Automation Basics

Objectives:

To get overview about automation .
To know about basic elements involved in the
automation process
To know how automation has been working in
the domestic and industrial spheres.
To understand how communication has helped
in automation of many things.
To understand advantages and limitations of
automation

What one will learn ?
What are the basic elements of Automation ?
Why automation is necessary ?
What are the different technologies available for
the automation.?
Where automation exists ?
What are the different controllers ?
What is SCADA and DCS ?
How communication is playing a vital role in the
process of Automation ?
What are the different protocols used in
Automation?


Contents:
What is AutomationRole of Automation in the different industries
Why Automation ? ( Advantages)
Basic elements of Automaton
Sensors LVDT,Thermostat,Thermistor ,pressure CT,PT,
Limit switches,Magntic Pick Up,Capacitive sensors etc
Controllers and controller based systems
Actuators Relays. Solenoids.
Types of Controllers Proportional,PI ,PID,
Categories of controllers
DCS & SCADA What is SCADA
How communication has enhanced automation.
Common Protocols CAN ,MODBUS,PROPHI, Substation automation
protocol 61850
When to go for Automation ?
Design of Automation system
Limitations / Disadvantages of Automation
Automation Myths Impact of Automation
How automation affects economics ?
Queries



What is Automation ?
The dictionary
defines automation as The
technique of making an
apparatus, a process, or a
system operate automatically.
Automation federation define
automation as
The creation and application of
technology to monitor and
control the production and
delivery of products and
services.

Automation means use of Available
technologies to reduce the need of
Human work.

Automation is a step beyond
mechanization.
Mechanization provides human
operators machinery to assist
themselves with the muscular
requirements of work
While
Automation greatly decreases the need
for human sensory and mental
requirements as well. .




Quality
Productivity
Manpower Cost
Plant
Total Automation
Manufacturing
Competitiveness
Solution
Automation:
Automation is basically the delegation of human control
function to technical equipment for

Automation cycle
Sense the Inputs
Process the Logic
Give the Outputs


Outputs
Machine
or
Process
Controller
Inputs
History of Automation
Manual control
Pnumatic control
Hard wired Logic Control
Electronic control using Logic gates
Programmable logic controller
Microcontrller based embedded
controllers
Cluster of controllers and
Master controller at Remote end.
Modern world
Ancient world
Major Mile stones in Technologies

Ancient world
( 8000BC to 330 )
The middle age through 1599
The age of scientific
revolutions 1600-1790
The industrial Revolution
1700-1920
The electrical age
1891 to 1934
The atomic and electronic age
1935 into 21
st
century
out of which last 20 years
belong to COMMUNICATION
and INFORMATION ERA



Invention of Wheel
Discoveries of various metals
Invention of Glass
Discovery of Electricity
Invention of Telegraphy
/Telephone
Invention of Electric Motor
Invention of Transistor 1948
Invention of Microprocessor
Invention of Mobile
Technology
Invention of Internet
Technology




Range of Technologies involved in AUTOMATION
Automation involves a very broad range of technologies including
1. Robotics
2. Expert systems
(an expert system is a computer system that emulates the decision-
making ability of a human expert )
3 Telemetry and communications
4 Electro-optics
Electro-optics is a branch of technology involving components,
devices and systems which operate by modification of the optical
properties of a material by an electric field.
5 Cyber security,
( protecting your personal information or any form of digital asset
stored in your computer or in any digital memory device)
6 Process measurement and control,
7 Sensors,
8 wireless applications, systems integration, test measurement, and
many, many more.
ROBOTICS
Where Automation exists ?
Automation encompasses many vital elements,
systems, and job functions.
Manufacturing , including food and pharmaceutical, chemical and
petroleum, pulp and paper
Transportation , including automotive, aerospace, and rail
Utilities , including water and waste water, oil and gas, electric
power, and telecommunications
Defense
Facility operations , including security, environmental control,
energy management, safety, and other building automation
..And many others

AUTOMATION IS EVERYWHERE
Automation is in all
functions and places
Aerospace
Automotive
Chemical and Petroleum
Computer Technology
Construction and Design
Electro-Optics
Environmental
Food and Pharmaceutical
Glass and Ceramics
Management
Marketing and Sales
Mining and Metals

Mining and Metals
Nuclear
Power Distribution
Process Measurement and
Control
Pulp and Paper
Robotics and Expert Systems
Safety
Sensor Technology
Systems Integration
Telemetry and
Communications
Test Measurement
Textiles
Water and Waste water
Wireless Application
.

Impact of Automation:
Automation has a significant
impact in the wide range of
industries including
Manufacturing industries
Automation has been
responsible for the shift in the
world economy from industrial
jobs to service jobs in the 20th
and 21st centuries.
Once omnipresent telephone
operators have seized to exist
as telephone exchanges are
automated.
ATM have reduced the need
for bank visits to obtain cash
and carry out transactions.
Impact of Automation:
As a result of increase in
Automation and (which is
ever increasing almost
every field as a result of
ease in use of new
Technologies)
the nature of jobs is getting
affected .
Telephone operators
Stock market agents
Railroad brake signal and
switch operators
Shoe and leather workers
Photographic process
workers and processing
machine operators
Model makers and
pattern makers





How much Automation ?
Automation represents one of the major trends of 20
th
century as in
many cases automation has provided extended system functionality
well beyond existing human capabilities.

Contrary to the implication of the term Automated humans have
remained a critical part of most automated systems as most
automation has been piece meal covering certain functions but not
all functions.Human beings have remained in the system as
integratorsmonitoring the automation for some functions and
performing others themselves

Full automation of the task may be technically possible but it maynot
be desirable if the performance of the joint human- machine
system is to be optimized.Intermediate levels of Automation may be
preferable for certain tasks in order to keep human operators
situation awareness at a higher level and allow them to perform
critical functions
Level of Control
One way to minimize the negative effect of Automation is
to devise implementation schemes that keep human
beings actively involved in the decision making loop
while simultaneously reducing the load associated with
doing everything manually



Levels of control and Automation:
(adapted from Endsley and kiris,1995)
LEVEL OF AUTOMATION
ROLE
HUMAN SYSTEM
NONE 1 Decide Act ---
Decision support 2 Decide Act Suggest
Consensual Artificial
intelligence (AI) 3 Concur Decide Act
Monitored AI 4 Veto Decide Act
Full automation 5 --- Decide Act
1 Manual system
5 Fully automatic system
EXAMPLES OF AUTOMATION
Common Examples of Automation
Day to Day life
ATM
Starting of the vehicle
Automatic washing
Machine
Electrically driven Pump
UPS, Canopy (power
supply Back up
Industry

Painting Robots in the
automobile mfg
industry
Soldering Machines
DCS Distributed
Control Systems
SCADA
AMF Generators
Technologies involved in the working of ATM
Computer and Electronics (HMI )
Communication using TCP/IP ( Communication with server at
remte end)
Sensors
(magnetic sensor to read data from the card)
Camera ,Timer

Electromechanical solenoids and actuators
(for counting currency accurately , and giving the same to user.)
Printer Printing technology



Home Automation
Subsystems of Home Automation:
Hot water systems.
Appliances. Systems
Home office, home entertainment and other electronic
equipments.
Lighting.
Heating and cooling/air conditioning systems.
Fans and air pumps/heat shifters.
Powered window blinds, shutters and awnings.
Powered vents and window openings.
Water pumps, pool pumps .
Garage doors.
Security systems.
Why Automation is required ?
Increase in comfort
More safety
Improve the quality and precision.
To do the job for which human beings will
not have the capacity.
To avoid monotonous work

Sensors
Controllers
Actuators
HMI
Display & alarm
Communication Protocol
Basic Elements of Automation
Sensors

Controllers
Actuators
HMI
Display & alarm
Basic Elements of Automation
Sensors
What is a sensor ?
Sensor is a device which measures a physical
quantity .
Temperature sensor (Input to thermometer
/Temperature indicator)
Level sensor input to Fuel gauge
Proximity sensor, Pressure sensor
Photoelectric sensor LDR / opto coupler /
photodiode
On/Off sensor push buttons / Relays /

Sensors:
sensors are used in a wide range of control systems that makes lives for
people
easier,
safer and
more productive both at work and at home.

Sensors extend the reach of human capabilities so that we can
save energy,
make faster decisions
and perform tasks with greater precision.

Sensors take on highly repetitive tasks
leaving us free to apply our intellectual and creative
abilities to further improve our lives.
How we wash our clothes and refrigerate our food OR how we drive our
cars and generate energy sensors help us.
Different types of sensors
Common usage of sensors:
Transport and case Refrigeration Systems:
Temperature sensors are used to measure the supply of air to
temperature controlled compartments while immersion probes
measure refrigerant temperature. Rugged sensors designed
specifically for measuring refrigerant pressure are used in
conjunction with variable speed compressors to improve system
efficiency.

Traffic /smart Highway
Piezoelectric axle detectors are used to collect traffic data on highways,
classify vehicles for automated toll booths, as well as provide timing
mechanism for speed and red light cameras.
Common usage of sensors:
Petrol Pump
A rugged, hermetically sealed electromagnetic rotary
encoder coupled to the fuel flow meter in gas pumps is
used to accurately convert rotational pulses into gallons
or liters dispensed.
Printers : The drying process of ink jet printers is
improved by monitoring air and paper humidity content.
Measuring air and toner humidity guarantees print quality
in laser printers/copiers.
Common usage of sensors:
Cooking System:
Long life, high-temperature oven probes operate up to
300C. The high accuracy optimizes cooking control
while protecting users.
Washer/Dryer:
Low cost/low power vibration sensors measure load
imbalance to avoid "walking." Humidity or thermopile
sensors are used in dryers to automatically shut off when
clothes are dry, extending the life of clothes and
improving efficiency.


Construction of C.T.
C.T. has a primary coil of one or more
turns of thick wire connected in series
with the line whose current is to be
measured.


The secondary consist of large number
of turns of fine wire, is connected across
the ammeter terminals.
Working
If a current transformer has primary to secondary current
ratio of 100:5 then it step up the voltage 20 times and
step down the current 1/20 times of its actual value.
If we know the current ratio I
1
/I
2
and the reading of a.c.
ammeter, the current can be calculated.

Current = ratio ammeter reading
Potential transformer
A PT is a step down transformer having many primary
turns but few secondary turns.

In step down the voltage decreases and current
increases, thus voltage can be easily measured by using
low range voltmeter.

The voltage is stepped down in known ratio called
voltage ratio.




Construction and working of P.T.
Construction
A potential transformer has many primary windings but
few number of secondary windings that makes it step
down transformer.
Voltmeter is connected to secondary winding usually
voltmeter of 150 v is suitable.
Working
Primary terminals are connected across the line to which
the voltage is to be measured.
The voltmeter gives the transformed value of voltage at
secondary.
The deflection of voltmeter when divided by transformed
ratio gives the actual voltage at primary.
Line voltage = deflection / trasf. Ratio
Where transformation ratio = V2/V1
Types of P.T.
Some types of p.t. are


1. Shell type
2. Dry type
3. Oil type


Rating Type
below 5000 v Shell type
5000-13800 v Dry type and
oil type
above 13800 v

only oil type
Precaution for For CT & PT


Utmost care should be taken to ensure that
CT secondary is never opens.

For safety purpose the secondary should be
completely insulated from the high voltage
primary and should be in addition grounded.
Automation and electricity demand


In the near future, home automation systems may be linked to the
electricity utility in a number of ways. The utility may communicate
variations in electricity prices to a smart electricity meter, that will
interface with the home automation controller.

Householders can then program appliances to reduce power or
switch off altogether during high price periods.

Alternatively householders could enter a supply contract that allows
the electricity supplier to signal equipment controlled by the home
automation system (such as air conditioners) to turn off certain
equipment for short periods.

The householder may choose to participate and obtain lower
electricity prices or other financial incentives.


Desirable Sensor attributes

Reliability

Accuracy and Repeatability

Good response time.

Withstanding capability.

Long Life

Less expensive
Repeatability and accuracy
Not repeatable
Not accurate
Not repeatable
Accurate
Repeatable
Not accurate
Repeatable
Accurate
What is difference between sensor and a
transducer?
SENSOR and TRANSDUCER both are actually
sensors, but:

TRANSDUCER: convert one form of energy into
ELECTRICAL energy

SENSOR: convert one form of energy into any other form
of energy

Commonly used sensors for industrial
applications
Information from the sensor
/ Transducer can be in
two forms

Analog

Digital
LVDT
Pressure Transducer
Strain Gauge sensor
Magnetic sensors
Piezoelectric sensors
Photoelectric sensors
Limit switches
Relays (Relay contacts
Auxiliary contacts of
switch/ contactor /breaker



In analog technology, a wave is recorded or used in its original form. So, for
example, in an analog tape recorder, a signal is taken straight from the
microphone and laid onto tape. The wave from the microphone is an analog
wave, and therefore the wave on the tape is analog as well. That wave on the
tape can be read, amplified and sent to a speaker to produce the sound.
In digital technology, the analog wave is sampled at some interval, and then
turned into numbers that are stored in the digital device. On a CD, the
sampling rate is 44,000 samples per second. So on a CD, there are 44,000
numbers stored per second of music. To hear the music, the numbers are
turned into a voltage wave that approximates the original wave.
The two big advantages of digital technology are:
The two big advantages of digital technology are:
The recording does not degrade over time. As long as the numbers can be
read, you will always get exactly the same wave.
Groups of numbers can often be compressed by finding patterns in them. It
is also easy to use special computers called digital signal processors
(DSPs) to process and modify streams of numbers (see How CDs Work for
a more detailed explanation).
SENSORS used in the Industry
Thermocouples
Proximity sensors
Limit switches
RPM sensor
4-20 mA Transducers (current
voltage,frequency,KW,KVA,KVAR,PF,Phase
angle)

Sensors
Controllers
Actuators
HMI
Display & alarm
Basic Elements of Automation

What is a controller ?


A controller is a device which
monitors and affects the
operational conditions of a given
system.

A controller is a transfer element
which compares the feedback
value received from a transducer
(sensor) to a predetermined value
(i.e. set-point) and processes it in
such a way that a control signal is
transmitted in the form of an
appropriate variable to the
actuating element .

Anything which is controllable
must be measurable and
comparable






Comparator compares a given
value with a set value

The simplest controller is a
comparator.



What is a controller ?

A device which accepts the
inputs , measure them and
depending on the
predetermined conditions
actuate one or more devices
is called the controller.

Input signal which represents
certain physical quantity can
be digital or analog in the
nature
An information from the sensor
is to be converted into
electrical form by signal
conditioners and amplifiers
before it is processed by the
controller
If the information is analog
then a suitable ADC is used to
enable controller read
information
Programmable Automation
Controller
A programmable automation controller (PAC) is a compact
controller that combines the features and capabilities of a PC-
based control system with that of a typical programmable logic
controller (PLC). PACs are most often used in industrial settings
for process control, data acquisition, remote equipment
monitoring, machine vision, and motion control. Additionally,
because they function PACs are able to transfer data from the
machines they control to other machines and components in a
networked control system or to application software and databases.
[edit]PAC Origins

Types of controllers
Controllers can be categorized based on
1 Parameter Or physical quantity they are controlling
Examples Temperature controller,RPM controller,
Pressure controller etc
2 The manner in which they are controlling the Physical quantity
Proportional controller P
Proportional Integral controller PI
Proportional Integral derivative Controller PID
ON OFF (Bang Bang) Controller
3 Analog or Digital controller
4 The device used for controlling { PLC , PC ( computer), Digital circuits
using comparators }


Controllers used for building automation can be
grouped in 3 categories.
1. Programmable Logic Controllers (PLCs)
2. , System/Network controllers, and
3. Terminal Unit controllers.

PLCs provide the most responsiveness and processing
power, but at a unit cost typically 2 to 3 times that of a
System/Network controller intended for BAS
applications.
Terminal Unit controllers are usually the least expensive
and least powerful.
Controller
Controllers are essentially small, purpose-built
computers with input and output capabilities.
These controllers come in a range of sizes and
capabilities to control devices commonly found in
buildings, and to control sub-networks of controllers.
Inputs allow a controller to read temperatures, humidity,
pressure, current flow, air flow, and other essential
factors.
The outputs allow the controller to send command and
control signals to slave devices, and to other parts of the
system.
Inputs and outputs can be either digital or analog
MicroProcessor and
Microcontroller
Microprocessors are these days replaced by Microcontrollers
Selection Criteria for Controller:
Speed
Memory
I/O handling capability
Communication capability
Built in Features
in Built ADC
in built DAC
Programming:
A controller chip without a S/W
loaded in it has little power to
control.
A controller understands only
zeros and ones (in fact it doesn't
even understand zeros and ones
it can only distinguish two levels
low and High
The lowest level language is
Machine language which has only
two characters . The morse code
is perhaps the best example of
machine language
Assembly level language depends on
the type of the controller each
contrller will have a fixed number
of instruction set.

Highest level languages are those
in which human beings
communicate..

There are many higher level
languages depending on the type
of application for which they are
used.

Examples are
FORTRAN
COBOL
BASIC
FOXPro

Compilers and Assemblers


C
C++
Java
Programming the controllers:
Controller without
programming has no value
Programming Languages
Higher level Languages
C,C++.Java,Visual Basic
Assembly languages
Controller specific
Machine language
Will have series of zeros
and ones
(morse code is the best
example)

Types of Instructions
I/O Handling
Assigning
Mathematical
Logical
Repetitive
Branching
A building Automation system (BAS)
Industrial Automation Process Control
System:
In practice, an industrial
automation process
control system can be
characterized as one or
more of the following:

I. Batch processing
II. Continuous processing
III. Discrete


Batch processes are used to
produce a relatively low
to intermediate
quantities of product.


BATCH processing
Applications that require specific
quantities of raw materials
combined
in specific ways for particular
durations to produce an
intermediate or end result.
Examples
1 production of adhesives and
glues, (which require the
mixing of raw materials in a
heated vessel for a period of
time to form a quantity of end
product.
2 Production of food, beverages and
medicine.
3 PCB assemblies


Continuous and Discrete Systems:


II. Continuous
Continuous processes used in
industrial automation
applications produce very
large quantities of product.
Examples
The control of the water
temperature in a heating
jacket, is an example of
continuous process control.
Some examples of
continuous processes are
the production of fuels,
chemicals and plastics.
3 Discrete

Found in manufacturing,
motion and packaging
applications.
Examples :
Robotic assembly,
commonly found in
automotive production,
can be characterized as
discrete process control.
Most discrete
manufacturing involves
the production of discrete
pieces of product, such as
metal stamping.


Supervisory control & Data Acquisition
(SCADA)
SCADA refers to a system that
collects data from various
sensors at a factory, plant or in
other remote locations and
then sends this data to a
central computer which then
manages and controls the
data.

SCADA focuses on gathering and
circulating the right amount of
system information to the right
person or computer within the
right amount of time.



DCS and SCADA
DCS is a very broad term used in a variety of industries, to monitor and
control distributed equipment.

SCADA is an acronym for Supervisory Control And Data Acquisition.
SCADA systems perform data collection and control at the supervisory
level. Some systems labeled as SCADA perform data acquisition only.

A SCADA system should not be critical to the controlled process. The
SCADA connects to a PLC or real time device, so there is a separate or
integrated real-time automated control system that responds quickly enough
to compensate for process changes within the time constants of the
process.

The SCADA controls and monitors the process, but the process must also
run independently from the SCADA system in case of failure.
Features of SCADA
Features of typical SCADA
software

Dynamic process graphic
Real-time and Historical
trending
Alarms
Recipe Management
Security
Device connectivity
Database connectivity



Role of communication in Automation:
Communication has played a
vital role in the process of
Automation

The controller receives the
inputs from various sensors
and also receives the inputs
from the communication bus.

Master control is usually at
centralized location and in it
must receive data from all the
locations to enable it to to
process the inputs and reach
to the decision
Different protocols are used to
transfer the data to the
controller
Sensors
Controllers
Actuators
HMI
Display & alarm
Basic Elements of Automation
What is an actuator ?
Definition for actuator:
a mechanism that puts
something
into automatic action .
An actuator is a
mechanical device for
moving or controlling a
mechanism or system.
An actuator is operated
by a source of energy,
usually in the form of an
electric current, hydraulic
fluid pressure or
Pneumatic pressure , and
converts that energy into
some kind of motion.




Different actuators used to control the
given system
Relay
Solenoid
Valve
Motor
MHT
Contactor


In addition to above types of
actuators a system can be
controlled by a digital signal (flag
)generated locally or received
from remote end device through
communication channel using a
certain protocol for the
communication
Actuators
Actuators can be
categorized based on
1. Energy source used
electrically operated
Pneumatically operated
Hydraulically operated
Gas operated


2. Type of Motion
Linear motion
Rotary motion
Oscillatory motion


Perhaps the most common
type of actuator is powered by
air the pneumatic cylinder,
also known as the air cylinder

. Air cylinders are air-tight
cylinders, typically made from
metal, that use the stored
energy of compressed air to
move a piston when the air is
released or uncompressed.
They are most commonly used
in manufacturing and
assembly processes.
Grippers, which are used in
robotics, use actuators that are
driven by compressed air to
work much like human finger
RELAY:
Relay is an electromechanical device and has a
predesigned operating voltage.
Essentially it has a coil,a plunger,a spring and atleast
one pair of sands operations coil gets energized and
electromagnetic action as aresult of current flow in the
coil attracts the plunger resulting in the change of
contact position.
Contacts are designed to carry large current compared
to the operating current of the coil.Contact material can
withsatnd several thousands operations
The relays are available in different types
(sealed,Unsealed) latching /non latching and ac/dc
operating voltages, The contacts available in the relays
are N/O .N/c or C/O types.
Relay and Contactor:
Contactor again works on the same principle however
contactor has two types of contacts .Main contacts
and auxiliary contacts. Auxiliary contacts are used to
give the status to the controller while main contacts carry
the controlled current.
Contactors are available in different sizes depending on
the current carrying capability of the main contacts
Solenoid:
A solenoid also operates on the principle of electromagnetism like
relay however in addition to changing the status of the contacts
solenoid plunger movement also initiates mechanical movement
leading to change in the positions of other mechanical components
to control the pnematic Hydraulic or electrical circuits.
Stepper Motors
Used for measured
rotation
Can be held at a
particular position of
the shaft
Ideal for many
autonomous robots
requiring higher
precision
Servo Motors :
Used in closed loop control
systems in which work is
the control variable.
An integral feedback
device (resolver) or
devices (encoder and
tachometer) are either
incorporated within the
servo motor or are
remotely mounted, often
on the load itself
Double acting actuator
A double acting actuator is a mechanical device designed to supply powered bi-
directional actuation for secondary mechanisms. This is in contrast to single action or
spring return actuators and solenoids, which feature a powered stroke in one
direction only and rely on a secondary source of energy to reset or return the
actuator. The double acting actuator is typically driven by electric motors or
compressed oil and gas. Electrically-driven double action actuators supply their bi-
directional force by means of a motor reversing control circuit. Compressed gas and
oil actuators feature opposed inlet valves that direct the motive agent to one side or
the other of the actuator mechanism.
Actuators are devices used to operate a machine or mechanism remotely by
supplying a predetermined range of powered output movement. This movement is
generally broken down into two strokes in opposed directions. These may be
activation and recovery strokes or bi-directional operating strokes. Activation and
recovery systems are well-illustrated by a metal stamping machine where the die is
pushed down for the activation stroke and recovered, or returned, to a neutral
position in readiness for the next cycle. A bi-direction output may be seen in
a valve actuator, which turns in one direction to open the valve and in the opposite
direction to close it.
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Summary


Automation has a wide spread presence in almost every industry and
homes
Automation systems consist of sensors controllers and an actuators.
There are variety of sensors depending on the physical quantity to be
controlled. In power system the most common sensors are CTs and PTs
The simplest type of controller is a comparator and the advanced controllers
are programmable and are capable of handling number of inputs and
outputs. Microcontrollers and computers are widely used these days in the
automation.
Controllers must be programmed for the given sets of Inputs and outputs to
get the desirable results. All the intelligence is embedded in the controller
after programming in higher level languages and using suitable compilers.
There are different types of actuators controlling linear and rotational motion
and the most common actuators are Solenoids ,Relays and Motors
Communication plays a very important role in the Automation system and
depending on the application a particular Protocol is used. Internet
technology has revolutionized the automation. In Substation Automation
61850 protocol is used for acquiring data .
Automation has many advantages including making our lives comfortable
and enable human beings to do the things which otherwise would have
been impossible to do manually with same efficiency and accuracy.
Automation changes the nature of jobs and demands new skills and it is a
myth that it leads to unemploymentIt has shifted the focus from
Manufacturing industries to the Service related industries