Manufacturing Automation (MTS 451)
2 Credits – 2 Lectures
Lecture 1
Dr. Syed Hammad Nazeer
Assistant Professor
Office: A Block, Faculty Room
Email: hammad@mail.au.edu.pk
Course Objective
• Mechatronics - an interdisciplinary field
• Industrial applications - becoming increasingly multidisciplinary
• Industrial Automation course - combine various fields
– to teach students a holistic approach to developing solutions for industrial
automation applications.
• Industrial Automation course umbrella includes "practical"
knowledge of :
– Computer controls
– PLCs
– Robotics
– PID/Fuzzy Logic Control
Course Learning Outcomes
Learning
CLO
CLO Statement PLO Domain
No
& Level
The students should be able to comprehend and
distinguish types of processes in industry, PLC
1 PLO 1 C2
architecture and programming, industrial sensors,
SCADA and HMI system and manipulators in industry.
The students should be able to write PLC program, use
2 industrial sensors, apply SCADA and HMI system and PLO 2 C3
manipulators to solve basic industrial problems
The students should be able to design and develop
solutions using industrial sensors, PLC & SCADA
3 PLO 3 C5
systems, Process and instrumentation diagrams for
complex engineering problems in industry
Course Outline
Week No Title CLO
Introduction to Industrial Applications with Mechatronics
Week 1 Systems ; Types of Processes & Process Control 1
Components
Week 2 PLC Programming : Basic Ladder Logic Elements 2
Over view of Rslogix 500 & 5000 : Introduction of Math
Week 3 1,2,3
Instructions
Week 4 Timers ; Case Study 1,2,3
Week 5 Counters ; Case Study 1,2,3
Week 6 Industrial Sensors, I/O Modules Wiring 1
Week 7 Advanced PLC Programming 1,2,3
Week 8 Case studies of PLC implementation 1,2,3
Week 9 Mid Term Exam
Course Outline
SCADA (Supervisory Control & Data Acquisition) : Using
Week 10 1,2,3
RSview 32 & Open Control
Week 11 Human Machine Interface for SCADA and PLCs 1
Week 12 HMI, SCADA with LabView
Continuous Process Control : PID Loops and Cascaded PID
Week 13 Loops 1
Process & Instrumentation Diagrams & Actuators
Week 14 Introduction of Numerical Control 1
Week 15 Manipulators in Industry 1,2,3
Week 16 Case studies 1,2,3
• Text Books & Reference:
•Jon Stenerson, “Fundamentals of PLC’s, Sensors & Communication”. 3rd Edition,
Prentice Hall Upper Saddle River, New Jersey 2004
•Automation, Production Systems & Computer Integrated Manufacturing
Mikell P.Groover
•Hugh Jack “Automating Manufacturing Systems with PLC’s”- (Available online)
Distribution of Marks
Module Percentage
Quizzes 10
Assignments 10
CEP 10
Mid Term Exam 25
Final Exam 45
Course Modules
• Basic Overview of Mechatronics Systems in Industry &
Applications:
• Automation
• Practical Aspects:
• PLC’s
– Ladder Logic
– Industrial Sensors & Actuators
• SCADA (Supervisory & Data Acquisition)
Basic Questions
• What is Automation?
• What are the advantages of Automation?
Introduction to Industrial Mechatronics
• Automation:
• Use of Control Systems to
reduce Human Intervention
• A Step beyond Mechanization
(Pure Mechanical Systems)
• Key Ingredients:
– Sensors
– Controller
– Actuator
• Applications:
– Production Plants, Manipulation, Manufacturing parts
(Textile, Petroleum, Paper & Automotive
Industries )
Introduction to Industrial Automation
• Advantages of Industrial Automation:
– Improving Efficiency & Quality
– Improving Safety
– Reducing Operation time & Errors
– Performing Operations in Dangerous
Environments (High Temperatures, Nuclear
Installations, Space etc)
Introduction to Industrial Automation
• Manufacturing Process Automation:
– Automation of Industrial Processes
– Controllers: Mainly PLC’s
– Actuators: Variable Speed Drives, Valves etc
– Sensors: Flow, Pressure Temperature etc
– Additionally SCADA
Automation Using PLC’s
Introduction to Industrial Automation
• Applications of Manipulators:
– Mainly used for Pick & Drop Applications in Production lines
– Painting, Welding in Automotive Industry
Types of Automation
• Fixed Automation:
• Production facility where the sequence of operations is fixed by
process configuration
– Examples:
• Production Plants (Paper etc), Automotive Industry with fixed
equipment
– Features:
• High Initial Investment
• High Production Rates
• Relative Inflexibility
• Programmable Automation:
• The production equipment is made to change the sequence of
operations
• The sequence of operation is generally modified by a program
Types of Automation
– Examples:
• Automation using Numerically Controlled Machine Tools, Industrial
Robots & PLC’s
– Features:
• High Initial Investment
• Flexibility to deal with Variation & Changes in Production
• Low Production rate then Fixed Automation
• Loss of time during change over
• Flexible Automation:
• An Extension of Programmable Automation
• Virtually no loss in time during change over (Tools, Machine
settings)
• Difference betweens parts is not significant
– Examples:
• Automotive production using Flexible Manufacturing systems
