1.

Introduction to Industrial Automation: -

1.1 Introduction to Industrial Automation. Evolution of industrial automation,
it’s needs and importance: -
Automation is the technology by which a process or procedure is performed with minimal
human interference through the use of technological or mechanical devices. It is the
technique of making a process or a system operate automatically. Automation crosses all
functions within almost every industry from installation, maintenance, manufacturing,
marketing, sales, medicine, design, procurement, management, etc. Automation has
revolutionized those areas in which it has been introduced, and there is scarcely an aspect of
modern life that has been unaffected by it.
The evolution of automation in industries has seen a transformation from manual labor to
advanced computer-controlled systems. It began with the use of basic machinery and simple
automation, such as the water wheel and steam engine during the Industrial Revolution. Over
time, technological advancements led to the development of electric motors, relay logic
systems, and eventually programmable logic controllers (PLCs). The digital revolution brought
about computer-based automation, including robotics, IoT, and Industry 4.0. Today,
automation is characterized by interconnected systems, data-driven decision-making, and the
integration of artificial intelligence, offering increased efficiency, precision, and adaptability in
industrial processes. This evolution has significantly impacted industries, enhancing
productivity, quality, safety, and competitiveness.

Need and Importance of Automation: Automation is necessary in industries to address

various needs and offers significant benefits:
1. Efficiency: Automation streamlines processes, reducing manual effort and time, thus
enhancing overall efficiency.
2. Importance: Automation improves productivity, quality, safety, and decision-making,
leading to cost savings and sustainability, making it a crucial component of modern industries.
3. Quality: It ensures consistent product quality, reducing defects and errors.
4. Safety: Automation handles hazardous tasks, minimizing risks to human workers.
5. Labor and Skill Shortages: It bridges labor gaps and reduces the dependence on skilled
workers.
6. Market Demands: To meet high production demands and stay competitive in the global
market.
7. Environmental and Regulatory Compliance: Automation helps in meeting environmental
regulations and reducing waste and energy consumption.
Benefits of automation: -
1. It increase productivity.
2. It increase product quality.
3. It increase accuracy.
4. It reduce manpower.
5. It reduce personal injury or accidents.

Limitations of automations: -
1. Current machine technology is not able to automate all desired task.
2. Certain task require more cost to automate than performing it manually.
3. The research and Development cost of automation is high.
4. Initial cost of automation system is very high.
5. Reduction of human relationship.

1.2 Automation hierarchy- field level, control level, supervisory and production
control level and enterprise level: -

1. Field level: -
 The field level is the lowest automation hierarchy level and is made up of field devices
such as actuators and sensors.
 These devices are responsible for collecting data from the physical world, controlling
processes, and transmitting information to higher-level control systems.
 Actuators are used to control the process parameters.
 Real time process parameters such as level, flow, temperature, and pressure are
converted into electrical signals by the field level sensors.
 Data collected from the sensors is transferred to the controller for further monitoring and
analysis of the real time parameters.
 Sensors include: - proximity sensors, flow meters, thermocouple, RTDs among others.
 Actuators include: -pneumatic actuators, flow control valves, relays, solenoid valves.

2. Control level: -
 The control level is made up of automation devices such as PLCs and CNC machines.
 Industrial automated controllers trigger the actuators as per the processed sensor signals,
control techniques, or programs.
 PLCs (programmable logic controllers) are widely used as industrial controllers of choice
because they can deliver automatic control functionalities as per sensors’ inputs.
 PLCs allow industrial automation operators to program control functions to execute
automatic process operations. PLCs are made of different modules such as; digital I/O,
communication modules, analog I/O and CPU.

3. Supervising and Production Control Level: -

 In this level the automatic devices and monitoring system enables the controlling and
intermediate functions.
 These machines can use HMIs (Human Machine Interface) supervising various
parameters such as setting production target, setting machine’s start and shut down time,
distribution control systems (DCS), supervisory control and data acquisition (SCADA).

4. Enterprise or Information level: -

 Often referred to as Enterprise Resource Planning (ERP), this is the top industrial
automation hierarchy level that is tasked with management of the entire industrial
automation system.
 Tasked executed at this level include; market and customer analysis, sales, orders, and
production planning just to mention a few.
 All industrial automation hierarchy levels consist of industrial communication networks that
transfer information from one hierarchy level to another. The communication networks can
vary from one hierarchy level to the other.

1.3 Analog control, Digital control- Supervisory Control and Direct Digital Control: -
1. Analog Control: -
Analog Signals: Analog control systems use analog signals, which can represent a wide
range of values. Common examples of analog signals include voltage, current, pressure,
temperature, and speed. These signals can vary smoothly and continuously
Control Elements: In an analog control system, you have control elements like sensors,
transducers, and actuators. Sensors (e.g., analog sensors) detect physical parameters and
convert them into analog signals. Transducers can convert one type of analog signal into
another (e.g., voltage to current). Actuators, on the other hand, receive control signals and
produce actions or adjustments, such as changing the speed of a motor or adjusting the
position of a valve.
Feedback Loop: Feedback is a crucial component of analog control systems. Feedback
involves comparing the actual process variable (measured by sensors) to the desired output.
The error signal is generating after comparison and using this error signal this adjusts the
control action. The feedback loop allows the control system to make continuous adjustments
to maintain the desired output.
Proportional-Integral-Derivative (PID) Control: PID control is a widely used technique in
analog control systems. It consists of three components: Proportional (P), Integral (I), and
Derivative (D). The proportional term responds to the current error, the integral term
accumulates/counts past errors, and the derivative term predicts future errors. By adjusting
these components, the control system can achieve accurate and stable control.
Open-Loop vs. Closed-Loop Control: Analog control systems can be categorized into open-
loop and closed-loop control. Open-loop control doesn't use feedback from the process to
adjust the control action, whereas closed-loop control uses feedback to continuously adjust
and maintain the desired output. Closed-loop control is generally more precise and reliable.
Applications: Analog control is used in a wide range of applications, including temperature
control in ovens, motor speed control, and many other industrial and automation systems. It is
well-suited for systems where smooth and continuous control is necessary.
Signal Conditioning: Analog signals may require signal conditioning, which involves
amplification, filtering, and scaling, to ensure that the signals are accurate for control
purposes.

Digital Control: -
Digital control systems utilize digital sensors to measure physical parameters such as
temperature, pressure, or position. These sensors convert analog physical data into digital
signals. Computers, whether they are general-purpose computers or specialized control
computers, are used as digital controllers in automation. Computers in digital control systems
provide a high level of precision and accuracy. They can perform complex calculations and
comparisons to maintain precise control over outputs. Computers use digital logic operations
to make control decisions Computers can process feedback from sensors
Supervisory Control oversees and coordinates multiple processes, subsystems, or equipment
at a higher level. Supervisory Control provides a high-level view and makes strategic
decisions. Supervisory Control collects and analyzes data from various sources to optimize
the entire system. Supervisory Control systems are typically more complex, with advanced
features for system-wide optimization. Supervisory Control is used in large-scale industrial
facilities and complex systems where coordination is essential. Supervisory Control in
automation, often implemented through a Supervisory Control and Data Acquisition (SCADA)
system, relies on the integration of computers to provide centralized control, monitoring, and
management of various processes and equipment. These computers are equipped with
specialized SCADA software that acts as the brain of the system. They provide a single point
of control and monitoring for all connected processes, machines, and systems. Supervisory
control systems present the acquired data to human operators through computer interfaces
Computers in supervisory control systems maintain historical data logs. This stored data
serves as a historical record of system performance Computers in supervisory control
systems enable remote monitoring and control.

a. supervisory control b. direct digital control

Direct Digital Control focuses on localized control within individual devices or processes.
Direct Digital Control offers precise, local control over specific equipment or processes. Direct
Digital Control focuses on local data acquisition and control for specific devices. Direct Digital
Control systems are usually simpler, tailored to control specific equipment or processes.
Direct Digital Control is commonly employed in localized control applications like HVAC
systems, manufacturing processes.
Direct Digital Control (DDC) in automation, when integrated with computers, provides a
precise and flexible approach to regulating and managing various processes and equipment.
Computers play a central role in DDC systems by processing digital data and executing
control algorithms DDC systems are typically centered around digital controllers, often in the
form of computers. These computers are equipped with specialized DDC software that acts
as the control brain of the system.
DDC systems rely on digital signals, which are discrete and binary These digital signals
provide high precision and reliability. DDC systems integrated with computers are widely used
in various applications, including industrial automation, manufacturing processes, building
management systems, HVAC control, and more.

1.4 Types of Automation-

Automation systems can be categorized on the basis of flexibility of integration in
manufacturing process
1. Fixed Automation: -
In this type of automation, the sequence of processing operations are fixed. It is used in high
volume production industry, where fixed the set of operations are expected. Continuous,
discrete, and mass production uses this automation. This automation requires high initial cost
or equipment, so it is used in most of the large-scale industries. Ex. paint shop, conveyor
automate assembly, distillery process, etc.
Fixed automation is suitable in following cases-
1. High production rate.
2. Predictable and stable demand for two to five years.
3. High initial investment.

2. Programmable Automation: -
It is use for changeable sequence of operation. The operation sequence is control by program
written by the person or programmer. The programmable automation system is use in low and
medium volume production. Investment in programmable automation is less. It is technically
use in batch process systems where job variety is low and product volume is medium to high.
Ex. Steel, rolling mills, and paper mills. following are the case study of programmable
automation 1. Lower production rate than fixed automation. 2.Flexibility to deal with variations.
3.Medium Investment. 4. Most suitable for batch production.

3. Flexible Automation: -
Flexible Automation is an extension of programmable automation. This system capable of
producing variety of products with virtually no loss of time. It is lower than fixed automation.
Human operators use high level of command to store data inti computer. Each production
machine receives preloaded settings and instructions from computers. This type of
automation is typically used where product variety are same and jobs are medium. Ex.
Multiple-purpose, CNC machines, automated guided vehicles, etc.
4. Integrated Automation-
It denotes complete automation of the plan. It may include technologies such as computer
aided design,(CAD) , computer design, CNC ,machine tool, flexible machine system,
automated storage and retrieval system, robots and automated cranes. Degree of automation
in this type depends upon manufacturing and assembly specification, labor condition, labor
cost.
OR
Q. List different type of industrial automation and explain them.
Types of Industrial Automation Systems:
 Fixed Automation System: In a Fixed Automation System, the production equipment is fixed
with a fixed set of operations or tasks and there are rarely any changes to these operations.
Fixed Automation System is usually used in continuous flow processes like conveyors and
mass production systems.
 Programmable Automation System: In Programmable Automation System, the sequence of
operations as well as the configuration of the machinery can be changed using electronic
controls. This system requires a significant amount of time and effort to reprogram the
machines and usually used in batch process production.
 Flexible Automation System: A Flexible Automation System is usually, always controlled by
computers and are often implemented where the product varies frequently. CNC machines
are the best example for this system. The code given by the operator to the computer is
unique to a particular job and based on the code; the machine acquires the necessary tools
and equipment for the production.
 Integrated Automation System: An Integrated Automation System is a set of independent
machines, processes and data, all working synchronously under the command of a single
control system to implement an automation system of a production process.

1.5 Different symbols used in Industrial control circuit: -

1. Crossing of conductors: - 2. Joint or junction of conductors: - 3. Earth or Ground: -

4. Chassis: - 5. Induction Lamp: - 6. Variable Resistor: - 7. Capacitor: -

8. Fuse: - 9. Switch: - 10. Switch Fuse Circuit: - 11. Three Pole Switch: -

12. On push button: - 13. Off push button: - 14. Pressure Switch Contact: - 15. Thermostat Contact: -

16. Flow switch: - 17. Thermal Overload Relay: - 18. Control Contact Overload: -

17. Timer delay relay 18. Off delay relay 19. On delay relay 20. Off delay relay contact
contact: - contact: - contact: -

21. Contactor or relay coil: - 22. Limit switch: - 23. Selector switch 2 position: -
24. Selector switch 3 position: - 25. Selector switch double break: - 26. Circuit Breaker: -

27. Selector switch with 3 28. Solenoid valve 29. Winding: - 30. Inductor: -
position double break: - double acting: -

31. Solenoid Coil: - 32. Controlled Transformer: - 33. Induction motor single phase: -
34.Three phase squirrel cage induction motor: - 35. DC shunt motor: -

1.6 Concept of power circuit and control circuit: -

1. Power Circuit:
 A power circuit is responsible for supplying electrical power to the primary components of
a system, such as motors, heaters, lights, or any other devices that require electrical
energy to perform their intended functions.
 Power circuits carry the high electrical current and voltage needed to drive the equipment.
These circuits often involve high-power components and heavy-duty wiring to handle the
electrical load.
 Power circuits are typically designed to provide a direct and uninterrupted supply of
electricity to the loads they serve.
 They are usually protected by safety devices like fuses and circuit breakers to prevent
overcurrent and short-circuit conditions that could lead to damage or fires.
Types of the power circuits: -
1. Single-Phase Power Circuit.
2. Three-Phase Power Circuit.
3. Direct Current (DC) Power Circuit.
4. Low Voltage Power Circuit.
5. Medium Voltage Power Circuit.
6. High Voltage Power Circuit.
7. Motor Control Circuit.

2. Control Circuits: -
 A control circuit, on the other hand, is a low-voltage circuit that manages the operation of
the power circuit and the associated equipment.
 Control circuits are responsible for sending signals and commands to control devices like
relays, contactors, and motor starters.
 These devices, in turn, control the flow of electricity in the power circuit to turn equipment
on or off, change the direction of motors, or adjust settings.
 Control circuits often involve switches, pushbuttons, sensors, timers, and control logic
elements like PLCs (Programmable Logic Controllers).
 They are designed to facilitate the safe and precise control of machinery and processes,
allowing for automation, interlocking, and coordination of various components.

 DOL Starter: -

 DOL starter is Direct Online Starter also known as across the line starter.
 It consists of protective devices, overload relay, main contactor for motor starting
operation.
 It is use for Low rating, usually 5HP motor.
 The wiring diagram for a DOL starter is shown above. A direct online starter consists of
two buttons, a GREEN button for starting and a RED for stopping purpose of the motor.
The DOL starter comprises an MCCB or circuit breaker, contactor and an overload relay
for protection. These two buttons, i.e. Green and Red or start and stop buttons control the
contacts.
 To start the motor, we close the contact by pushing the Green Button, and the full line
voltage appears to the motor. A contactor can be of 3-poles or 4-poles. Below given
contactor is of 4-pole type.
 It contains three NO (normally open) contacts that connect the motor to supply lines, and
the fourth contact is “hold on contact” (auxiliary contact) which energizes the contactor coil
after the start button is released.
 If any fault occurs, the auxiliary coil gets de-energized, and hence the starter disconnects
the motor from supply mains.

STAR-DELTA STARTER: -

A Star-Delta starter, also known as a Wye-Delta starter, is an electrical control device used to
start three-phase induction motors. It is specifically designed to reduce the high starting
current of these motors, which can be several times the normal running current. Here's an
explanation of the concept of a Star-Delta starter:
Key Components and Concept:
1. Three-Phase Induction Motors: Star-Delta starters are commonly used with three-phase
induction motors, which are widely used in industrial applications due to their efficiency and
reliability.
2. Starting Current: When a three-phase motor starts, it experiences a surge in current,
often referred to as inrush current. This high starting current can lead to electrical and
mechanical stress on the motor and the power supply system.
3. Star Connection (Y-Connection): In the first stage of the motor's start-up, the motor
windings are connected in a star configuration (Y-connection). This connection reduces the
voltage applied to the motor, resulting in lower current flow.
4. Reduced Torque: While in the star configuration, the motor operates at reduced voltage
and torque, allowing it to start smoothly and with much lower current. However, the torque
generated is also reduced at this stage.
5. Delta Connection(Δ-Connection): After a predetermined time, typically a few seconds,
the motor is switched to a delta configuration (Δ-connection). This configuration provides full
voltage to the motor, allowing it to run at its rated speed and with the required torque.

1.7 The need of PLC over hardware relay logic, benefits and limitations of PLC in
industrial automation.: -
Programmable Logic Controllers (PLCs) offer several advantages over traditional hardwire
relay logic in industrial control systems. Here are some of the reasons why PLCs are
preferred:
1. Flexibility and Programmability:
i. Adaptability: PLCs are highly flexible and can be easily reprogrammed to accommodate
changes in the control process without the need for rewiring.
ii. Programming Ease: PLC programming uses a ladder logic, a graphical programming
language that is more comfortable for control system designers, making it easier to
understand and modify.
2. Space and Cost Savings: -
i. Reduced Wiring: PLCs significantly reduce the amount of wiring required in a control
system.
ii. Compact Design: PLCs are compact and can replace a large number of relays, timers, and
counters, saving physical space.
3. Diagnostic Capabilities: -
i. Monitoring and Troubleshooting: PLCs offer extensive diagnostic capabilities. They can
monitor inputs and outputs in real-time, log data, and provide error messages, which
makes it easier to identify and troubleshoot issues in the control system.
ii. Remote Access: Some PLC systems support remote access and monitoring, enabling
maintenance personnel address problems without being physically present at the control
panel.
4. Integration with Other Systems:
i. Communication Protocols: PLCs are designed to communicate with other devices and
systems. This allows integration with other automation and control components, such as
Human-Machine Interfaces (HMIs), sensors, and other PLCs.
ii. Data Exchange: PLCs can exchange data with higher-level systems, such as Supervisory
Control and Data Acquisition (SCADA) systems, to improve overall system efficiency.
5. Complex Control Logic:
i. Mathematical Operations: PLCs can perform mathematical operations and complex control
logic that may not be easy to implement using hardwired relay logic.
ii. Timers and Counters: PLCs have built-in timers and counters that can be easily
programmed.
6. Documentation and Standardization:
i. Documentation: PLC programming allows for clear and structured documentation of the
control logic, making it easier for engineers.
ii. Standardization: PLCs support standard programming languages and are more conducive
to standardization.
Benefits and Limitations of PLC in Industrial Automation: -
Advantages: -
1. Flexibility. 2. Reliability.
3. Scalability. 4. Real time operation.
5. Integration. 6. Diagnostics.
7. Programming. 8. Cost Effective.
9. Communication Abilities. 10. Safety Features.

Disadvantages: -
1. Programming in PLC can be complex for the complex system.
2. It provides limited processing power.
3. It is difficult to switch between PLC brands because of lack of standardization.
4. The connectivity that it offers is not always smooth and that can be trouble.
5. The system is more open to the cyber risk.

Questions: -
1. Comparison between field level and entreprise level: -
Field Level Automation:
Scope:
Localized Control: Field-level automation deals with the control and monitoring of individual
devices and processes at the lowest level of the automation hierarchy.
Components:
Sensors and Actuators: It involves the use of sensors to collect data and actuators to control
physical processes at the operational or shop-floor level.
Functionality:
Real-time Control: Field-level automation is often focused on real-time control of machinery
and processes, ensuring efficient and immediate response to changes in the environment.
Examples:
PLCs (Programmable Logic Controllers): These are commonly used at the field level to
control machinery and processes in manufacturing and industrial settings.
Sensors and Instrumentation: Devices like temperature sensors, pressure sensors, and flow
meters are part of the field-level automation to collect data.
Communication:
Local Area Networks (LAN): Communication networks at the field level are typically localized
and may use protocols optimized for real-time control.

Enterprise Level Automation:

Scope:
Global View: Enterprise-level automation deals with the coordination, optimization, and
management of the entire organization or multiple facilities. It provides a holistic view of the
business processes.
Components:
SCADA (Supervisory Control and Data Acquisition): SCADA systems are often used at the
enterprise level to monitor and control processes across different locations.
ERP (Enterprise Resource Planning): Systems like ERP manage overall business processes,
including manufacturing, finance, human resources, and more.
Functionality:
Business Process Optimization: Enterprise-level automation focuses on optimizing business
processes, resource allocation, and decision-making based on data collected from various
sources.
Examples:
Enterprise-wide Software: ERP systems like SAP, Oracle, or Microsoft Dynamics that
integrate various business functions.
Data Warehousing and Analytics: Systems that collect, store, and analyze data from different
sources to provide insights for strategic decision-making.
Communication:
Wide Area Networks (WAN): Communication networks at the enterprise level span larger
geographical areas and often use standard protocols for data exchange.

2. difference.
3. List different systems used in Industrial Automation
Programmable Logic Controllers (PLCs):
PLCs are ruggedized computers designed to control industrial processes and machinery.
They receive input from sensors and other devices, execute control algorithms, and provide
output to actuators and devices.
Distributed Control Systems (DCS):
DCS is a control system that uses multiple controllers distributed throughout a system to
control different processes. It is commonly used in large-scale industrial processes such as
chemical plants and power plants.
Supervisory Control and Data Acquisition (SCADA) Systems:
SCADA systems provide a centralized platform for monitoring and controlling industrial
processes. They collect data from sensors and devices in real-time, enabling operators to
make decisions and adjustments.
Human-Machine Interface (HMI):
HMIs provide a graphical interface for operators to interact with and monitor the industrial
automation system. They display real-time data, control settings, and allow for manual
intervention.
Industrial Communication Systems:
Various communication protocols are used for data exchange between devices in industrial
automation. Examples include Profibus, Modbus, Ethernet/IP, and Foundation Fieldbus.
Motion Control Systems:
These systems control the movement of machinery and equipment. They involve the use of
servo drives, motors, and controllers to achieve precise motion in industrial processes.
Industrial Robotics:
Industrial robots are automated systems that can perform tasks such as welding, assembly,
painting, and material handling. They are programmed to operate autonomously or in
collaboration with human workers.
SCARA (Selective Compliance Assembly Robot Arm) Systems:
SCARA robots are specific types of industrial robots designed for tasks requiring high-speed
and precision, such as assembly and pick-and-place operations.
Manufacturing Execution Systems (MES):
MES systems manage and optimize manufacturing operations on the shop floor. They collect
and analyze data to improve production efficiency, quality, and traceability.
Process Control Systems:
These systems regulate and control continuous production processes, such as those in
chemical plants, refineries, and petrochemical facilities.
Building Automation Systems (BAS):
BAS systems control and monitor building facilities, including heating, ventilation, air
conditioning (HVAC), lighting, and security.
Safety Instrumented Systems (SIS):
SIS are designed to prevent or mitigate the impact of hazardous events in industrial
processes. They include safety controllers, sensors, and shutdown systems.
Energy Management Systems (EMS):
EMS systems monitor and optimize energy consumption in industrial facilities to improve
efficiency and reduce costs.
Quality Control Systems:
These systems ensure the quality of products through the use of sensors, cameras, and
automated inspection processes.
Asset Management Systems:
Asset management systems track and manage the lifecycle of industrial assets, including
maintenance schedules, repair history, and performance monitoring.