Fixed

IT Automation: ItLevelis used

3 in high volume production with dedicated equipment, which has a
Production
fixed set of operation and designed to be efficient for Control
this set. Continuous flow and Discrete
Mass Production systems use this automation. e.g. Distillation Process, Conveyors, Paint
Shops, Transfer linesLeveletc.
2 Supervisory
Programmable Automation: It isCA-1 used for aSET:A Control
changeable sequence of operation and
ECE361
configuration(for of the
Regd.machines using
last 2electronic controls.
odd However,
number e.gnon-trivial programming
effort may be needed Level 1Nos
to
with digits making
reprogram the machine or
51)
sequence of operations. Investment on
Automatic
programmable
Industrial Auto equipment is less, as production process Control is not changed frequently. It is
Date of Allotment: Jan 27, 2021 Date of Submission: Feb 3rd, 2021
typically used in Batch process where job variety is low and product volume is medium to
high, and sometimes Levelin0mass production also. e.g. in Steel Rolling Mills, Paper Mills etc.
Note: 1. Submission in form of a single PDF file has to Sensors be done online
Flexible Automation:
2. All questions toIt is
beused in Flexible
attempted as Actuators
Manufacturing
and marks Systems (FMS) which is invariably
per given
computer controlled. Human operators give high-level
3. Similar answers will be taken as copied and both sheets commands
will get in themarks
zero formfor ofthe
codes
entered
copiedinto computer identifying product and its location in the sequence and the lower
answer Process / Machine
level changes are done automatically. Each production machine receives
Quesettings/instructions
1 (3marks) from computer. These automatically loads/unloads required tools and
carries out their processing instructions. After processing, products are automatically
4. Antransferred to control
aircraft flight next machine.
system has It is
thetypically
followingused in jobMatch
elements. shopstheand batch of
elements processes where
left column
product varieties are high and job volumes are medium to low. Such systems typically use
with its corresponding representation on the right column
Multi purpose CNC machines, Automated Guided Vehicles (AGV) etc.
Integrated Automation: It denotes complete automation of a manufacturing plant, with all
A. Inertial Navigation System I. Controller
processes functioning under computer control and under coordination through digital
B. information processing.
Ailerons, Elevators, It includes
Rudders, Enginetechnologies
II. Plantsuch as computer-aided design and
manufacturing, computer-aided process planning, computer numerical control machine
C. tools,
Computer/Autopilot
flexible machining systems, automated III. Actuator
storage and retrieval systems, automated
D. material
Aircraft handling systems such as robotsIV. andSensor/Measurement
automated cranes and conveyors,
computerized scheduling and production control. It may also integrate a business system
through a common database. Typical examples of such technologies are seen in Advanced
Solution:
Que 2 (3 marks)
Process Automation Systems and Computer Integrated Manufacturing (CIM)

(c) Choose
3. A-IV, B-III, C-I, D-II
the correct hierarchical organization of the Automation Pyramid

A- Supervisory
Inertial Control,
navigation systemB-is Process/Machine, C- Sensors/Actuators,
the sensor which measures the altitude andD- Enterprise,
attitude of the E-
flight
Automatic Control, F- Production Control
Ailerons, Elevators and Rudders are control surfaces and the engine generates thrust. They
together act as actuators
Solution:
Que 3: (3marks)
Computer/Autopilot is the controller part of the flight
Aircraft is the plant of this closed loop system
7. What are the levels of automation pyramid present in the given system?

(c)

Solution:

(b) Level 0 and Level 1

Application Example 2
Que.5 (6 marks)

5. What are the three major functions of the Supervisory Control level in the automation pyramid?
Solution:
(b) Set
Que. No.Point
5 (15Generation,
marks) Process Monitoring, Operator Interface

6. For increasing profit in business a company has to come to a decision regarding shifting from
manual motor coil winding to buying an automatic motor coil winding machine for coiling
motors brought in by the customers. The company buys the automatic machine by taking a loan
from a bank that has to be paid back in 24 equal monthly instalments. From figures given
below for both manual and automatic operation compute the amount of profit the company can
earn in 2 years. Assuming enough demand the automatic machine operates for 200
hours/month everyday neglecting times for maintenance. The company will decide to shift to
automatic only if there is more profit in automatic than manual.

Manual Automatic
Cost (infrastructure) NIL ₹6,00,000
Manpower 6 (@ ₹2,000/month) 2 (@ ₹15,000/month)
Average energy consumption
NIL 4 kW
(₹10/kWh)
Rate of annual simple
interest to be applied on the NIL 20% per year
borrowed amount
Cost of raw materials/month ₹2,000 ₹10,000
No. of motors coiled/month 40 200
Coiling charge/motor ₹1,000 ₹1,000

Solution:

(b) Manual: Rs. 6,24,000; Automatic: Rs. 28,08,000

Manpower Cost for 2 years
Cost of energy consumption for
2 years
Manual Automatic
₹(2,000×6×24) = ₹2,88,000 ₹(15,000×2×24) = ₹7,20,000
NIL ₹(10×4×200×24) = ₹1,92,000
 Mass Manufacturing of Discrete Products: Products are discrete objects and manufactured in
large volumes. Product variation is very limited. Typical examples are Appliances,
Automobiles etc.
Batch Production: In a batch production process the product is either discrete or continuous.
7. What are the levels of automation pyramid present in the given system?
However, the variation in product types is larger than in continuous-flow processes. The same
CA-1 ECE361
set of equipment is used to manufacture all theSET:B
product types. However for each batch of a
(for Regd Nos with last 2 digits making evenmust
given product type a distinct set of operating parameters number e.g. 52 ) This set is often
be established.
referred to as the “recipe” for the batch. Typical examples here would be Pharmaceuticals,
Date of Allotment:
Casting Foundries,Jan 27, 2021
Plastic moulding, Printing etc. Date of Submission: Feb 3rd, 2021
Job shop Production: Typically designed for manufacturing small quantities of discrete
Note: 1. Submission in form of a single PDF file has to be done online
products, which are custom built, generally according to drawings supplied by customers.
Any 2.variation
All questions
in thetoproduct
be attempted
can be and marks
made. as per given
Examples include Machine Shops, Prototyping
3. Similar
facilities etc. answers will be taken as copied and both sheets will get zero marks for the
copied answer
Que 1 (3 marks)
2. Match the types of Automation system given on the left column with examples of products
manufactured using these automation types on the right column.

A. Fixed Automation
Solution: I. Conveyers

B. Programmable Automation II. CNC Machines

(b) Level 0 and Level 1
C. Flexible Automation III. Chemical Process Automation Systems
Level 0: the system has Level transmitter (Sensor)
D. Integrated Automation IV. Assembly Robots
Level 1: a closed loop automatic control is present. Level Control Valve is the actuator which
maintains the level of water by receiving the control signal from Level Controller.
Que 2 (3 marks)
8. A process control system has the following elements. Match the elements of left column
with its corresponding representation on the right column

A. Embedded PID I. Plant

B. Hydraulic Valve II. Controller

C. Boiler Drum III. Sensor/Measurement

D. Level Transmitter IV. Actuator

Que 3 (3 marks)
7. What are the levels of automation pyramid present in the given system?
Solution:

(a) A-II, B-IV, C-I, D-III

Embedded PID is the PID controller algorithm which is burned into a microcontroller
Hydraulic valve is the actuator which opens according to the control signal from embedded PID
Boiler Drum is the process/plant of the whole closed loop system
Level Transmitter is the sensor which measures the level in the boiler drum and sends the signal
back to embedded PID

Solution:

(b) Level 0 and Level 1

Level 0: the system has Level transmitter (Sensor)

Application Example 1
Que.4 (6 marks)

5. What are the three major functions of the Supervisory Control level in the automation pyramid?
Solution:
Que.Set
(b) No.Point
5 (15Generation,
marks) Process Monitoring, Operator Interface

6. For increasing profit in business a company has to come to a decision regarding shifting from
manual motor coil winding to buying an automatic motor coil winding machine for coiling
motors brought in by the customers. The company buys the automatic machine by taking a loan
from a bank that has to be paid back in 24 equal monthly instalments. From figures given
below for both manual and automatic operation compute the amount of profit the company can
earn in 2 years. Assuming enough demand the automatic machine operates for 200
hours/month everyday neglecting times for maintenance. The company will decide to shift to
automatic only if there is more profit in automatic than manual.

Manual Automatic
Cost (infrastructure) NIL ₹6,00,000
Manpower 6 (@ ₹2,000/month) 2 (@ ₹15,000/month)
Average energy consumption
NIL 4 kW
(₹10/kWh)
Rate of annual simple
interest to be applied on the NIL 20% per year
borrowed amount
Cost of raw materials/month ₹2,000 ₹10,000
No. of motors coiled/month 40 200
Coiling charge/motor ₹1,000 ₹1,000

Solution:

(b) Manual: Rs. 6,24,000; Automatic: Rs. 28,08,000

Manpower Cost for 2 years
Cost of energy consumption for
2 years
Manual Automatic
₹(2,000×6×24) = ₹2,88,000 ₹(15,000×2×24) = ₹7,20,000
NIL ₹(10×4×200×24) = ₹1,92,000