hardware: sensing elements, electronic circuits or microprocessors
• Software elements
• A lot of embedded technology at this level
Level 1: Automatic control
• A separate hardware, not embedded into the machine: special purpose hardware like
PLC, industrial PCs, etc
• Software is a real time in the sense that the output must be generated with a given
amount of time.

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 7. Levels of Industrial Automations

Level 2: Supervisory control

• The hardware is mostly a general purpose; it is general purpose computers with
strong data interface. Because many channels data from the whole process are
connected to the supervisory control

• Software is very special purpose. For example, supervisory control software for a
refinery is completely different from that of a power plant. It is very specific to the
machine

• Not true that you have computer based automation for functioning the performing
on that level, some functions may be done by human being, for example, if you go
to a power plant or if you go to a big refinery, you will find that in the shop floor,
there is a control room.

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 7. Levels of Industrial Automations

Level 3: Production control

• Not a powerful machine as such (view of a factory, many pieces of equipment
have been produced per hour, whether functional or not functional.
• The software is generally offline; it is not concerned with the machine itself.

Level 4: Enterprise
• Not so much closed to the hardware
• Analysis, decision, and monitor of the process and performance

Remarks:
• Level 2 – Level 4: could be tuned as industrial information technology rather than
industrial automation technology
• Focus on the first three layers:

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 Lecture 1: Introduction - References

1. Stamatios Manesis and George Nikolakopoulos. Introduction to Industrial Automation.

Taylor & Francis Group, LLC. 2018

2. Mikell P. Groover. Automation, Production Systems and Computer-integrated

Manufacturing. 2nd edition, Prentice Hall, 2001.
3. Abdu, O., and Taleb, M., Architecture of industrial automation systems. European
Scientific Journal, Vol. 10, No. 3. 2014.
4. F. Ebel, S. Idler, G. Prede, D. Scholz., Fundamentals of automation technology. 2008.

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 Lecture 1: What next..

Lecture 1: Introduction to Automation Technology and Robotics

Lecture 2, 3: Sensor, Actuator, Interface Devices, Communication Technology

Lecture 4: Control Technology and Applications

Lecture 5, 6, 7: Basics and Advanced of PLC Programming

Lecture 8: Introduction to the SCADA and DCS systems

Lecture 9: Support Systems in Manufacturing Automation

Lecture 10: Introduction to robots and Manufacturing Application

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