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Industrial Automation
Industrial Automation:
Automation takes a step further mechanization that uses a particular machinery mechanism aided
human operators for performing a task. Mechanization is the manual operation of a task using powered
machinery that depends on human decision making.
On the other hand, automation replaces the human involvement with the use of logical programming
commands and powerful machineries.

Industrial automation can be defined as the use of set technologies and automatic control devices that
results the automatic operation and control of industrial processes without significant human
intervention and achieving superior performance than manual control. These automation devices
include PLCs, PCs, PACs, etc. and technologies include various industrial communication systems.

Types of Industrial Automation Systems:

1. Fixed or Hard Automation
This type of automation is employed to perform fixed and repetitive operations in order to achieve high
production rates. It uses special purpose or dedicated equipment to automate the fixed sequence
assembling or processing operations. Once it is employed, it is relatively hard to change or vary the
product design. Therefore, it is inflexible in providing product variety, but increases the efficiency with
higher production rate and reduces unit cost.
Some of these automated systems are distilled process, paint shops and conveyors.

2. Flexible or Soft Automation:

This automation system provides the automatic control equipment that offers a great flexibility for
making changes in the product design. These changes can be performed quickly through the commands
given in the form of codes by the human operators.
This automation allows the manufacturers to produce multiple products with different ranges as a
combined combination process rather than separate.

Some of the examples of this automation system are automatic guided vehicles, automobiles, and
multipurpose CNC machines.

2. Programmable Automation:
In this automation, a specific class of product changes and also assembling or processing operations can
be changed with the modification of control program in the automated equipment.
This automation is best suited for batch production process where product volume is medium to high.
But in this, it is hard to change and reconfigure the system for a new product or sequence of operations.
Therefore, new product or reconfigure of sequence of operations requires a long setup.
Examples of this automation system are numerically controlled machines, paper mills, steel rolling mills,
industrial robots, etc.
4. Integrated Automation:
Integrated automation systems work through a common manufacturing system database. This central
automation control point makes it possible to integrate industrial and non-industrial processes and
robot integration through automated production technologies. Integrated automation systems are used
in computer integrated manufacturing and several types of advanced process automation systems.

Benefits of Industrial Automation:

 To increase productivity
 To provide optimum cost of operation
 To improve product quality
 To reduce routine checks
 To raise the level of safety
 Assist Remote Monitoring

Industrial Automation Systems:

Programmable Logic Controller (PLC):
A Programmable Logic Controller, or PLC, is a ruggedized computer used for industrial automation.
These controllers can automate a specific process, machine function, or even an entire production line.

Working:
The PLC receives information from connected sensors or input devices, processes the data, and triggers
outputs based on pre-programmed parameters.
Depending on the inputs and outputs, a PLC can monitor and record run-time data such as machine
productivity or operating temperature, automatically start and stop processes, generate alarms if a
machine malfunctions, and more. Programmable Logic Controllers are a flexible and robust control
solution, adaptable to almost any application.
Human Machine Interface:
Human Machine Interface, often known by the acronym HMI, refers to a dashboard or screen used to
control machinery. Line operators, managers and supervisors in industry rely on HMIs to translate
complex data into useful information.

Example:
For example, they use HMIs to monitor machinery to make sure it’s working properly. Easy-to-
understand visual displays give meaning and context to near real-time information about tank levels,
pressure and vibration measurements, motor and valve status and other variables.

Supervisory Control and Data Acquisition (SCADA):

A SCADA system is a combination of hardware and software that enables the automation of industrial
processes by capturing Operational Technology (OT) data. SCADA connects the sensors that monitor
equipment like motors, pumps, and valves to an onsite or remote server.
One of the major efficiencies of SCADA is the ability to monitor and control systems in your facility from
multiple locations. Depending on the configuration of the SCADA control system, the state of your
production processes can be viewed from an operator workstation overlooking the physical facility, a
HMI located directly beside machinery, or even from the home of an employee.
You can also influence and control a SCADA environment without having to directly respond to each
event. For example, using logic-based rules, operators are able to designate the completion of certain
actions when sensors detect abnormalities. Is the rotating bit on a plywood cutting machine vibrating
excessively? The SCADA software can be programmed to power down the machine immediately and
avoid causing further potential harm to materials or operators.
Instrumentation:
The process in which assembly of several electrical, measuring and control instruments interconnected
for measuring, analyzing and controlling the electrical and non-electrical physical quantities is called as
Instrumentation.

Industrial Automation:
Instrumentation is the science of automated measurement and control. Applications of this science
abound in modern research, industry, and everyday living. From automobile engine control systems to
home thermostats to aircraft autopilots to the manufacture of pharmaceutical drugs, power Plants, Oil
and Gas, Refineries etc and automation surrounds us.
The first step, naturally, is measurement. If we can’t measure something, it is really pointless to try to
control it. This “something” usually takes one of the following forms in industry:
 Fluid pressure
 Fluid flow rate
 The temperature of an object
 Fluid volume stored in a vessel
 Chemical concentration
 Machine position, motion, or acceleration
 Physical dimension(s) of an object
 Count (inventory) of objects
 Electrical voltage, current, or resistance etc
Once we measure the quantity we are interested in, we usually transmit a signal representing this
quantity to an PLC/DCS systems where either human ( manual ) or automated action then takes place. If
the controlling action is automated, the PLC/DCS sends a signal to a final controlling device which then
influences the quantity being measured.
This final control device usually takes one of the following forms:
 Control valve (for throttling the flow rate of a fluid)
 Electric motor
 Electric heater etc
Both the measurement device and the final control device connect to some physical system which we
call the process. To show this as a general block diagram:
The common home thermostat is an example of a measurement and control system, with the home’s
internal air temperature being the “process” under control. In this example, the thermostat usually
serves two functions: sensing and control, while the home’s heater adds heat to the home to increase
temperature, and/or the home’s air conditioner extracts heat from the home to decrease temperature.
The job of this control system is to maintain air temperature at some comfortable level, with the heater
or air conditioner taking action to correct temperature if it strays too far from the desired value (called
the setpoint).