Understanding

Automation Control
Systems

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

 What You Will Learn

After completing this lesson, you should be able to:

• Define an automated system
• Classify automation control system types
• Identify equipment used to control processes
• Identify tools used with automation control systems
• Recognize who works with automation control systems
• Recognize who manufactures automation control systems
 What Is an Automated System?

Automated systems revolutionized manufacturing and are becoming

more prevalent everywhere, from factories to grocery stores and car
washes. Automated systems can even be found in your home.

Definition:
Automated System: A
system that has been
made less dependent on
direct human control or
management.
What Is an Automated System?

Discussion: Automated Systems

We use many fully- or partially-automated systems in
our daily lives:
• Washing machine
• Thermostat and heating system
• Dishwasher
• Microwave
• Toaster
What other automated systems can you think of?
What Is an Automated System?

Take Note: Automated Systems

Think of a washing machine.
List the tasks that would be performed manually if the
washing machine were not automated:
 What Is an Automated System?

Industrial automation systems are designed to make or process

raw materials or parts into finished products using basic
production resources like:
• Machines
• Equipment
• Tools
• Energy:
– Electric
– Fluid (hydraulics)
– Air (pneumatics)
– Heat
– Kinetic
– Atomic
 What Is an Automated System?

Automated systems are used in many industrial applications:

• Automobile assembly • Oil and gas extraction
• Washing machines • Bottling
• Printing presses • Packaging
 Advantages of Automated Systems

Automated systems offer many advantages:

• Accuracy:
– Can perform detailed work and follow
precise instructions without error.
• Safety: Can work in places where
it would be unsafe for humans:
– In areas with high radiation levels
– Under water
– In space
• Speed:
– Can process and calculate information
much faster than humans
– Can adjust the machine or process
instantly
 Automated System Advantages

Automated systems offer many advantages:

• Efficiency:
– Can run 24 x 7 x 365 without fatigue
– Can maintain consistent quality of
workmanship; materials are not
wasted due to human error.
– Are cost effective
• Repetition:
– Can perform the same task over
and over without making mistakes,
getting bored or needing breaks
Automated System Advantages

Video: Ingot Application

Watch an example of an automated system.

10
Automated System Advantages

Discussion: Automated Systems Video

Answer the following questions:
• Could a human drill the disks perfectly each time?
• How much longer do you think it would take to wash and
drill the disks manually?
• Rejected disks were pushed off the conveyor into a scrap
bin. Could a human operator reject defective parts as
quickly or consistently?
• How fast do you think the products move in real time?
Would you be able to see parts rejected?
 How Automated Systems Work

The function of an automated system can be divided into three steps:

Start/Stop
Panel Motor

12
 How Automated Systems Work

1. Monitor: The control device (computer or controller) receives inputs

(i.e., information) from system devices (pushbuttons, sensors, etc.)

Start/Stop
Panel Motor

1. Monitor

Controller

13
 How Automated Systems Work

2. Evaluate: The control device evaluates the inputs.

Start/Stop
Panel Motor

1. Monitor

Controller
2. Evaluate

14
 How Automated Systems Work

3. Control: The control device sends output commands to operate

the machinery (motors, pumps, etc.).

Start/Stop
Panel Motor

1. Monitor 3. Control

Controller
2. Evaluate

15
How Automated Systems Work

Discussion: Bicycle Manufacturing

Think about an automation system used to
manufacture bicycles:
1. What types of information might be monitored by a
controller?
2. What decisions/evaluations might be made as
bicycles are manufactured?
3. What devices might be controlled by a controller in
the system?
How Automated Systems Work

Example: Comparing a Manual and Automated Process

Automation changed grocery store checkout lines in many
ways.
Before automated systems:
• Grocers stamped prices on each item
as they stocked the shelves.
• At checkout, the cashier read the price
of each item and manually entered it
into the register.
• The cashier took the payment,
calculated the required change, and
hand wrote a receipt.
How Automated Systems Work

With automated systems:

• Products are manufactured with UPC codes that contain
useful data, including price.
• At checkout:
– Each product is scanned by a bar code reader and data, such as
item and price, are sent to the cash register.
– All discounts, coupons, etc. are calculated and the items are
automatically tallied.
• The system then:
– Accepts payment
– Gives change automatically
– Prints a receipt
– Prints coupons based on your purchases
• Finally, the automated system:
– Records all of the items purchased by you and other shoppers
– Updates the store inventory making re-order of items easier for
the grocer.
How Automated Systems Work

Discussion: Bar Code Reader

Do you have a bar code reader app
on your phone?
What information can you receive
using a bar code reader?
How has this technology impacted
our lives?
How do you think this technology has
improved industrial automation?
How Automated Systems Work

Question: Three Steps of an Automated System

As we learned earlier, the function of an automated system
can be divided into three steps:
• Monitor
• Evaluate
• Control
In an automated grocery store checkout line, what activities
fall under each of these three steps?
 Control System Types

Automated systems employ a variety of control methods:

• Discrete control
• Process control:
– Batch
– Continuous
• Motion control:
– Robotics
• Power control
• Safety control
 Discrete Control

Discrete control is used extensively in assembly line production.

Definition:
Discrete Control: A manufacturing process that involves
the assembly of parts into products, such as light bulbs,
telephones, fuel pumps, etc.
 Discrete Control

Discrete control is used to manufacture a wide range of products,

including:
• Automobiles
• Furniture
• Appliances
• Commercial machinery
Discrete Control

Question: Other Discrete Applications

What other applications can you think of that would use a
discrete manufacturing process?
 Process Control

Unlike discrete control, which is used to produce things by assembling

parts, process control is used to produce things that must be contained
in a bucket or tank, such as liquid, powder or vapor.

Definition:
Process Control: To maintain conditions, such as
temperature, within a desired range by adjusting selected
variables in a system.
 Process Control

Process control is used extensively in industrial applications, such as:

• Food and beverage

• Oil refining
• Chemical processing
• Electricity generation
 Process Control

Process control applications are

typically classified as either:
• Batch
• Continuous

Batch and continuous systems share

some similarities:
• Material must be combined in precise ways
at precise points in the process.
• Precise control of process conditions must
be maintained to ensure product quality and
safe operation.
 Batch Control

In Batch control material is added to a vessel, a process takes place,

then the product is removed.

Definition:
Batch Control: A manufacturing process in which products
are produced in batches or lots.
 Batch Control

Some applications that use a batch control manufacturing process

include:
• Brewing
• Pharmaceuticals and chemicals
• Paint and ink
• Adhesives
• Baking
Batch Control

Video: Batch Process

Watch an example batch control process.
Notice how consistently the process is repeated.

30
Batch Control

Question: Other Batch Processes

What other industrial applications use a batch control
manufacturing process?
 Continuous Control

Continuous control is used for applications that are ongoing.

Definition:
Continuous Control: A manufacturing process in which raw
material is fed and removed from the process at the same
time (e.g., fluid that is constantly moving). Once started, an
application may run in an uninterrupted, or continuous,
manner for months or years.
 Continuous Control

Some applications that use continuous control include:

• Oil refining
• Electricity generation
• Plate glass manufacturing
• Paper production
• HVAC
• Waste product treatment
Continuous Control

Video: Continuous Process

Watch an example of a continuous control
process.

34
Continuous Control

Question: Continuous Control

What other products do you think are manufactured using a
continuous control process and why?
 Motion Control

Motion control is another distinct control system type.

Definition:
Motion Control: A system in which position and/or velocity
of machines are controlled using various devices.
 Motion Control

Devices commonly used for motion control include:

• Hydraulic pumps with flow sensors
• Linear actuators with position sensors
• Electric motors with feedback sensors
• Computerized machine tools
• Robots
Motion Control

Interesting Fact:
Robotic systems are useful for processes like spraying or
coating because they:
Dramatically improve quality:
• Sealant is applied evenly and consistently.
• Drips are minimized or eliminated.
Make the work environment safer:
• Workers are not exposed to harmful fumes.
• Repetitive tasks are minimized or eliminated.
 Motion Control

Motion control is widely used in the following industries:

• Packaging: • Textile manufacturing:
– Folders – Knitting machines
– Glue stations – Looms
– Label makers • Semiconductor production:
– Smart conveyors – Water transport
• Printing: – Pick and place operations
– Winders/unwinders • Assembly:
– Presses – Robotics
– Folders – Computerized machining
– Conveyors
Motion Control

Video: Motion Control

Watch an example motion control process.

40
Motion Control

Take Note: Robots

Robots are used in many non-industrial applications,
such as vending machines, car washes, etc.
How many other robotic applications can you list?
 Power Systems

A power system converts its source of power (e.g., fossil fuels, nuclear
energy, falling water, wind) to turn a turbine and generate electricity.

Power systems:
• Regulate electricity
generation
• Control electrical power
transmission and
distribution
 Power Systems

Power systems are highly automated and interconnected to assure a

reliable source of electricity.

Definition:
Power System: A collection of devices that:
• Generates, transmits, and distributes electrical power
• Controls production and distribution systems using
instrumentation and control devices
Power Systems

Discussion: Power Control

Discuss the elements of power a control system must
manage to keep the community running smoothly and
safely.
 Safety Systems

Safety systems employ any type of control scheme (discrete, process

control, etc.)

Safety systems and control systems are usually merged under a single
system that performs all required manufacturing and safety functions.
Safety Systems

Definition:
Safety System: An engineered system that reduces the risk
of harm to people, equipment, or the environment that may
arise from the operation of a process or equipment.
 Safety Systems

Some general attributes of a safety system include:

• Acts on its own to return to a safe condition in the event of a failure
or malfunction
• Requires kinetic energy external to the process (must fail in a safe
condition)
Safety Systems

Discussion: Safety Hazards

Think about the safety hazards at an amusement park.
What safety devices and processes are required to keep
guests safe while they enjoy the park?

48
 Safety Systems

Systems perform certain safety functions by using and interconnecting a

range of devices, such as:
• Interlocks
• Light curtains
• Safety relays
• Safety contactors
• Safety drives
 Safety Systems

Safety systems are designed to reduce risks associated with:

• Hazardous areas (risk of fire, explosion, chemical spill)
• Open (unguarded) machinery
• Exposed electrical components
 Automation System Equipment

Let’s take an introductory look at some basic automation equipment

that most automation systems include:

Controller: The “brains” of the system, a

solid-state unit that can be programmed by a
user to automatically control machines and R U NF O R SC DE O K

industrial processes.
 Automation System Equipment

Controllers are used to perform the following functions:

• Logic
• Timing
• Report generation
• Data manipulation

Controller
 Automation System Equipment

Input/Output (I/O) System: A group of related I/O (input/output) devices

and modules that provide a common function.

The I/O system sends data (input) to and receives data (output) from a
controller.
I/O System

I/O Devices

I/O Modules
 Automation System Equipment

Common input devices include:

• Touch screens
• Bar code scanners
• Keypads
• Pressure or temperature sensors
• Speed measurement devices
 Automation System Equipment

Common output devices include:

• Indicator and warning lamps
• Horns and alarms
• Motors
Automation System Equipment

Take Note: I/O Modules and Devices

List other common input and output devices.

56
 Automation System Equipment

Programming System: The user interface between the programmer and

the computer. A programming system supplies data and instructions in the
form of a program to the controller and typically consists of:
• A computer
• Associated software used to program and monitor controller
operation

Computer

Software
 Automation System Equipment

Communications Network: The physical connection between a series

of components or devices. Network connections can be made by using:
• Wires
• Fiber optic cables
• Radio waves (wireless)

PC Graphic
Terminal

Communications
Network

Controller Controller Drive

 Tools

The people who install, maintain, and repair

automation systems use a variety of tools to
check device connections and diagnose
problems.

Some frequently used tools in industrial

automation include:
• Electrical measuring tools
• System status displays
• Customized software programs:
– Diagnose problems related to system programming and operation
• Hand tools and power tools:
– Adjust and maintain the mechanical components of the system
 Job Functions

A wide variety of jobs and work functions are required to get and keep
automation systems up and running.
Job Functions

Take Note: Tasks

List the tasks of each job function that appeal to you:

61
 Operators

Common operator job functions include:

• Operating machines (Start, Stop, etc.)
• Entering and recording production data (counts, recipe numbers, etc.)
• Monitoring fault conditions (acknowledging alarms, clearing material
jams, etc.)
 Maintainers

Common maintainer job functions include:

• Troubleshooting system
problems
• Maintaining and repairing
system components
 Engineers

Common engineer job functions include:

• Designing and programming new systems
• Testing expected system functionality
 Top Manufacturers

Thousands of companies manufacture and sell automation systems.

Some major automation control system manufacturers include:
• ABB • Omron
• Emerson • Rockwell Automation (Allen-Bradley brand)
• Honeywell • Schneider
• Mitsubishi • Siemens
• Yokogawa

Chalk Talk: Other Automation Manufacturers

List other automation manufacturers you may be
familiar with and note what types of automation
products they offer.
Top Manufacturers

For More Information: Top Manufacturers

Most of the top automation manufacturers have websites
that provide useful information about:
• Company history
• Products offered
• Competitive advantages

66
 Lesson Summary

Having completed this lesson, you should be able to:

• Define an automated system
• Classify automation control system types
• Identify equipment used to control processes
• Identify tools used with automation control systems
• Recognize who works with automation control systems
• Recognize who manufactures automation control systems
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.