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This gives introduction to Automation ,discusses basic elements of Automation,impact of Automation and advantages /disadvantages of Automation
Automation Basics:
Automation Basics R J Phansalkar
Objectives:
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 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:
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 ?:
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. .
Slide 6:
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:
Automation cycle Sense the Inputs Process the Logic Give the Outputs Outputs Machine or Process Controller Inputs
History of Automation:
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
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ROBOTICS
AUTOMATION IS EVERYWHERE:
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:
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:
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
Level of Control:
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
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EXAMPLES OF AUTOMATION
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Home Automation
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
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Sensors Controllers Actuators HMI Display & alarm Communication Protocol Basic Elements of Automation
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Sensors Controllers Actuators HMI Display & alarm Basic Elements of Automation
Sensors:
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 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.
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Different types of sensors
highways, classify vehicles for automated toll booths, as well as provide timing mechanism for speed and red light cameras.
Construction of C.T.:
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 :
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:
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.
Types of P.T. :
Types of P.T. Some types of p.t. are Shell type Dry type Oil type Rating Type below 5000 v Shell type 5000-13800 v Dry type and oil type above 13800 v only oil type
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Sensors Controllers Actuators HMI Display & alarm Basic Elements of Automation
What is a controller ? :
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 ? :
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
Types of controllers:
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 }
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Controllers used for building automation can be grouped in 3 categories . Programmable Logic Controllers (PLCs) , System/Network controllers, and 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.
Types of Controller:
Types of Controller ON OFF controller a bangbang controller ( onoff controller ), also known as a hysteretic controller , that switches abruptly between two states. (also called a Bang- bang Controller) Bangbang controls frequently arise in minimum-time problems. For example, if it is desired to stop a car in the shortest possible time at a certain position sufficiently far ahead of the car.. the solution is to apply maximum acceleration until the unique switching point , and then
apply maximum braking to come to rest exactly at the desired position. This solution, which can be "uncomfortable" for the passengers, is a bangbang solution: maximum engine throttle followed by maximum braking. A familiar everyday example is bringing water to a boil l in the shortest time, which is achieved by applying full heat, then turning it off when the water reaches a boil.
Slide 57:
Proportional controller
Controller:
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
Programming:
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
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C C++ Java
Types of Instructions:
Types of Instructions I/O Handling Assigning Mathematical Logical Repetitive Branching
Slide 66:
A building Automation system (BAS)
Continuous and Discrete Systems 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. 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.
Features of SCADA:
Features of SCADA Features of typical SCADA software Dynamic process graphic Real-time and Historical trending Alarms Recipe Management Security Device connectivity Database connectivity
Different Protocols:
Different Protocols IEEE Instrumentation BUS CAN Bus Modbus Prophi Bus 61850 Protocol TCP/IP
Different Protocols:
Different Protocols IEEE Instrumentation BUS CAN Bus Modbus Prophi Bus 61850 Protocol TCP/IP
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Sensors Controllers Actuators HMI Display & alarm Basic Elements of Automation
What is an actuator ?:
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 Actuators can be categorized based on Energy source used electrically operated Pneumatically operated Hydraulically operated Gas operated 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 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.
Solenoid:
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.
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Stepper Motors Used for measured rotation Can be held at a particular position of the shaft Ideal for many autonomous robots requiring higher precision
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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
Summary :
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
THANKS:
THANKS
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http://www.youtube.com/watch?NR=1&v=b2KQVkdAGzQ Pressure safety Valve operation