Topic 1

INTRODUCTION TO INDUSTRIAL AUTOMATION

Dr. Mahesh S. Narkhede

Electrical Engineering Department
Government Polytechnic, Mumbai
msnarkhede@ymail.com
https://drmaheshsnarkhede.wordpress.com/
 LESSON OUTCOME

After studying this topic you will be able to

• Explain significance of Automation
• State importance of Automation
• State advantages of Automation
• State disadvantages of Automation
• Classify Automation
• Explain requirements of Automation
• Explain general idea of control, manufacturing and
assembly processes
 INTRODUCTION
• Automation is a Technology that is
concerned with the use of Mechanical,
Electronic & computer based systems in the
operation & control of production.
• It uses control systems (such as numerical
control, programmable logic control) with
other applications of computer aided
technologies (CAx ) such as CAD, CAM,
CAPP to control industrial machinery and
processes.
 IMPORTANCE OF AUTOMATION
• Automation plays a important role in the global
economy. Automation greatly reduces the
need for human sensory and mental
requirements.
• It has increased production rate, reduced
manpower costs, made production cheaper.
 ADVANTAGES OF AUTOMATION
• Increased productivity.
• Improved quality
• Improved robustness (consistency), of processes
or product.
• Increased consistency of output.
• Reduced direct human labour costs and
expenses.
• Can complete tasks where a high degree of
accuracy is required.
• Replaces human operators in tasks that involve
hard physical or monotonous work
• Reduces some occupational injuries (e.g., fewer
strained backs from lifting heavy objects)
 ADVANTAGES OF AUTOMATION
• Replaces humans in tasks done in dangerous
environments (i.e. fire, space, volcanoes,
nuclear facilities, underwater, etc.)
• Performs tasks that are beyond human
capabilities of size, weight, speed, endurance,
etc.
• Reduces operation time and work handling
time significantly.
• Frees up workers to take on other roles.
• Provides higher level jobs in the development,
deployment, maintenance and running of the
automated processes.
 DISADVANTAGES OF AUTOMATION
• Technology limits - Current technology is
unable to automate all the desired tasks.
• Unpredictable development costs - The
research and development cost of
automating a process is difficult to predict
accurately beforehand.
• Initial costs are relatively high - The
automation of a new product requires a
huge initial investment in comparison with
the unit cost of the product .
• Displaces workers due to job replacement
CLASSES (TYPES) OF INDUSTRIAL AUTOMATION
• Fixed Automation
• Programmable Automation
• Flexible Automation
CLASSES (TYPES) OF INDUSTRIAL AUTOMATION
• Fixed Automation : It is used when volume of
production is very high. e.g. Machining of
components in Automobile industry. Here same
product is produced continuously.
Disadvantages : Initial cost of setup is very high.
If product is changed then process has to be
changed
CLASSES (TYPES) OF INDUSTRIAL AUTOMATION

• Programmable Automation: It is used when

volume of production is comparatively low &
there are variety of components to be made.
This adaptability feature is obtained by
programmable equipment like PLC.
CLASSES (TYPES) OF INDUSTRIAL AUTOMATION
• Flexible Automation : This system possesses
features of both. This is also called as
Computer integrated manufacturing system.
It consists of series of workstations that are
interconnected by a material handling and
storage system. A central computer is used
to control the various activities that occur in
the system
 REQUIREMENTS OF AUTOMATION
• Product identification
• Production rate / capacity
• Technology ( Automation Tools)
• ANN – Artificial Neural Network
• DCS – Distributed Control System
• HMI – Human Machine Interface
• SCADA – Supervisory Control and Data
Acquisition
• PLC – Programmable Logic Controller
• Instrumentation
• Motion Control
• Robotics
 HAPPY LEARNING!
Dr.Mahesh S. Narkhede
Electrical Engineering Department
Government Polytechnic, Mumbai
msnarkhede@ymail.com
https://drmaheshsnarkhede.wordpress.com/