Industrial Automation (Automação de Processos Industriais)
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1 Industrial Automation (Automação de Processos Industriais) Slides 2010/2011 Prof. Paulo Jorge Oliveira Rev Prof. José Gaspar Page 1
2 Industrial Revolution 1760/ /40 (historians E. Hobsbawm,, T. S. Ashton) A steam engine built according to James Watt's patent in 1848 at Freiberg in Germany [wikipedia] Page 2
3 Industrial Revolution 1760/ /40 (historians E. Hobsbawm,, T. S. Ashton) Steam engine and detail of the governor, James Watt's [wikipedia]. Page 3
4 A jewel: Maillardet's Automaton, 18 th century, the largest known mechanical memory Page 4
5 Maillardet's Automaton, 18 th century: the largest known mechanical memory Four drawings and three poems Page 5
6 Maillardet's Automaton, 18 th century: the robot saved for the future the name of its manufacturer Ecrit par L Automate de Maillardet Page 6
7 Microcontrollers Computer + IO PLC Many options for controlling real world devices! Why PLCs? Page 7 Arduino Raspberry-pi National Instruments AD/DA Premium P57
8 Page 8
9 Industrial Automation Objectives of the course: Analysis of systems for industrial automation. Methodologies for the implementation of solutions in industrial automation. Programming languages of PLCs (Programmable Logic Controllers). CAD/CAM and Computerized Numerical Controlled machines. Discrete Event Systems Modeling. Supervision of Processes in Industrial Automation. Page 9
10 Program at a glance: 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 ): Ladder Diagram; Instruction List and Structured Text. 4. GRAFCET (Sequential Function Chart) [1 week] Norm, elements of the language, modelling. 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. Page 10
11 Industrial Automation 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. One extra value for students attending more than 70% of recitations and do short summaries of the classes. Page 11
12 Assessment and grading: Short summaries of the classes Download this XLS file from the webpage of the course. Page 12
13 Schedule (semester view, laboratories & exam): Lab. registration 1 1 st preliminary lab. 2 nd preliminary lab. 1 st lab. assignment 2 nd lab. assignment 3 rd lab. assignment Exams First week 1 week 1 week 3 weeks 3 weeks 0.5h seminar (one date >= week 8) 3h, 14Jan or 30Jan Important: define the students representative Page 13
14 Industrial Automation Schedule (week view, see also IST-GOP / fenix): Recitation classes Monday Tuesday h 12.30h Ea h 11.00h Ea3 Lab. Classes (once per week) Monday 09.30h 11.00h L1 LSDC4 (room 5.21) Friday 09.30h 11.00h L2 LSDC4 (room 5.21) Groups registration for the Laboratory By September 25 th 2009 with the students representatives. Page 14
15 Industrial Automation Bibliography: Automating Manufacturing Systems with PLCs, Hugh Jack (online version available). Peterson, James L., "Petri Net Theory and the Modeling of Systems", Prentice-Hall,1981. Modeling and Control of Discrete-event Dynamic Systems with Petri Nets and other Tools, Branislav Hruz and MengChu Zhou, New reference --- secondary--- Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, Petri Nets and GRAFCET: Tools for Modeling Discrete Event Systems, R. DAVID, H. ALLA, New York : PRENTICE HALL Editions, Computer Control of Manufacturing Systems, Yoram Koren, McGraw Hill, Christos Cassandras, "Discrete Event Systems - Modeling and Performance Analysis", Aksen Associates, Moody and Antsaklis, Supervisory Control of Discrete Event Systems, Kluwer Academic Publishers, Page 15
16 Industrial Automation (Automação de Processos Industriais) Introduction to Automation Slides 2010/2011, Prof. Paulo Jorge Oliveira Rev , Prof. José Gaspar Page 16
17 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. Need to use automatic tools and systems. Automation was fostered by the invention of computers. 1 Motivated by the continuous growth of the world population and migration to cities. Page 17
18 Industrial Process: Making Cement [Outão / Setúbal / Portugal] Some systems are very large and complex but still need to work like a clock Page 18
19 Industrial Process: Tetra Pak / Parmalat Complexity handled with modularity. Filling machine, complete line: ml slim TP/h - Straw Applicator - Beverage Carton Film Wrapper - Conveyors - Carboardpacker Page 19
20 Robot +Robot +Robot Global Ctrl Actuator Sensor Controller = Automated Industrial Process Other courses as e.g. Control The subject of this course Page 20
21 Industrial Automation 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. Page 21
22 1.1 Components used in industrial automation Robotic Manipulators the generic workers Computerized CNC Machines the specialized workers Handling materials specialized load and unload Low level actuation motors Page 22
23 Robotic Manipulators Page 23
24 Robotic Manipulators Riding an ABB IRB 6600 Robot 1 [Youtube] API Note: please understand the power, and do not do this; keep always the safety! Page 24
25 Robotic Manipulators - End Effectors Page 25
26 Robotic Manipulators 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 Page 26
27 Robotic Manipulators Workspace: Examples Page 27
28 Robotic Manipulators Central problems to address and solve: Direct / Inverse kinematics Trajectory generation Coordinate frames where tasks are specified Level of abstraction of the programming languages Page 28
29 Robotic Manipulators Use in Flexible Cells of Fabrication: it is required that the manipulators have correct interfaces for the synchronization and inputs for external commands. Page 29
30 Computerized Numerical Controlled (CNC) Machines 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 Examples: Milling, Lathes,... MITSUI SEIKI Machining Center Page 30
31 Computerized Numerical Controlled (CNC) Machines Compact CNC plasma cutting machine Effective cutting :1.5 m X 3 m Plasma torch cutting capacity up to 5cm (mild steel), Gas torch option allows up to 10cm. Page 31
32 Solutions for Handling materials For transport... Major characteristics: Load/unload automation Accuracy, reliability Payload and robustness Interface Synchronization with exterior Page 32
33 AGVs (Automatic Guided Vehicles) Major characteristics: Load/unload automation Accuracy, reliability Payload and robustness Interface Synchronization with exterior Page 33
34 AGVs (Automatic Guided Vehicles) Example of fleet operating in industry Page 34
35 AGVs (Automatic Guided Vehicles) Kiva Systems Inc - warehouse automation - used by Staples, Toys R Us, bought by Amazon ($775 million) Page 35
36 AGVs (Automatic Guided Vehicles) Kiva Systems Inc, warehouse automation Page 36
37 Industrial Automation 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. Page 37
38 1.2 Cabled Logic versus... Page 38
39 ... versus Programmed Logic Page 39
40 Cabled Logic versus versus Programmed Logic Relay control panel PLC control panel Page 40
41 ... versus Networked Logic Page 41
42 Industrial Automation 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. Page 42
43 Relay diagram / Ladder diagram: main sub-system hardware (actuators, sensors) integration break complete system into sub-systems, select hardware integrate hardware (logic and sequencing) Actuators Motors Solenoide valve Command relay Pneumatic cylinder Electro pneumatic Sensors Pressure switch Temperature sensors Proximity sensors Ref: Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, Page 43
44 Demonstration of precise actuation Schneider Electric Page 44
45 Actuation Motors Major characteristics: Type of start Type of control Accuracy, reliability Payload and robustness Interface with exterior Synchronization Page 45
46 Example of AC motor, with driver Page 46
47 Solenoid Valve Page 47
48 Command Relay Page 48
49 Cylinders (Pneumatics) Page 49
50 Valves (Electro-pneumatics) Page 50
51 Page 51
52 Sensors Push buttons Page 52
53 Selector with three positions Page 53
54 Sensors Pressure Switch Page 54
55 Temperature Sensors RTD = Resistance Temperature Detector IC = Integrated Circuit Page 55
56 Thermocouple Proximity detector Page 56
57 Magnetic detector Magnetic switch Page 57
58 Symbols associated to all components Standards Page 58
59 Methodologies for the implementation of solutions in industrial automation Device: Relay Contact Diagram or Ladder Diagram Page 59
60 Ladder Diagram or Contact Diagram Page 60
61 Methodologies for the implementation of solutions in industrial automation Contacts diagram Example Page 61
62 Example: Page 62
63 Logic Functions Page 63
64 Example: Page 64
65 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 Page 65
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