Introduction to Course

In this Course cover

1.Automation
2.PLC
3.SCADA
4.Industry 4.0
 Introduction
Lecturer -
Syed Ameer- Around 15+ years of work experience in
Industry 4.0/ Smart Factory and Shop floor OT, IIOT, PLC’s and
HMI SCREEN DEVELOPER/design programming, Automation,
DCS, field Instrumentation devices
linkedin Link: https://www.linkedin.com/in/syed-ameer-
026bba9a/
WhatsApp Number : +9198855487

Student-…
 Introduction to
Automation
Industries
1. What is Automation
The word Automation is derived from Greek words “Auto” and
“Mation”
AUTO- SELF
MATION-MOTION

Automation is a set of technologies that result in operation of

machine without significance of human
• Automation is encompassing virtually every walk of life
• Automation solution are required right from Agricultural to
space technology
• Plant automation is the necessity for the manufacturing
industry to survive in today globally competitive market
Overview of
automation
industries
1. What is Industrial Automation?
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
 Importance of
automation in
various sectors
Automation is important in many sectors because it can improve
efficiency, reduce costs, and increase safety:
Improved safety: Automation can reduce the risk of accidents by
using robots to load and unload materials, or by using safety
curtains to keep workers away from assembly lines.
Increased productivity: Automation can help businesses produce
more products in less time, which can lead to increased profits.
Cost reduction: Automation can reduce the cost per unit of
productivity by allowing businesses to perform tasks more
efficiently. In some cases, automation can also replace human
labor.
Improved product quality: Automation can lead to improved
product quality because it provides unmatched precision and
consistency throughout production batches.
Enhanced resource utilization: Automation can help businesses use
resources more efficiently.
Innovation: Automation can free human potential from mundane
tasks, which can foster innovation.
Adaptability: Automation can help businesses adapt to dynamic
market landscapes swiftly.
Introduction to key
concepts and
technologies in
automation
Automation is the use of technology to carry out tasks with minimal human intervention. Key concepts and
technologies in automation include:

1. Robotics: Robots are machines programmed to perform tasks autonomously or with remote control. They
are commonly used in manufacturing, healthcare, and maintenance.

2. Artificial Intelligence (AI): AI enables machines to learn from data, adapt to new inputs, and perform tasks
that typically require human intelligence. This technology is used in automation for decision-making
processes.

3. Internet of Things (IoT): IoT refers to the network of interconnected devices that can communicate and
exchange data. Automation systems can utilize IoT to monitor and control various processes remotely.

4. Machine Learning: Machine learning algorithms enable systems to improve performance without being
explicitly programmed. This technology is crucial for optimizing automation processes.

5. Industrial Automation: Industrial automation involves the use of control systems such as PLCs
(Programmable Logic Controllers) and SCADA (Supervisory Control and Data Acquisition) to automate
machinery and processes in industries.

6. Process Automation: Process automation aims to streamline repetitive tasks within a workflow. It involves
the use of software to automate tasks like data entry, document processing, and customer communication.

By integrating these key concepts and technologies, automation can enhance efficiency, productivity, and
safety in various industries and applications.
The history of
industrial
automation
First Industrial Revolution-1760
Second Industrial Revolution-1871
Digital Revolution-1914
Industry 4.0- 2014- Present
Industry 5.0- coming soon……
 Industry 1.0 (mechanization with the rise of
steam power)-1760-1870
Advantages of Industry 1.0: Disadvantages of Industry 1.0:
• 1. Increased productivity: The • 1. Poor working conditions:
introduction of machines Workers in factories often faced
powered by steam engines led to long hours, low wages, and
a significant increase in . unsafe working conditions.
production. • 2. Environmental impact: The
• 2. Creation of new job increased use of coal and other
opportunities: The shift from resources led to pollution and
manual labor to machine- environmental degradation.
operated processes created jobs
in factories and manufacturing. • 3. Social inequality: The
Industrial Revolution widened
• 3. Economic growth: The mass the gap between the rich factory
production of goods made them owners and the poor working
more affordable and accessible to class, leading to social unrest.
Industry 2.0 (mass production with electricity)-1871-1914
Advantages of Industry 2.0: Disadvantages of Industry 2.0:
• 1. Increased productivity: Mass • 1. Labor exploitation: The working
production techniques allowed for goods conditions in factories during this time
to be manufactured more quickly and were often harsh, with long hours and low
efficiently. wages leading to labor exploitation.
• 2. Standardization: The use of assembly. • 2. Environmental impact: The rapid
lines led to products being made more industrialization during this period led to
consistently and of higher quality. increased pollution and environmental
degradation.
• 3. Technological advancements: The
introduction of electricity and other new • 3. Social inequality: The benefits of the
technologies revolutionized many Second Industrial Revolution were not
industries, leading to further innovation. evenly distributed, leading to widening
wealth gaps and social inequality.
• 4. Economic growth: The Second
• 4. Urbanization challenges: The mass
Industrial Revolution played a significant
migration of people from rural areas to
role in the economic growth of many
cities in search of work resulted in
countries during this time period. overcrowding and inadequate living
conditions in urban areas.
Third Industrial (automation with the introduction of
computers and electronics)-1914-2014
Advantages of Industry 3.0: Disadvantages of Industry 3.0:
1. Increased productivity: 1. Job loss: Automation and
Automation and computerization technology advancements can lead
streamline processes, leading to to unemployment as machines
higher output. . replace human workers.
2. Skills gap: Workers need to
2. Improved quality: Machines acquire new skills to operate and
can produce goods with greater maintain automated systems.
precision and consistency.
3. Dependence on technology:
3. Cost efficiency: Reduced labor System failures or cyber-attacks can
costs and increased efficiency disrupt operations.
result in lower production costs. 4. Environmental impact: Increased
4. Technological advancements: industrialization can lead to greater
Industry 3.0 paved the way for energy consumption and waste
Industry 4.0(automation with the introduction of
computers and electronics)-2014-Present
Advantages of Industry 4.0 include: Disadvantages of Industry 4.0 may
include:
1. Increased efficiency: Automation and
data integration lead to improved 1. Cost: Implementing Industry 4.0
productivity and reduced downtime. technologies can be expensive,
especially for smaller companies.
2. Enhanced connectivity: IoT 2. Workforce displacement:
.
technologies allow for real-time Automation may lead to job losses in
monitoring and communication between certain industries, requiring
machines and systems. retraining for employees.
3. Customization and flexibility: 3. Data security risks: Increased
Production processes can be tailored to connectivity can make systems more
individual customer needs more easily. vulnerable to cyber attacks.
4. Predictive maintenance: Data analytics 4. Skill gaps: Workers may require
new skills to operate and maintain
can predict equipment failures before advanced technologies.
they occur, reducing costly downtime.
5. Dependency on technology:
5. Sustainability: Industry 4.0 technologies Reliance on digital systems can lead
can help reduce waste and energy to disruptions if there are technical
Evolution of automation in
industries
• The third industrial revolution, also
known as the digital revolution,
began in the mid-20th century with
the advent of computers and
automation technologies like
programmable logic controllers
(PLCs) and computer-aided
manufacturing (CAM). This era saw
a significant increase in the use of
automation in industries such as
automotive manufacturing and
electronics
INSTRUMENTATION in Automation
industry
• Objectives for topic will be cover
• Termonology ,symbols,Standards
• Measuring Means
Pressure, Temperature ,Level,Flow
• Controllling
• Simple closed Loop Control
Instrumentation
• Measurement
• Monitoring
• Control
Definitions of Instrumentation:
An electrical or Pneumatic device
placed in the filed to provide
measurement and/or control
capabilities for the system.
 Measurement:
Sensor is part of Measurement.
• What is the sensor?
A device which detects or measures a physical property and records, indicates,
or otherwise responds to it is called sensor
Types of sensors and their
applications
TEMPERATURE SENSORS
• LARGEST COMMERICALLY
AVAILABLE SENSORS FOR BUY
• RANGE -40 deg C TO 100 deg C
TYPES OF TEMPERATURE
SENSORS
• Thermocouples
• Thermistors
• Radiation Pyrometer
• Radiation thermometers
• Resistance Temperature
Detector(RTD)
• Fiber Optic Temperature Sensors
• Silicon Temperature Sensors
 Importance of sensor technology in
industrial processes
Sno Topic description
1. Real-time data Sensors provide up-to-the-second data that helps with decision-making and process control.

2. Monitoring and control Sensors monitor and control critical parameters like temperature, pressure, flow, and
level. This helps optimize efficiency and quality.
3. Safety and security Sensors detect people and objects, and monitor noise levels.
4. Predictive maintenance Sensors gather data that helps predict equipment failures, which allows for proactive
maintenance.

5. Quality control Sensors monitor and control product quality, detect defects, and ensure correct assembly.

6 Sustainability Sensors can track output in real-time, which helps enhance sustainability.
7 Maintenance costs Automated control systems can minimize potential factory maintenance costs.

8 Production mobility Digitalization can improve production mobility, which gives advanced manufacturing firms a
competitive advantage
Scope of Instrumentation
• Information technology
• Electronics and communication engineering
• Computer engineering
• Aerospace
• Marine Sciences/Biology
• Metrology
• Automation(Mechincal and Process)
• Power Instrumentation
• Nuclear Instrumentation
• Biomedical
• Analyitcal
 Automation Technology
Instrumentation plays an Important role in almost every aspect of automation
Technology

• Industrial Automation
• Manufacturing
automation
• Process Automation
• Building Automation
Everyone needs to measure and/or control something- and that what
instrumentation is all about
Instrumentation
Type of Signal
signal Transmission
1. Electrical Signal – The value of Current or voltage represent the
value of the measured variable(4-20 mA 1-5 Vdc)
2. Pneumatic Signal- The value of the air or gas pressure represent
the value of the measured variable(3-15 PSIG)
3. Hydraulic Signal- The value of the fluid pressure represent the
value of the measured variable
Controllers : These are the devices
that do the controlling
• Programmable Logic
controllers(PLCs)
• Programmable Automation
Controller(PAC)
• Distributed Control Systems(DCS)
• Proportional, Integral, Derivative(PID)
Controllers
• Supervisory Control and Data
Acquisition(SCADA)
• Building Automation Controller(BAC)
• Energy Management System(EMS)
Control Elements
These are the devices the controller
operates
• Pneumatic valves
• Solenoid valves
• Rotary valves
• Motor
• Switches
• Relays
• Variables frequency drives
- Types of sensors and their
applications