Topics covered

Importance of the automation of an industrial system.

Unit I Basic concepts:
plant, control, operator, sensors, drives, open loop control,
closed loop control,
continuous processes, discrete processes, mixed processes,
batch processing.
Functional and physical architecture of the control of a system.
Introduction to Automation pyramid. Function of each level. Technological
elements of each level:
sensor networks, field buses, controllers (PLCs),
Industrial Automation instrumentation, drives, robots, plant buses, RTUs, local area
networks and control centers.
OSI communications model.
Control types: centralized, distributed. Real time control

10 technologies that will impact the

world for next 10 years

1. AI & ML
2. QUANTUM COMPUTING
3. BIO TECHNOLOGY
4. AUTOMATION & ROBOTICS
5. BLOCK CHAIN
6. INTERNET OF THINGS
7. VIRTUAL REALITY (Metaverse)
8. CLEAN ENERGY
9. 6G
10. CYBER SECURITY
 Automation of Industrial Systems What is Industrial Automation
• Automation is a term for technology applications
where human input is minimized. • automation => Auto ( ‘self’) + Matos (‘moving’)
• With rapid advances in technology, all industrial
processing systems, turned from mechanization to • Automation is a broad term applied to any mechanism
automation. that moves by itself or is self dictated.
(factories, machinery, test facilities, etc.)
• A mechanization system needs human intervention • When compared with manual systems, automation
to operate the manual operated machinery.
systems provide superior performance like precision,
• As new and efficient control technologies evolved, power, and speed of operation.
computerized automation control is being driven by
the need for high accuracy, quality, precision and
performance of industrial processes.
• Involves the use of control devices (PC/PLCs/PACs
• Automation is a step ahead of mechanization which etc.) to control industrial processes and machinery by
makes use of high control capability devices for
efficient manufacturing or production processes. reduce labor intervention and replacing dangerous
assembly operations with automated ones.

What is Industrial Automation

• It is closely linked to control engineering.

• In industrial automation control, a wide number of

process variables such as temperature, flow, pressure,
distance, and liquid levels are sensed simultaneously.

• All these process variables are acquired, processed and

controlled by microprocessor systems or PC based
data processing controller
 History of Automation

Schematic of a Pulp and Paper Industrial Process

Schematic of a simplified batch-dyeing process An example of Automatic Control system

for textile materials.
 Need for Industrial Automation Benefits of Automation
• Lower operating costs
1. To reduce Periodic or Manual checking
• Improved worker safety
2. To increase the Productivity
3. Reduce the Production Cost • Reduced factory lead times

4. To improve Product Quality • Faster ROI

5. To increase the Flexibility • Ability to be more competitive
6. Operator Friendly and Improves the Safety • Consistent and improved production and quality
• Increase system versatility

Disadvantages of Automation Industrial Automation

Equipment
1. Lead Humans To Lose Their Jobs

2. Capital expenditure

3. Modified automation becomes redundant

when production processes change

The advantages of automation often outweigh the disadvantages but

every case needs careful consideration to ensure that the right
decision is made. .
Basic Elements of an automated system
Industrial Automation Equipment
• Industrial automation (IA) is an integrated, flexible and
low-cost system platform
• IA consists of various equipment and elements which
perform a wide variety of functions like sensing,
control, supervision and monitoring related to industrial
processes.
• The structure of industrial automation which describes
the various functional elements of IA.
Basic Elements of an automated system
Industrial Automation Equipment
• The sensors or sensing elements convert
physical process variables (flow, pr., temp. etc.) 🡺
electrical or pneumatic form.
• Various sensors used in industry 🡺
thermocouples, Resistor Temperature Detectors
(RTDs), strain gauges, etc.
• Signals from these sensors are used for
processing 🡺 analyzing and 🡺 decisions to produce
the control output.
• The various control techniques are implemented to
produce the required output by comparing the
current sensed process variable with set values.
 Industrial Automation Equipment
• Finally, the controllers produce the computed outputs
and are applied as electrical or pneumatic signal inputs
to the actuating elements.
• Actuators convert the electrical or pneumatic signals to
the physical process variables.
• Some actuators⇒ control valves, relays, motors, etc.
Open Loop Control System
• An open loop control system is straightforward.
• The control action is independent of the desired output is
achieved or not.
• In short, there is no feedback involved.
• In this case, no idea if the desired output is obtained as there
could be additional disturbances during the control process.
• The faithfulness of this type of control system depends greatly on
the accuracy of the initial calibration and, hence, are less reliable.
• where accuracy of the output isn’t an issue, it would be beneficial
to go with open loop control as it would be a lot cheaper.
A good example is control of simple traffic lights where the
operation of each light depends only on a fixed time.
Control System Elements
• The microprocessor-based electronic controllers or simply
industrial computers that accept the signals from various sensors
& command signals from supervisory systems or from human
operators.
• Depending on the structure of control nature ⇒ controllers can
be continuous control systems or sequential/logic control .
• The controller processes the sensing values and supervisory
values and depends on the control structure, it produce the
control output to various actuating devices.
• A modern type of control device used in automation systems is
the Programmable Logic Controller (PLC).
• PLCs come with dedicated software so that these are capable of
being programmed to perform corresponding control operations.
• PLCs have rugged CPU, digital I/O, analog I/O and
communication modules such that they can operate at industry
environment conditions to control the various process
parameters.
Open Loop Control System
 Closed Loop Control System Closed Loop Control System
• The closed loop control systems are also known as feedback • The control action is dependent on the desired output.
control systems.
• output is compared with the reference input and an error-signal is
generated.

• This error signal is fed to the controller to reduce this error and
hence obtain the desired output.

• A closed loop control system can have one or more feedback

paths.

• These types of control systems are very reliable and the accuracy
of the output is very high.

• The cost of the system is high due to complexity of the system.

Production Processes Production Processes

• Method to manufacture products ⇒ for its customers.
Continuous processes
• Selection of right production process enables
businesses to meet ⇒ customer demand,
⇒minimize waste,
⇒ and maximize profits.
Discrete processes
• So, for a manufacturing business, it’s essential to to
decide production process which suits unique needs.
Mixed processes
• The manufacturing process is complex and rests on
several inputs, including factors of production:
Batch processes
Man ⇒ Material⇒ Machine⇒ Method ⇒
Management
 Continuous Processes
• Continuous flow of material through various
processing equipment.
• If the continuous process is operating in a steady state,
it produces a consistent product no matter how long the
operation may run.
⇒ common for industries with uninterrupted processes
where quality and performance are priority
Ex -- water treatment plant. production of gasoline
wastewater is continuously added, while treated
water is continuously discharged to maintain a clean
water supply for the area.
Mixed Mode Production Process
⇒ Process + discrete manufacturing in the same plant.
• meet the demands of customers in control without
necessarily compromising on quality.
• gives the advantages of batch manufacturing and flow
manufacturing process with ERP software system.
• guaranteed assurance of Reliability and quality
Discrete Processes
• This method is used to manufacture complex products
in relatively low volumes with the help individually
counted units which can be counted numerically
⇒ involve the production of individual objects.
⇒ each object maintains its unique identity.
⇒ Discrete manufacturers frequently have to deal
with engineering changes, creating ripples in the
entire business’s operations.
Ex -- Automobiles, furniture, toys, smartphones, and
aeroplanes
Mixed Mode Production Process
• Mixed Model Production is the practice of assembling
several distinct models of a product on the same
assembly line without changeovers
• then sequencing those models in a way that smoothes
the demand for upstream components.
• The objective is to smooth demand on upstream
workcenters, manufacturing cells or suppliers and
thereby reduce inventory, eliminate changeovers,
improve kanban operation.
• It also eliminates difficult assembly line changeovers.
 Batch Processes
• Instead of a continuous flow which goes on for days/
weeks, batch processing involves limited quantities of
material called batches.
• By the nature of the process, batch manufacturing is
discontinuous.
• This process that leads to the production of finite
quantities of material with definite quantities of input
materials to an ordered set of processing activities
• uses a finite period of time and one/more of equipment.
⇒ start with some raw material⇒ process it⇒
package and dispatch it,
⇒ then start the next batch with some new raw
material.
Functional, physical architecture
of control of a system.
• System is the collection of things that are put together
to perform a specific task.
• A control system directs the input it receives through
the systems and regulates their output.
• Control system architecture can range from simple
local control to highly distributed control systems.
Batch Processes
• Batch manufacturing is also not discrete. There are no
things that you can easily separate or identify.
• A portion of a batch can be isolated into some specific
container, but that doesn't make the process discrete.
Ex – Batch of Automobile spares –
can individually marked, but spares inside is still part of
the same batch and cannot be distinguished from one to
the next.
• The distinguishing factor of a product -Automobile is
the batch or lot from which it was Model.
Functional, physical architecture of
control of a system.
• Reliability criteria for industrial facilities will dictate
the application of redundant or distributed control
systems or PLCs
• Based on architecture
• Local Control System Architecture
• Centralized Control System
• Distributed Control System
 Local Control System Architecture Local Control System Architecture

● Accept inputs from a supervisory controller to initiate or

terminate locally-controlled automatic sequences, and adjust
control setpoints,
● but the control action itself is determined in the local
controller.

● Operator interfaces and displays are also local.

● operator can troubleshoot any problem with the system,

● Operator has to move around the facility to monitor systems

or respond to system contingencies.

● Examples -- the packaged control panels furnished with

chillers or skid-mounted pump packages.

Centralised Control System Architecture Centralised Control System Architecture

● all sensors, actuators, and other equipment within the facility are
connected to a single/ group of controller located in a common
control room.

● Locating all controls, operator interfaces and indicators in a single

control room ⇒ improves operator knowledge of system
conditions and speeds the response to contingencies.

● used for power plants / other facilities using single-loop controllers

or early digital controls in the past

● should only be considered for small industrial facilities and have

fully redundant processors.

● Proper wiring pathways must be provided to assure that control

signals to and from equipment or systems
 Distributed Control System Architecture

● offers the best features of both local control and centralized

control.

● controllers are provided locally to systems or groups of

equipment, but networked to one or more operator stations in
a central location through a digital communication circuit.

● Control action for each system or subsystem takes place in the

local controller

● Central operator station has complete visibility of the status of

all systems and the input and output data in each controller,

● Central operator station has the ability to intervene in the

control logic of the local controllers if necessary.

Automation Pyramid Automation Pyramid

• It is a pictorial example of the different levels of
industrial automated production plants.

• It also serves as a visual example of how technology

is being integrated into industry.

• Every layer or level has is own tasks and IT

infrastructure within the production plants.

• In general, the automation pyramid is divided into 6

layers.
 Level 1 – Field devices
• Level of machinery + equipment + devices + plant
components.
• It has a low level of intelligence,
• uses sophisticated equipment which generate a large
volume of data
• due to large data, the communication networks used
here are very heterogeneous, with low bandwidth and
relatively restricted features, such as CAN, Modbus,
Profibus, Fieldbus and Ethernet technology.
CAN protocol- Controller area network is a method of communication between
electronic devices embedded in a vehicle, such as the engine-management
systems, active suspension, central locking, air conditioning, airbags, etc.

Level 2 – Process Control Level 3 – Supervision of Process

• Level ⇒ where the equipment that automatically controls the
activities of the plant.
• The third level of the automation pyramid is known as
the supervisory level utilizes SCADA.
• Control level includes logical devices ⇒ iPCs, PLCs, PIDs, etc.
• SCADA → supervisory control and data acquisition.
• The control level uses these devices to control and “run” the
devices in the field level that actually do the physical work. • SCADA is essentially the combination of the previous
• They take in information from all of the sensors, switches, and levels used to access data and control systems from a
other input devices to make decisions on what outputs to turn single location.
on to complete the programmed task.
• requires large data communication networks with a greater • it usually adds a graphical user interface, or an HMI, to
degree of sophistication with higher speeds to provide control control functions remotely.
systems with the ability to respond to field information in real
time. • Process plants will often employ this technology to
• use protocols such as Profibus DP, DeviceNet, ControlNet, control remote devices in their systems.
Modbus TCP and EtherNet

Level 5- Corporate Management
• This level uses the companies integrated management system which is
known as the ERP (enterprise resource planning).
• Company’s top management can see and control their operations.
• ERP is usually a suite of different computer applications that can see
everything going on inside a company.
• It utilizes all of the previous levels technology + some more software to
accomplish this level of integration.
• This allows the business to be able to monitor all levels of the business
from manufacturing, to sales, to purchasing, to finance and payroll, plus
many others.
• The integration of the ERP promotes efficiency and transparency within a
company by keeping everyone in the same page.
• corporate management detaches itself from factory tools and focuses on
the administration of company resources, such as sales and resource
management, with a focus on the financial results of the production
process.
• Thus, these networks hardly have access to information and technical
reports available at lower levels and are based entirely on Ethernet
technology.
Level 4- Plant Management
• The fourth level (planning level) ⇒ utilizes a
computer management system known as MES
(manufacturing execution system).
• MES monitors the entire manufacturing process in a
plant or factory (from the raw materials to the
finished product).
• Management see exactly what is happening and
allows to make decisions based on realtime
information.
• Mgmt. adjusts raw material orders or shipment plans
based on real data received from the systems.
• To guarantee interoperability between different
systems, OPC technology based protocol converters
are used at this level, Open Platform Communication
Sensor Networks
● A group of spatially distributed autonomous devices
equipped with sensors, which collaborate to achieve a
common goal.
● Sensor networks gathers data and information from various
sensors and devices in an automated system.
● They monitor and control various processes, detect
anomalies, and make decisions based on the data collected.
● This information is then transmitted to a central control
system for analysis and decision-making.
● The benefits of sensor networks in automation include
increased efficiency, improved safety, and reduced
downtime.
● found applications in various fields, including
environmental monitoring, industrial process control, and
military surveillance.
 Sensor Networks Field buses
Characteristics of sensor Networks ● Field buses are communication networks used to transfer data
● Distributed sensing: Each node in the network collects between control devices, sensors, actuators, and other field
data from its local environment.. devices.

● Collaborative processing: Nodes work together to process ● They provide a reliable and efficient way to transfer large
the data and make decisions. amounts of data in real-time between these devices.

● Field buses support various protocols such as MODBUS,

● Energy efficiency: Sensor nodes typically have limited
PROFIBUS, CANBUS, and Ethernet/IP, each with its own
power supplies and must conserve energy.
unique features and capabilities.
● Robustness: The network should be able to continue
● Field buses play a critical role in seamless communication and
functioning even if some nodes fail. control of devices, which leads to improved efficiency and
reduced downtime.
● Scalability: The network should be able to accommodate
a large number of nodes.

https://youtu.be/ndc6at_d7uQ
Advantages of Field buses Field buses
● Improved communication: a reliable and robust
communication infrastructure for the transfer of information
between the field devices and the control system.

● Reduced cabling costs: Field buses reduce the number of

cables required for the communication b/w the field devices and
the control system, leading to reduced cabling costs.

● Improved system integration: Field buses enable the

integration of various field devices and control systems, leading
to a more efficient and effective automation system.
● Enhanced diagnostics: Field buses provide enhanced
diagnostic capabilities, allowing for the detection and resolution
of communication problems.
● Scalability: addition of new devices and nodes as the process
evolves and expands.
 Programmable Logic Controller (PLC)
• PLC is an industrial-grade digital computer designed to perform
control functions—especially for industrial applications.

• The majority of PLCs today are modular, allowing the user to add
functionality including discrete and analog I/Os, PID control,
position control, motor control, serial communication, and
high-speed networking.

• Integrating a PLC into any production line or mechanical process is

highly beneficial

• They can withstand a range of temperatures, electrical noises,

vibrations, and impacts.

• Operation processes are easily changed or replicated, and important

situational information and statistics are collated and communicated.
Programmable Logic Controller (PLC)

Programmable Logic Controller (PLC) Programmable Logic Controller (PLC)

• Central Processing Unit (CPU) or Embedded Computer:
A microprocessor-based computer brain, often on a single board. It
executes the control programs after reading and processing the
input signals, then sends out applicable response commands on
output channels.
• Input/ Output section:
I/O modules act as the real-time data interface between the
machine interfaces and the CPU. It is mainly a data transfer system,
but may also do some initial data conversion into signals that can
be recognized by the CPU (for input) or the machine interfaces (for
output).
• Programming device:
This is often a separate device, like a PC or similar terminal, using
Human/Machine Interface software (HMI). The CPU is connected
to this device through a communication link. Being able to
re-program PLCs through an interface makes them very flexible,
and eliminates the need for re-wiring or adding additional hardware
for each new logical configuration. The devices can also control
multiple complex systems at the same time, making them
cost-effective.
https://youtu.be/F7IKeBgP-Sw

Programmable Logic Controller (PLC)
• Gateway interface:
Enables communication with other processor-based devices, or
for remote troubleshooting.
The data transfer might be via a field bus or by IP-based
protocols, such as: simple serial (RS-232 or 485), ModBus,
Profibus, Ethernet, Profinet, CanOpen, etc.
Most of these standardized protocols were invented and
implemented by specific manufacturers (Siemens, Alan Bradley,
Omron, Beckhoff, etc.)
• Power supply:
All the elements of the PLC will need a power supply to
function
– separate ones will be required for any remote PLC devices.
Uninterruptible Power Supplies (UPS) may be required for
continuous operation or areas with poor electricity supply.
Plant Buses
● In industries many sensors, actuators, control devices are
geographically distributed and interacting with each other via
several data buses.
● The plant bus is a map-type system that can integrate other
computers and systems.
● This bus runs throughout the plant to connect all sub-group control
stations and level stations.
● The plant bus updates the plant database through the lower level
buses which are maintained at the unit level.
● The plant bus transmits unit operation commands to the lower level
controller
Field bus interacts b/w field instruments and the control devices
Process bus connects the supervising level computers to the control
devices like PLC’s.
Factory bus connects the higher level of the organization to the
supervising level.
● Different protocols are used for the communications like RS-485,
profibus, CAN control modbus,etc.
Instrumentation
● Instrumentation – is a collection of Instruments and their
application for the purpose of Observation, Measurement and
Control
● An instrument is a device that measures or manipulates process
physical variables such as flow, temperature, level, or pressure
etc.
● Instruments often comprise control systems of varied processes.
● Instrumentation can refer to devices as simple as direct-reading
thermometers, or as complex as multi-sensor components (
Analysers )of industrial control systems.
● Popular Process Instrumentation Products
○ Pressure, temperature, flow, & level
○ Water analysis & gas detection
○ Static & dynamic weighing
○ Pneumatic & electrical automation
○ On-off & control valves
Remote Terminal Units RTU
● An RTU is a control device typically installed in a remote location as
part of a large system.
● The main purpose of an RTU ⇒ monitor and control field devices,
such as valves, actuators, sensors, and more.
● RTUs are essential components of SCADA systems, establishes
interfaces between SCADA control and physical processes.
● The RTU is now microprocessor-based and able to execute more
advanced logic, similar to PLCs.
● New communication protocols RS-232, RS-482, and Ethernet were
introduced, allowing for even more information to be exchanged
reliably.
● The most important components of an RTU are the central processing
unit (CPU), power supply, communication port, and physical I/O.
● An RTU’s role is to compile the information provided by these field
devices and communicate it to the central SCADA control.
https://realpars.com/rtu/
Remote Terminal Units RTU
https://control.com/technical-articles/what-is-a-remote-terminal-unit-rtu/
Control centers.
● refers to a central location where the operations of various
devices, machines, and systems in an industrial/ mfg
environment are managed and monitored.
● The control center serves as the hub for communication
between devices and enables the real-time monitoring and
control of automated processes.
● It typically includes control panels, HMIs, and other
components that allow operators to view and control the status
of automated processes, receive alarms and notifications, and
make adjustments as necessary.
● These also incorporate features such as data collection and
analysis, reporting, and remote access, to provide greater
visibility and control over automated operations.
● Control centers play a critical role in ensuring the efficient and
effective operation of automated systems, and they are widely
used in industries such as manufacturing, energy, transportation,
and others.
Local area networks LAN
● In automation, a local area network (LAN) is used to connect
various devices, sensors, and control systems to facilitate
communication and the exchange of data between them.
● Automation LANs can support real-time, high-speed data
transmission, enabling devices to exchange data quickly and
efficiently.
● They are widely used in industrial and manufacturing
environments to control and monitor production processes,
automate machine operations, and provide seamless
communication between devices on the factory floor.
● Automation LANs can also support communication protocols
such as Modbus, Profinet, EtherNet/IP, and others, to ensure
compatibility with different automation devices and systems.
OSI communication model
● The OSI (Open Systems Interconnection) is a standard
model for the communication b/w two devices in a network.
● It divides communication process into 7 distinct layers.
● Each layer addresses specific communication needs and
build upon functionality of lower layers.
● In automation, the OSI model is often used as a reference
for the design and implementation of communication
protocols and networks, and to ensure interoperability
between different systems.
1. Application Layer: Provides the interface between the
application and the network, allowing the application to
access network resources and services.
 OSI communication model Control types: centralized, distributed. Real time control
2. Presentation Layer:
Handles–data formatting, compression and encryption/ decryption. Control Type in Industrial Automation refers to the various
3. Session Layer: methods and techniques used to manage and control industrial
Establishes & manages communication sessions b/w devices. processes and equipment.
4. Transport Layer:
Provides end-to-end communication, error recovery,flow control. Control types in industrial automation can be classified based on
5. Network Layer: the level of automation, the architecture of the control system,
Provides routing and forwarding of data packets b/w devices. and the type of control algorithms used.
6. Data Link Layer:
Responsible for transmitting data frames and providing error Centralized Control:
detection and correction. ● A single central control unit is used to manage and control all
7. Physical Layer: the devices in the system.
Defines the electrical, mechanical, and functional specifications
for transmitting data over a physical connection. ● typically used in simple systems where the devices are
physically close to each other.
Control types: centralized, distributed. Real time control
Distributed Control:
● The control functions are distributed among multiple devices
in the system.
● Each device has its own local control unit and communicates
with other devices to co-ordinate the overall system behavior.
● typically used in large and complex systems where the devices
are spread out over a large area.
Real-Time Control:
● The control system must respond to changes in the system in a
timely manner, typically within a few milliseconds.
● Real-time control is essential in applications where precise
control and coordination of multiple devices is critical,
● used in robotics, aerospace, and process control.
OSI communication model .
Application Layer:
● This is the topmost layer and the closest to the end user.
● It provides the interface for applications to communicate
between devices like PLCs, HMIs, and other control
systems over the network.
● In automation, this layer includes protocols like Modbus,
OPC, and others to communicate
Presentation Layer:
● This layer is responsible for formatting the data in a way
that can be easily understood by the recipient.
● It handles tasks such as data compression, encryption,
and decryption, which are essential for secure
communication in automation.
Centralized Control: Distributed Control:
The choice of control type depends on
• the specific requirements of the application,
• including the size and complexity of the system,
• the level of automation required, and
• the types of devices being controlled.
Jobs on Industrial Automation
https://youtu.be/rJvThzbMmHE
End of Unit I
*****
Session Layer:
● This layer establishes, maintains, and terminates the
communication session between devices.
● In automation, this layer is responsible for managing the flow of
data between devices and ensuring that all communication is
carried out correctly.
Transport Layer:
● This layer provides reliable, end-to-end communication between
devices.
● It implements error correction and flow control mechanisms to
ensure that data is transmitted accurately and efficiently over the
network.
Network Layer:
● This layer is responsible for routing data between devices on the
network.
● It determines the best path for data to travel based on various
factors such as network load and availability of resources.
Data Link Layer:
● This layer provides reliable delivery of data frames between
adjacent nodes in a network.
● It implements error detection and correction mechanisms to
ensure that data is transmitted accurately.
Physical Layer:
● This is the lowest layer of the OSI model and is responsible for
transmitting data over the physical media, such as Ethernet
cable or wireless signals.
● It defines the electrical, mechanical, and functional
specifications for the transmission of data.
By adhering to the OSI model, automation systems can ensure
interoperability and seamless communication between different
devices and systems in a network
Safety Automation – Safety Devices
As a factory becomes more automated, it is vital we protect the humans
working in these spaces. Devices are necessary to prevent operators,
technicians and maintenance specialists from any harm when operating
or troubleshooting machines. A safety-first policy is the right policy in
the automated arena.
Many safety devices are designed to halt the automated device as quickly
as possible once a human presence is detected.
Mechanical devices such as door switches are mounted on handles or
hinges of safety cages or screens, and they halt the process inside as soon
as the cage is opened. These are often employed when a visible physical
barrier is already necessary to protect from debris flying around, marking
pedestrian areas between workspaces.
Optoelectronic sensors such as light curtains or laser scanners use
invisible laser light to detect foreign objects in proximity to the machine.
These are great on production lines that don’t need a physical barrier, and
access is required often.
Input/Output Devices
Input device: a device used to provide data and control signals to an
information processing system (IPS) such as a PLC (via its I/O system)
or other control mechanism. A commonly used name is field sensor.
Examples include:
• Human interaction devices – switches and push buttons, keyboards,
touch screens
• Sensing devices – proximity sensors, photoelectric sensors, ultrasonic
sensors
• Mechanically-activated switches – limit switches, vacuum switches,
temperature switches, level switches, pressure switches
Output device: a device used to act on the results of data processing
carried out by an IPS, translating the processing back into an action
required by the automated machinery under control. A commonly used
name is actuator. Examples include:
• Mechanical movement – pneumatic or hydraulic cylinders, magnetic
valves, motor starters, control relays, pumps, fans
• Visual or Auditory feedback – horns and alarms, stack lights
• System feedback – electronic alerts via messaging systems
Robotics
Robotics used in industrial automation are an evolution
of the automated machinery, designed to closer mimic
the flexibility of a human operator.
Most industrial robots are based on a single arm, with
6-axis movement:
Axis 1 – Rotates robot (at the base of the robot)
Axis 2 – Forward / back extension of robot’s lower arm
Axis 3 – Raises / lowers robot’s upper arm
Axis 4 – Rotates robot’s upper arm (wrist roll)
Axis 5 – Raises / lowers wrist of robot’s arm
Axis 6 – Rotates wrist of the robot’s arm