Vidya Vikas Educational Trust (R),

Vidya Vikas Polytechnic

27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Department of Mechanical [General]

Lecture – Tutorial – Practical

Notes

Subject : Elements of Industrial Automation

Subject Code : 20ME44P

Semester : 4th Semester

Name of the Student: …………………………………………….

Register Number: …………………………………………….

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
APPENDIX 5 (Certificate issued by guide)
Name of the Institution: VIDYA VIKAS POLYTECHNIC
Address with pin code: 27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka
570028

Department: MECHANICAL ENGINEERING (General)

CERTIFICATE

Certified that this Practical Record entitled “Elements of Industrial Automation 20ME44P” which is

being submitted by Mr.………………………….……………………bearing Register

Number…..………………………, is a bonafide student of Mechanical Engineering Department, studying in

Third Semester in our Institution and has fulfilment the Laboratory prescribed by Department of Technical

Education, Bangalore during the year 2021-2021.

It is certified that all corrections/suggestions indicated for internal Assessment have been incorporated in the

Report.

Signature of the Staff In-charge

Signature of H.O.D

CIE (Internal Assessment Marks Obtained in Words):…………..……………………………………………

External Examiner 1:………………………………

Dept. …………………………College…….…………………

External Examiner 2:………………………………

Dept. …………………………College…….…………………

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Course Outcomes

Introduction to Elements of Industrial Automation

In present scenario, Manufacturing industries are moving towards complete automation. Small and medium
industries are in a phase of switching to PLC and SCADA technology for data acquisition and control.
Industrial automation systems are used to control and monitor a process, machine or device in a
computerized manner that usually fulfils repetitive functions or tasks. They are intended to operate
automatically in order to reduce and improve human work in the industry. Advantages of this technology is
commonly attributed to higher production rates and increased productivity, more efficient use of materials,
better product quality, improved safety, shorter workweeks for labor, and reduced factory lead times.

The Automation Engineer will design, program, simulate and commission automated machines and plant-
wide processes to perform many job functions. Depending on the size of the organization, the engineer will
perform some or all of these responsibilities. Therefore, it is necessary for diploma engineers to have
knowledge of both PLC and SCADA technology. This course attempts to provide basic theoretical and
practical aspects of automation technologies to develop operational competency. Hence this course is the
foundation for diploma engineers who want to further specialize in the field of industrial automation

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
CIE and SEE Assessment Methodologies

Format for CIE written Test

(a)For CIE Skill Test -4

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
(b) For CIE Skill Test -5

SEE Scheme of Evaluation

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Content
Duration Tutorials Practical
Introduction: Study of following Appliances /
1. Need and benefits of Industrial automation systems and identify various
Automation, Automation Hierarchy, elements used and their function
Basic components of automation system, 1. Air conditioning System
description of each component 2. Automatic water level control
Week 1 2. Automation technology as a part of 3. Elevator (for Three Floor)
engineering sciences, Key development 4. Washing Machine
milestones in the history of automation Write the Block Diagram For each and
technology, Effects of automation on explain with a Multimedia Presentation
people.
3. Types of automation system
Programmable logic controller: Demonstrate the working of below
1. Introduction, Compare Relay Logic shown Switches/Sensor.
Control and PLC Logic Control, Internal a. Various industrial Switches (Push
Architecture of PLC Button, ON/OFF, Toggle, Emergency,
2. I/O Modules (Interfaces), Memory Rotary Switches etc.)
organization. b. Proximity- Inductive, Capacitive and
Input devices: Optical Sensor
Week 2
• Mechanical Switches c. Temperature Sensor
• Proximity Switches d. Float Sensors
3. Input devices: Note: Connect each sensor directly to the
• Photo electric Sensors and Switches LED/Lamp with appropriate power
• Encoders supply
• Temperature Sensors
• Position/Displacement Sensors
1. Input devices: Only Theory Explanation and
• Strain Gauges Demonstration
• Pressure Sensors
• Liquid level detectors
2. Input devices:
Week 3
• Fluid flow measurement
• Smart Sensors
3. Output Devices:
• Relay
• Directional control Valve
1. ADC and DAC Only Theory Explanation and
2.Motors- DC motor, Synchronous Demonstration
Week 4
motor, Servo motor,
3.Induction motor, Stepper motor

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
PLC Programming: • Execute energized motor or bulb using
1. Programming standards, List Different Switches in series or Parallel
PLC Programming, Ladder diagram, • Write ladder diagram to test digital
Week 5 2. Standard IEC 1131-3, Symbols used logic gates and Execute/Simulate the
for I/O Devices same.
3. Ladder diagram for logic gates. AND,
OR, NOT, NAND, NOR, XOR, XNOR
1. Writing Equivalent ladder diagram for • There are 3 mixing devices on a
Electric Switch, Belt drive, motor circuitprocessing line A, B, C. After the process
Latching, Sequential O/P begin mixer-A is to start after 7 seconds
elapse, next mixer-B is to start 3.6
2. Introduction to Timer functions. second after A. Mixer-C is to start 5
Applications of timing functions in seconds after B. All of then
Week 6 process control -- On Delay Timer remain ON until a master enable switch
is turned off. Develop PLC ladder
Function, Off-delay Timer Function
diagram, timing diagram and simulate
the same
3. PLC counter functions, Applications
of PLC counter function in process • Write a Ladder Program to count the
control number of Items moving
1) Relay, Jumps and Subroutines • Execute the Ladder Program for relay-
based motor control automation such that
2) Develop Ladder Program for relay- the motor reverses its direction when the
based motor control automation such that limit switches are activated and also
the motor reverses its direction when the Demonstrate by interfacing with PLC
limit switches are activated
• Simulate the PLC ladder diagram
3) Develop a PLC ladder diagram to developed for an alarm system and also
Week 7 construct an alarm system which Demonstrate by interfacing with PLC
operates as follows.
- If one input is ON nothing happens.
- If any two inputs are ON, a red light
goes ON.
- If any three inputs are ON, an alarm
sirens sound.
- If all are ON, the fire department is
notified.
Develop PLC program for the following Execute a PLC program for the following
application applications
Week 8
a) Traffic Light i) Traffic light controlling
b) Water Level Indicator ii) Water level controlling
• Develop automatic door system using • Execute automatic door system using
optical sensor and linear actuator optical sensor and linear actuator
Week 9
• Develop Automatic Elevator control • Design ladder diagram for an
Automatic Elevator control

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Design ladder diagram for car parking. • Simulate a ladder diagram for car
Design ladder diagram for operating and parking.
Week 10
controlling the Lift. • Test and simulate a ladder diagram
designed to operate and control the Lift
Week 11 Embedded System- Block Diagram of Only Theory Explanation and
Embedded System, Applications of Demonstration
Embedded System
• Robotics Drones
• Braking System
• Air conditioning & Refrigerator
• Engine control System,
• Automatic Washing machine
• Microwave Oven
• Keyless entry in Automobiles.
Week 12 1) Concepts on Distributed control • Multi media Exposure to DCS system
System, • Demonstrate the HMI interface to
2) Concepts on HMI control Light in AND/OR Logic
3)Introductions to SCADA
Week 13 1)Typical SCADA block diagram, • Multi media Exposure to SCADA
2)Benefits of SCADA, system
3) Applications of SCADA

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Theory and Practical for week 01

1. Need and benefits of Industrial Automation

Industrial automation systems are systems used to control and monitor a process, machine or device in a
computerized manner that usually fulfils repetitive functions or tasks. They are intended to operate
automatically in order to reduce and improve human work in the industry. These systems replace the
repetitive and mechanical tasks and the decisions makeing in the manufacturing process. This is done
through the use of logical programming commands and powerful machinery. Industrial automation systems
bring various benefits to organizations which includes.
a) Productivity. These systems make automation possible for factories and industrial processes, allowing
a continuous mass production 24/7, this improves productivity and reduces assembly times.
b) Quality. By means of adaptive control and monitoring in different stages and industrial processes, these
systems are useful in eliminating human error and thus improve the quality and homogeneity of the
products offered. The performance is not reduced after several hours of continuous work.
c) Greater consistency. Machines and computers work at a constant and continuous pace. Therefore,
automated production processes have a longer duration, stability and solidity.
d) Flexibility. Implementing a new task in a traditional production chain involves hours or days of user
training. On the other hand, with an automated system, reprogramming a robot or machine is a simple
and fast process that provides greater flexibility in the production process.
e) More precise information. Automation of data collection improves accuracy and reduces costs. Such
increased accuracy enables company managers to make better decisions.
f) Safety. It is safer to use robots on production lines with dangerous working conditions for humans.
g) Cost reduction. Although the initial investment in industrial automation systems might be rather high,
implementing this technology will translate into a reduction of data analytics costs.
h) Improved working conditions. Workers in a factory where an industrial automation system has been
implemented work fewer hours and spend their time on high value-added tasks.
i) Increased added value. When the action of machines and computers frees employees from performing
these functions, they can carry out more value-added tasks in other areas of the company that provide
greater benefit.
j) Improved human capacity. The systems that companies implement to automate their services not only
perform the tasks that a human being would do, but they are capable of performing functions that
exceed the capabilities of a real person.

2. Automation Hierarchy, Basic components of automation system, description of each

component

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Level 01: Device level. This is the lowest level in automation
hierarchy. It includes the actuators, sensors, and other hardware
components that comprise the machine level. The devices are
combined into the individual control loops of the machine; for
example, the feedback control loop for one axis of a CNC
machine or one joint of an industrial robot.
Level 02: Machine level. Hardware at the device level is
assembled into individual machines. Examples include CNC
machine tools and similar production equipment, industrial
robots, powered conveyors, and automated guided vehicles.
Control functions at this level include performing the sequence
of steps in the program of instructions in the correct order and
making sure that each step is properly executed.
Level 03: Cell or system level. This is the manufacturing cell or
system level, which operates under instructions from the plant
level. A manufacturing cell or system is a group of machines or
workstations connected and supported by a material handling
system, computer and other equipment appropriate to the manufacturing process. Production lines are
included in this level. Likely functions include part dispatching and machine loading, coordination among
machines and material handling system, and collecting and evaluating inspection data.
Level 04: Plant level. This is the factory or production systems level. It receives instructions from (he
corporate information system and translates them into operational plans for production. Likely functions
include: order processing, process planning, inventory control, purchasing, material requirements planning,
shop floor control, and quality control.
Level 05: Enterprise level. This is the highest level consisting of the corporate information system. It is
concerned with all of the functions necessary to manage the company: marketing and sales, accounting,
design, research, aggregate planning, and master production scheduling.

3. Elements or Components of Automation System

An automated system consists of three basic elements:
(1) power to accomplish the process and operate the system.
(2) a program of instructions to direct the process, and
(3) a control system to actuate the instructions.
The relationship amongst these elements is illustrated in Figure below.

(1) Power to accomplish the automated process: An automated system is used to operate some process,
and power is required to drive the process as well as the controls. The principal source of power in
automated systems is electricity. Electric power has many advantages in automated as well as non-
automated processes
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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
(2) Program of Instructions: The actions performed in an automated process are defined by a program of
instructions. Each part or product style made in the operation requires one or more processing steps that are
unique to that style, these processing steps are performed during a work cycle. A new part is completed
during each work cycle (in some manufacturing operations, more than one part is produced during the work
cycle; e.g., a plastic injection molding operation may produce multiple parts each cycle using a multiple
cavity mold). The particular processing steps for the work cycle are specified in a work program like.
a) Work Cycle Programs.
b) Process parameters
c) Decision-Making in the Programmed Work Cycle.
i) Operator interaction
ii) Different part or product styles processed by the System.
iii) Variations in the starting work units.

(3) Control System: The control element of the automated system executes the program of instructions. The
control system causes the process to accomplish its defined function which is to carry out some
manufacturing operation. The controls in an automated system can be either closed loop or open loop.
Closed Loop

Open Loop

4. Types of automation system:

Automated production systems are classified into three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation
a) Fixed automation: Fixed automation is a system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration. The operations in the sequence are usually simple. It is
the integration and coordination of many such operations into one piece of equipment that makes the system
complex. The typical features of fixed automation are:
• High initial investment for custom-engineered equipment
• High production rates
• Relatively inflexible in accommodating product changes
The economic justification for fixed automation is found in products with very high demand rates and
volumes. The high initial cost of the equipment can be spread over a very large number of units, thus
making the unit cost attractive compared to alternative methods of production.

b) Programmable automation: In programmable automation, the production equipment is designed with

the capability to change the sequence of operations to accommodate different product configurations. The
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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
operation sequence is controlled by a program, which is a set of instructions coded so that the system can
read and interpret them. New programs can be prepared and entered into the equipment to produce new
products. Some of the features that characterize programmable automation include:
• High investment in general-purpose equipment
• Low production rates relative to fixed automation
• Flexibility to deal with changes in product configuration
• Most suitable for batch production

c) Flexible automation: Flexible automation is an extension of programmable automation. The concept of

flexible automation has developed only over the last 15 to 20 years, and the principles are still evolving. A
flexible automated system is one that is capable of producing a variety of products (or parts) with virtually
no time lost for changeovers from one product to the next.
There is no production time lost while reprogramming the system and altering the physical setup (tooling,
fixtures and machine settings). Consequently, the system can produce various combinations and schedules
of products, instead of requiring that they be made in separate batches. The features of flexible automation
can be summarized as follows:
• High investment for a custom-engineered system
• Continuous production of variable mixtures of products
• Medium production rates
• Flexibility to deal with product design variations

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Study of following Appliances / automation systems and identify various elements used and their
function with the Block Diagram For each.

1) Air conditioning automation systems

2) Automatic water level control automation systems

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
3) Elevator (for Three Floor) automation systems

4) Washing Machine automation systems

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