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 Robotics and Applications
and Control
Electric Load Calculations
Industrial Safety
Industrial Electrical Devices LT/HT
Industrial Control Devices Cables and Types of Cables
AC/DC Motors Inverters
Generators, Cooling Towers, Troubleshooting with
Chillers and Burners
electrical and electronic
PLC
devices
HMI (Human Machine
Interface) Identification and Bar Code
Servo Systems systems
Stepper/Servo Motors Preventive and Corrective
Sensors, Encoders and Maintenance of Machines
Transducers
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, -Controller, -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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Institute of Professional Advancement 2/22/2011
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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