INDUSTRIAL

AUTOMATION

Karim Yasser Negm (1180433)

Date: 7/6/2021

Engineering Seminar MEEN280

Submitted to: Dr. Mohamed Shaltout

 Industrial Automation
What is it?
Industrial automation is the use of control systems, such as
computers or robots, and information technologies for handling
different processes and machineries in an industry to replace a
human being. It is the second step beyond mechanization in the
scope of industrialization.

Advantages of Industrial Automation

1. Lower operating cost

Healthcare expenditures, paid leave, and holidays connected with a human
operator are all eliminated when industrial automation is used. Additional
employee benefits such as bonuses, pension coverage, and so on are not required
with industrial automation. Above all, despite its high initial cost, it saves the firm
money by reducing the workers' monthly salaries.

2. High Productivity
Although many companies hire hundreds of production workers for up to three
shifts to run the plant for the maximum number of hours, the plant still needs to be
closed for maintenance and holidays. Industrial automation fulfills the aim of the
company by allowing the company to run a manufacturing plant for 24 hours a day
7 days a week and 365 days a year. This leads to a significant improvement in the
productivity of the company.
 3. High Quality
Automation alleviates the error associated with a human being. Further, unlike
human beings, robots do not involve any fatigue, which results in products with
uniform quality manufactured at different times.

4. High Flexibility
Adding a new task in the assembly line requires training with a human operator,
however, robots can be programmed to do any task. This makes the manufacturing
process more flexible.

5. High Information Accuracy

Adding automated data collection can allow you to collect key production
information, improve data accuracy, and reduce your data collection costs. This
provides you with the facts to make the right decisions when it comes to reducing
waste and improving your processes.

6. High Safety
By employing robots to tackle hazardous conditions, industrial automation may
make production lines safer for employees.

Disadvantages of Industrial Automation

High Initial Cost
The initial investment associated with making the switch from a human production
line to an automatic production line is very high. Also, substantial costs are
involved in training employees to handle this new sophisticated equipment.

Where is industrial automation used?

Industrial automation has found its way into many industries and processes, in
every industry indicated in the chart below automation has found substantial use.
With the major application in these industries including but not limited to

DCS: Short for Distributed Control System. Used to monitor the whole plant
through data readings from field instruments. DCS is process oriented. Distributed
Control System (DCS) consists of one or more controllers used to implement
advanced process control techniques.

SCADA: Short for Supervisory control and data acquisition. A control system
architecture comprising computers, networked data communications and graphical
user interfaces (GUI) for high-level process supervisory management, while also
comprising other peripheral devices like programmable logic controllers (PLC) and
discrete proportional-integral-derivative (PID) controllers to interface with process
plant or machinery. SCADA is data-gathering oriented.

Machinery: Used to monitor specific machines usually the more critical ones, it
reads data from field Instruments and controls field parameters through field
devices. Uses special industry standards with high-speed loops.

Safety is discussed in detail later. Mainly PLC based and provide 3 main functions
Control, Prevention, Mitigation.
Industrial safety system consists of:

1. Process control systems: A process control system includes a data collection

and distribution system that collects and stores data from various data
sources

2. Prevention and Shutdown Systems: A safety instrument system to protect

the manufacturing plant from leakage or explosion or other harmful effects.

3. Mitigation systems: Decrease the severity and mitigate the effects of a

possible emergency.

Packages: Monitors specific units and equipment, includes Motor drives,

Cooling Fans, Motor Control Center MCC.

Process Control Hierarchy