Institute of Professional Advancement 2/22/2011

Industrial Electronics

Institute of Professional Advancement

Industrial Electronics

Syed Qaseem Ali

qaseemali@gmail.com
0333-2347208

MSEE (Power and Control) IIT, Chicago, USA

BE (Electronics) NEDUET, Karachi, Pakistan

Introduction

• Name
• Student or Professional
• Qualification
• Experience and Affiliation
• Why are you attending this course?
• What do you expect to learn?

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Industrial Electronics

Course Outline
• Introduction to Automation
and Control
• Industrial Safety
• Industrial Electrical Devices
• Industrial Control Devices
• AC/DC Motors
• Generators, Cooling Towers,
Chillers and Burners
• PLC
• HMI (Human Machine
Interface)
• Servo Systems
• Stepper/Servo Motors
• Sensors, Encoders and
Transducers
• Robotics and Applications
• Electric Load Calculations
• LT/HT
• Cables and Types of Cables
• Inverters
• Troubleshooting with
electrical and electronic
devices
• Identification and Bar Code
systems
• Preventive and Corrective
Maintenance of Machines
• Instrument Calibration

Labs
• Different Types of sensors
• Encoders
• AC Motors
• DC Motors and types
• Stepper Motor and types
• Servo Motor
• PLC
• Different Types of Cables
• Frequency Drives

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Industrial Electronics

Introduction to Automation and

Control
• What is Automation?
• The procedure of minimizing human
intervention/dependence in production of
goods and services is called automation.
• It is not merely Mechanization, but replaces
human sensory and mental dependence too.
• Example:
• Automated Software testing, Manufacturing Processes,
Automatic Assembly lines, Automatic Lifts, Automatic Cars,
Processes in a human body etc.

How to minimize human intervention?

• We can minimize human intervention by using
Control Devices.
• Control Devices may be mechanical,
electronic, electro-mechanical, Biological,
Organic.
• Examples:
• Relays, Motors, µ-Controller, µ-Processor, PLC, SCADA, DCS.

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Industrial Electronics

Types of Automation
• There are three basic types of Automation
• Fixed automation
– For fixed sequence of operation and very high
production rates and volume.
• Programmable automation
– Can accommodate a specific kind of change, but
retrospectively has a fixed process, for medium
production rates and batch production.
• Flexible automation
– Designed for manufacturing variety of products low
production volume and rates, varying product designs.

Fixed Automation
• Applicability
– Mass production, Long Product Cycles.
• Advantages
Speed, Efficiency, Troubleshooting will be easy,
Low Unit Cost
• Disadvantages
– Rigid, Initial Investment will be high, Low Volume
production will be costly (Cost will vary)

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Industrial Electronics

Programmable Automation
• Applicability
– Batch Production, Product with different options.
• Advantages
– Product Variants possible, Low Unit Cost for Large
Batches
• Disadvantages
– Changeover time reduces Efficiency, Limited
Variations possible, Higher cost than Fixed
Automation

Flexible Automation
• Applicability
– Varying production rates, varying demands, Short
product lifecycles.
• Advantages
– High level of Flexibility, One time investment for a
wide variety of products (including different designs),
Benefitial for prototyping
• Disadvantages
– Initial Investment, Changeover/Setup time Very high.

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Industrial Electronics

Reasons for Automation

• Human error minimization, increased product
quality.
• Labor Cost reduction
• Speeds up the process
• Increased Safety
• Data Acquisition becomes easy
• Lower Product Cost
• Changeover and setup time decreases
• In process inventory and wastage is reduced

Control Systems
• Open Loop without Feedback
– Examples
• Drill Machine, Car (without the human), Grass cutter,
Automatic Toaster, Garage door opener
• Close Loop with Feedback
– Examples
• Car (with the human), Thermostat in an AC, Automatic
Lifts, Cruise Control of a car

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Industrial Electronics

Industrial Safety

• Hazard
– Any process, place, event, equipment or action
that could result in any type of injury to
personnel.

Types of Hazards
• Chemical
• Physical
– Electrical
– Thermal
– Environmental (Noise, Spatial)
• Biological
• Human Hazard (Stupidity, Human Needs)
• Ergonomic

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Industrial Electronics

Most common Hazards in an industrial

setup
• Chemical
– Material Safety Datasheets
– NFPA 704

Chemical
• Liquifued oxygen container
• Petrol Pump

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Industrial Electronics

Safety Equipment / PPEs (Personal

Protective Equipment)
• Safety Glasses
• Bunny Suits / Hazmat Suits
• Gloves
• Air purifying respirator
• Hard Hat / Helmet
• Face guard
• Safety Shoes
• Ear Plugs / Ear Muffs
• Fire Resistant Clothing
• Safety Harness (to prevent falling from high places)
• Reflective Vest
• First Aid Kit
• Fire Extinguisher

* For a comprehensive list visit http://www.protecdirect.co.uk/Personal-Protective-PPE.htm

Most common Hazards in an industrial

setup
• Electrical Hazard
– High Voltage
– High Current
– Loose/Naked Wiring

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Industrial Electronics

Most common Hazards in an industrial

setup
• Mechanical
– Uncovered moving parts
– Rotating parts

Most common Hazards in an industrial

setup
• Thermal and Ergonomic
– Hot or cold surfaces
– Hot or Cold environments
– Repetitive tasks – RSSI
– Work environment
– Continuous Noise

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Industrial Electronics

References
• http://www.seas.upenn.edu/~meam520/slides/intautoslides.pdf
• http://www.inverter-china.com/blog/articles/Automation/83.html
• http://www.scribd.com/doc/37526868/Lect-1-Introduction-to-
Industrial-Safety
• http://en.wikipedia.org/wiki/Industrial_safety_system
• http://industrialplantsafety.com/
• http://www.acusafe.com/Hazard_Analysis/HAZOP_Technique.pdf
• http://en.wikipedia.org/wiki/Hazard_and_operability_study
• http://www-
ssrl.slac.stanford.edu/safety/acceleratorwork/documents/7_10_ge
neral_industrial.pdf
• http://www.lanl.gov/safety/electrical/docs/arc_flash_safety.pdf
• http://en.wikipedia.org/wiki/Hazard_symbol

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