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Industrial Automation(Automação de Processos Industriais)
http://users.isr.ist.utl.pt/~jag/courses/api1819/api1819.html
Prof. Paulo Jorge Oliveira, original slides
Prof. José Gaspar, rev. 2018/2019
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A steam engine built according to James Watt's patent in 1848 at Freiberg in Germany [Wikipedia]
Industrial Revolution 1760/80 – 1820/40 (historians E. Hobsbawm, T. S. Ashton)
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Steam engine and detail of the governor, James Watt’s [Wikipedia].
Industrial Revolution 1760/80 – 1820/40 (historians E. Hobsbawm, T. S. Ashton)
Air pressure implies proportional rotation(desired small flow)
Out flow regulates air pressure.
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Steam regulator is still useful nowadays: pressure cooker
Industrial Revolution 1760/80 – 1820/40 (historians E. Hobsbawm, T. S. Ashton)
www.silampos.pt
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A jewel: Maillardet's Automaton, 18th century, the largest known mechanical memory
https://www.fi.edu/history-automaton
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Maillardet's Automaton, 18th century: the largest known mechanical memory
https://www.fi.edu/history-automaton
Four drawings and three poems
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Maillardet's Automaton, 18th century:the robot saved for the future the nameof its manufacturer
https://www.fi.edu/history-automaton
Ecrit par L’Automate de Maillardet
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Many options for controlling real world devices! Why PLCs?
Microcontrollers Computer + IO PLCA
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Objectives of the course:
Industrial Automation
• Analysis of systems for industrial automation.
• Methodologies for the implementation of solutions in industrialautomation.
• Programming languages of PLCs (Programmable Logic Controllers).
• CAD/CAM and Computerized Numerical Controlled (CNC) machines.
• Discrete Event Systems Modeling.
• Supervision of Processes in Industrial Automation.
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1. Introduction to Automation [1 week]Introduction to components and methodologies.
2. Introduction to PLCs [2 weeks]Components of Programmable Logic Controllers (PLCs). Architecture, functional structure, IO.
3. PLCs Programming Languages [2w]Standard languages (IEC-1131-3): Ladder Diagram; Instruction List and Structured Text.
4. GRAFCET (Sequential Function Chart) [1 week]Norm, elements of the language, modelling.
Program at a glance:
Industrial Automation
5. CAD/CAM and CNC Machines [1 week]Types of Computerized Numerical Controlled machines. Interpolation of trajectories. Flexible fabrication cells.
6. Discrete Event Systems [1 week]Modeling of discrete event systems (DESs). Automata. Petri networks. State and dynamics of PNs.
7. Analysis of DESs [2 weeks]Properties of DESs. Methodologies for the analysis: reachability graph and matricial equation.
8. DESs and Industrial Automation [1week]Relations GRAFCET / Petri networks. Analysis of industrial automation solutions as DESs.
9. Supervision of Industrial Processes [2w]Methodologies for supervision. SCADA. Synthesis based on invariants. Examples of application.
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Assessment and grading:
• 2 Preliminary laboratory assignments - training purposes (0% of the final grade).
• 2 Laboratory assignments (20%+20% of the final grade). Groups of 3 students.
• 1 Seminar (20% of the final grade). Topics to be selected with each group.
• 1 Exam (40% of the final grade).
Upon student choice, the second exam can be oral.
• Minimum grade: 9.0/20.0 val. in each component.
Industrial Automation
One extra value for students attending more than 70% of recitations and do short summaries of the classes.
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Assessment and grading:
Shortsummariesof theclasses
Download this XLS file from the webpage of the course.
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Lab. registration 1 First week
1st preliminary lab. 1 week
2nd preliminary lab. 1 week
1st lab. assignment 3 weeks
2nd lab. assignment 3 weeks
3rd lab. assignment 0.5h seminar (one date >= week 8)20min presentation + 10min discussion
Exams (do at least one) 3h, 11Jun or 05Jul 2019
Schedule (semester view, laboratories & exam):
1 Important: define the students’ representative
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Schedule (week view, see also IST-GOP / fenix):
• Recitation classes
Monday 15.30 h – 17.00 h Ea3Friday 15.30 h – 17.00 h Ea5
• Lab. Classes (once per week, choose one shift)
1st shift Monday 17.00h – 18.30h LSDC4 (room 5.21)2nd shift Thursday 09.30h – 11.00h LSDC4 (room 5.21)3rd shift yet to schedule LSDC4 (room 5.21)
• Groups registration for the LaboratoryBy September 25th 2009 with the students’ representatives.
Industrial Automation
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Bibliography :
Industrial Automation
--- References mostly found in the slides :
• Automating Manufacturing Systems with PLCs, Hugh Jack (available online).
• Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, 1996.
• Petri Net Theory and the Modeling of Systems, James L. Peterson, Prentice-Hall,1981.
• Supervisory Control of Discrete Event Systems, Moody and Antsaklis, Kluwer Academic Publishers, 1998.
• Discrete Event systems: Modeling and Performance Analysis, Christos Cassandras, Aksen Associates, 1993 (newer book in 2008).
--- More references :
• Computer Control of Manufacturing Systems, Yoram Koren, McGraw Hill, 1986.
• Petri Nets and GRAFCET: Tools for Modeling Discrete Event Systems, R. David, H. Alla, New York : Prentice Hall Editions, 1992.
• Supervisory Control of Concurrent Systems: A Petri Net Structural Approach, Marian V. Iordache, Panos J. Antsaklis, Birkhauser, 2006
• Modeling and Control of Discrete-event Dynamic Systems with Petri Nets and other Tools, Branislav Hruz and MengChu Zhou, 2007.
• Técnicas de Automação, João R. Caldas Pinto, Lidel Ed. Técnicas Lda, 2010 (3ª Edição)
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Prof. Paulo Jorge Oliveira, original slidesProf. José Gaspar, rev. 2018/2019
Industrial Automation(Automação de Processos Industriais)
Introduction to Automation
http://www.isr.ist.utl.pt/~jag/aulas/api1819/api1819.html
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IST / DEEC / API Chap. 1 – Introduction to Automation
Industrial Automation is Necessary and is Happening
Consistent production growth in the last three centuries (since the Industrial Revolution)1.
The production of increasing amounts of goods requires the storage and handling of large quantities of resources.
1 Motivated by the continuous growth of the world population and migration to cities.
Need to use automatic tools and systems.
Automation was fostered by the invention of computers.
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Industrial Automation - Industry 4.0
1760-1840 Industrial
Revolution
1913Assembly line by Henry Ford
1955 NC/CNC 1968 Bedford /
GM PLC
2011 Industry 4.0 term revived at
the Hannover Fair
1807-1811 French invasions, 1821 Independence of Brasil1974-1975 Independence of Guiné-Bissau, Moçambique, Cabo Verde, São Tomé
e Príncipe, Angola
[Wikipedia]
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Industrial Automation - Industry 4.0Cyber physical systems, Internet of things (IoT) and Visual computing
https://en.wikipedia.org/wiki/Electric_power_distribution
https://medium.com/datadriveninvestor/the-internet-of-things-90263f7b1249
https://eisti.fr/en/formation/visual-computing-option
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Industrial Process:
Making Cement
[Outão / Setúbal / Portugal]
Some systems are very large and complex but still need to “work like a clock”
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Industrial Process:
Tetra Pak / Parmalat
Complexity handled with modularity.Filling machine, complete line:- 200 ml slim 20000 TP/h- Straw Applicator- Beverage Carton Film Wrapper- Conveyors- Carboardpacker
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Ctrl Actuator
Sensor
Subsystem +Subsystem +Subsystem + … + Global
Controller
= AutomatedIndustrial
Process
Subsystems sequencing, synchronization, …
Start and stop digital (binary) signals and events.
The subject of this course.
Other courses as e.g. Control
Complex Systems based on Local and Global Controllers
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Ch. 1 – Introduction to Automation [1 week]
1.1 Introduction to components in industrial automation.
1.2 Cabled logic versus programmed logic versus networked logic.
1.3 Introduction to methodologies for problem modeling.Methodologies of work.
Industrial Automation
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1.1 Components used in industrial automation
Robotic Manipulators– generic load, unload, handle, work
Computerized CNC Machines– specialized workers
Handling materials– specialized load and unload
How it is done:– Low level actuation and sensing– Motors and sensors, local and global integration
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Robotic Manipulators
Chap. 1 – Introduction to Automation
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Robotic Manipulators - End Effectors
Chap. 1 – Introduction to Automation
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Major characteristics:
• Number of degrees of freedom• Types of joints (prismatic/revolution)• Programming tools and environments(high level languages, teach pendent, ...)
• Workspace• Accuracy, reliability• Payload and robustness
Chap. 1 – Introduction to Automation
Robotic Manipulators
Workspace, examples:
• Spherical• Cylindrical• …
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Central problems to address and solve:
• Direct / Inverse kinematics• Trajectory generation / Trajectory following• Coordinate frames where tasks are specified• Level of abstraction of the programming
languages
Chap. 1 – Introduction to Automation
Robotic Manipulators
Use in Flexible Cells of Fabrication:
it is required that the manipulatorshave correct interfaces for the synchronization and inputs forexternal commands.
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Riding an ABB IRB 6600 Robot 1 [Youtube]
API Note: please understand the power, and do not do this; keep always the safety!
Robotic Manipulators
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Computerized Numerical Controlled (CNC) Machines
Examples:Milling, Lathes, ...
Major characteristics:
• Number of degrees of freedom• Interpolation methods• Load/unload automation, and also in tool change• Programming (high level languages, teach pendent, ...)• Workspace• Accuracy, reliability• Payload and robustness• Interface • Synchronization with exterior
Chap. 1 – Introduction to Automation
MITSUI SEIKI Machining Center
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Computerized Numerical Controlled (CNC) Machines
Compact CNC plasma cutting machineEffective cutting :1.5 m X 3 mPlasma torch cutting capacity up to 5cm (mild steel), Gas torch option allows up to 10cm.
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Computerized Numerical Controlled (CNC) Machines
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For transport
Solutions for Handling materials
Chap. 1 – Introduction to Automation
Major characteristics:
• Load / unload automation
• Accuracy, reliability
• Payload and robustness
• Interface
• Synchronization with exteriorConveyors, wheels on the ground
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Automatic Guided Vehicles (AGVs)
Chap. 1 – Introduction to Automation
Major characteristics:
• Load/unload automation
• Accuracy, reliability
• Payload and robustness
• Interface
• Synchronization with exterior
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Example of fleet operating in industry
Automatic Guided Vehicles (AGVs)
Chap. 1 – Introduction to Automation
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Automatic Guided Vehicles (AGVs)
Kiva Systems Inc- warehouse automation- used by Staples, Toys R Us, ...- 2012 bought by Amazon ($775 million)
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AGVs (Automatic Guided Vehicles)
Kiva Systems Inc, warehouse automation
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Ch. 1 – Introduction to Automation [1 week]
1.1 Introduction to components in industrial automation.
1.2 Cabled logic versus programmed logic versus networked logic.
1.3 Introduction to methodologies for problem modeling.Methodologies of work.
Industrial Automation
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1.2 Cabled Logic
Chap. 1 – Introduction to Automation
CB
CB
212 CCB
One Relay Two Relays making one AND gate
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1.2 Cabled Logic versus ...
Chap. 1 – Introduction to Automation
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Cabled Logic versus ...
... versus Programmed Logic …
Relaycontrolpanel
PLCcontrolpanel
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... versus Networked Logic
Chap. 1 – Introduction to Automation
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IST / DEEC / API
Ch. 1 – Introduction to Automation [1 week]
1.1 Introduction to components in industrial automation.
1.2 Cabled logic versus programmed logic versus networked logic.
1.3 Introduction to methodologies for problem modeling.Methodologies of work.
Industrial Automation
![Page 45: Industrial Automation - ULisboausers.isr.ist.utl.pt/~jag/courses/api18b/docs/API_I_C1.pdf · Standard languages (IEC-1131-3): Ladder Diagram; Instruction List andStructured Text](https://reader035.vdocuments.mx/reader035/viewer/2022062914/5e7f91a759034e37d237531c/html5/thumbnails/45.jpg)
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Demonstration of precise actuation – Schneider Electric
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IST / DEEC / API
Ch. 1 – Introduction to Automation [1 week]
1.1 Introduction to components in industrial automation.
1.2 Cabled logic versus programmed logic versus networked logic.
1.3 Introduction to methodologies for problem modeling.Methodologies of work.
Industrial Automation
![Page 47: Industrial Automation - ULisboausers.isr.ist.utl.pt/~jag/courses/api18b/docs/API_I_C1.pdf · Standard languages (IEC-1131-3): Ladder Diagram; Instruction List andStructured Text](https://reader035.vdocuments.mx/reader035/viewer/2022062914/5e7f91a759034e37d237531c/html5/thumbnails/47.jpg)
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Ref: Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, 1996.
Relay or Ladder diagram, design methodology:
• identify the main hardware, actuators & sensors, to build the system• break the system into subsystems; tune hardware selection• integrate hardware, logic and sequencing, locally and globally.
SensorsPressure switchTemperature sensorsProximity sensors
ActuatorsMotorsSolenoid valveCommand relayPneumatic cylinder / Electro pneumatic
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Example of AC motor, with driver
Chap. 1 – Introduction to Automation
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Actuation
Major characteristics:
• Type of start• Type of control• Accuracy, reliability• Payload and
robustness• Interface with exterior• Synchronization
Motors
Chap. 1 – Introduction to Automation
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Solenoid Valve
Chap. 1 – Introduction to Automation
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Command Relay
Chap. 1 – Introduction to Automation
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AB
C
Command Relay
from: http://www.engineersgarage.com/insight/how-relay-switch-works
A = NO = Normally Open
B = NC = Normally Closed
A BC
AB
C
DC off DC on
A
B
C
C
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Cylinders (Pneumatics)
Chap. 1 – Introduction to Automation
Force:
whereP = the pressure of the hydraulic fluidA = the area of the pistonF = the force available from the piston rod
PAFA
FP
Air flow in or out
https://www.smctraining.com/en/webpage/indexpage/1108
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Solenoid Valves (Electrovalves, Electro-pneumatics)
The solenoid has 2 positions. Each position implies one direction of fluid flowing:
Two types: ON/OFF valves, Proportional Valves
Symbols commonly used to represent the two cases:
Power in
solenoid
Exhaust out
Power in Exhaust out
solenoid
Example of a commercial valve:
https://www.smctraining.com/en/webpage/indexpage/354
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Solenoid Valves and Cylinders
Note about the most flexible systems:- Proportional pneumatics (proportional valve), - Servo-pneumatics (e.g. feedback of the position of the piston).
https://www.smctraining.com/webpage/indexpage/341/
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Push buttons
Chap. 1 – Introduction to Automation
Sensors
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Selector with three positions
Chap. 1 – Introduction to Automation
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Sensors
Pressure Switch
Chap. 1 – Introduction to Automation
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Temperature
Sensors
Chap. 1 – Introduction to Automation
RTD = Resistance Temperature DetectorIC = Integrated Circuit
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Thermocouple Proximity detector
Chap. 1 – Introduction to Automation
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Magnetic detector Magnetic switch
Chap. 1 – Introduction to Automation
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Symbols associated to all components
Standards - Joint International Committee (JIC) Wiring Symbols
Chap. 1 – Introduction to Automation
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Contact Diagram or Ladder Diagram
Chap. 1 – Introduction to Automation
Methodologies for the implementation of solutions in industrial automation
Device: Relay
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Example of relay and ladder diagrams:
Chap. 1 – Introduction to Automation
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LogicFunctions
Chap. 1 – Introduction to Automation
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Example of relay and ladder diagrams, and gate logic:
Chap. 1 – Introduction to Automation
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The world is always moving forward:Exploit the advantages of Programmed Logic!
Relay control panel PLC control panel
Rule of thumb: if using more than 6 relays then a PLC is already lesser expensive