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Industrial Automation

Transcript: What is a Production? What is System? Production is the process of transforming raw materials or purchased components into finished products for sale Manufacturing subsystem that includes all functions required to design, produce, distribute, and service a manufactured product. What is a process? A series of actions or steps taken in order to achieve a particular end. A system is a collection of elements or components that are organized for a common purpose. A manufacturing process in which single products are produced for a particular customers what is a job production? What is a batch process? Maria Jose Palta Erazo 7C Technology is a body of knowledge devoted to creating tools, processing actions and extracting of materials. Industrial Automation Where identical different items are produced on an assembly line. What is a production process? what is a flow production? WHAT IS technology? A manufacturing process in which components or goods are produced in groups and not in continuous stream What is a production system? Mechanical or chemical steps used to create an object, usually repeated to create multiple units of the same item.

Industrial automation

Transcript: PLC vs Microcontrollers It is a monetary measure of the market value of all final goods and services produced in a period (quarterly or yearly). Nominal GDP estimates are commonly used to determine the economic performance of a whole country or region, and to make international comparisons. Commercial Successful Machines TOP FIVE AUTOMATION MACHINES Industrial controllers FEEL FREE TO COPY & PASTE THEM! Introduction Gross Domestic Production (GDP) SENSORS P - programmable L - logic C - controller To replace the human with machine to increase the Production Precision Repeatability GDP Industrial automation ATM CNC AND VMC INDUSTRIAL ROBOT LASER CUTTING MACHINE A PLC is basically a gigantic microcontroller. It does the same things a microcontroller can do, but with higher speed, performance, and reliability (sometimes). A microcontroller is really just a tiny low power CPU/computer with some output registers wired to pins instead of other registers or devices. add logo here

Industrial Automation

Transcript: Industrial Automation Industial Ethernet Industrial Power Supply Human-machine interface Field Bus Supervisor Level Control Level Access control Industrial PC AC Motors Security and Protection Programmable logic controller UPS Sensors and Indicators DC Software protection by Ilia Golovachev Field Level Motor Controller

industrial automation

Transcript: Course contents 1- Introduction. 2- OPC. 3- Field communication. 4- HMI. Lab evaluation 1- Exam (30%). 2- course work (70%): - Attendance (20%). - seminars (50%). Session objectives 1- Define the scope of Industrial Automation. 2- Describe the various elements of an Industrial Automation Systems and their hierarchy. 3- Explain how these levels relate to each other in terms of their functions. history 3500BC Use of Wheel and axle for transportation 270BC The earliest documented example of an automatic control system device. In this example, the device was a water clock, shown below. 1700s 1769 James Watt invented the steam engine -- later used to provide power to industry 1800s Electricity! 1900s 1913 Ford Motor Co. opens first moving assembly line 1962: First industrial robot 1968: The first PLC emerged (the MoDiCon)→ Dick Morley, of Bedford and Associates, (Schneider now) 1975: The first DCS emerged → Honeywell / YOKOGAWA 2000s: Networked PCs and windows based HMI software led to SCADA systems Definition Automation: derived from Greek words “Auto”(self) and “Matos” (moving). Automation therefore is the mechanism for systems that “move by itself”. Industry: Systematic Economic Activity that could be related to Manufacture/Service/ Trade. Industrial Automation is the set of technologies that results in operation of machines and systems without significant human intervention and achieves performance superior to manual operation . Why automation? Human factors: To reduce or remove routine manual and clerical tasks Cost - Increasing labor productivity - Reduction of labor and operating costs - increased global competition and narrow profit margins, Safety Remove humans from hazardous environments andexposure to chemicals, fumes, temperature or radiation Technical capability - Standardize components or processes - To accomplish what cannot be done manually - To avoid the high cost of not automating Automation elements Automation hierarchy Level 0: This level’s elements interface directly and physically to the process equipment and machines. The sensing elements translate the physical process signals to convenient electrical or pneumatic forms of information so that these signals can be used for analysis, decisions and finally, computation of control inputs. These computed control inputs need to be converted to physical process inputs, before they can be applied to effect the desired changes in the process outputs. Such physical control inputs are provided by the actuation elements. Level 1 Controllers are elements that accept command signals from human operators or Supervisory Systems, as well as feedback from the process sensors and produce or compute signals that are fed to the actuators. Control Systems can be classified into two kinds: 1- Continuous Control: Process Control, Feedback Control 2- Sequence / Logic Control: These do not involve analog process variables, but instead variables that are set valued. Level 2 Supervisory control systems perform, typically the following functions: - Set point computation - Performance Monitoring / Diagnostics - Start up / Shut down / Emergency Operations - Control Reconfiguration / Tuning: - Operator Interface: for manual supervision and intervention. Level 3 This solves the decision problems like production targets, resource allocation, task allocation to machines, maintenance management etc. This is called ‘level 3’ layer. Production control performs at a hierarchically higher level over the supervisory controllers. Typical functions they perform are: - Process Scheduling. - Maintenance Management. - Inventory Management. - Quality Management. Level 4 This deals less technical and more commercial activities like supply, demand, cash flow, product marketing etc. This is called as the ‘level 4’ layer. Seminar's topics: 1- IEC 65810 2- HART protocol. 3- Pneumatic control, and pneumatic final control elements. 4- SIS. 5- Intelligent electronics devices technology. 6- implementation of wireless technology in industrial automation 7- panel design considerations. 8- PAC technology. 9- constructing and understanding of P&I diagrams. END Industrial Automation

industrial automation

Transcript: JOB PRODUCTION PRODUCTION SYSTEM manufacturing process in which components or goods are produced in groups and not in a continuous stream by: Valentina Aristizabal 7C PROCESS: SYSTEM Manufacturing subsystem that includes all functions required to design, produce, distribute, and service a manufactured product. form of production where all the different operations requires for production are carried out in sequence one after the other. BATCH PRODUCTION PRODUCTION The processes and methods used to transform tangible and intangible inputs FLOW PRODUCTION PRODUCTION PROCESS Sequence of interdependent and linked procedures Mechanical or chemical states used to create an object. industrial automation A body of knowledge dedicated to creating tools, processing actions and extracting of materials. TECHNOLOGY Set of detailed methods,procedures and routines created to carry out a specific activity . Type of business model that performs or creates single and customized projects for a specific client

industrial automation

Transcript: What is automation ? Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Industrial automation deals with the optimization of energy-efficient drive systems by precise measurement and control technologies. kuka robot handling flat glass And one more thing... Thank you for your attention! Subject 3 Subject 1 Conclusion Subject 3 Industrial Automation Subject 2 is here

Industrial Automation

Transcript: Safety through Crane Algorithm New 1000 Series- Key Features J1000 5 frame sizes 23 ~ 105A 145 ~ 220A 255A 360 ~ 930A 1200 ~1600A 4 control voltages 110 ~ 220V AC 230 ~ 440V AC 24VDC 24VAC (optional) 630 Range 200 V, 3-phase power supply, 1.2 - 69A (0.2kW – 18.5kW, ND) 400 V, 3-phase power supply, 1.2 - 38A (0.2kW to 18.5kW, ND) Overload Capacity 150% (HD) or 120% (ND) for 60 sec Power Supply 200~240 V 3-phase 50/60 Hz 380~480 V 3-phase 50/60 Hz *Allowable voltage fluctuation -15%/+10% A1000 Series Applications V1000 Series- Specifications A1000 - C for Crane Control Product Range 0.4 EMX3 Soft Starters AC drives- Product range V1000 LnTOUCH HMI 4.3” TO 15” screen Multi-language, Graphics, Extended alarms Recipe, Data logging, Printing, Ethernet Fieldbus communication A1000 Series- Specifications Features Regenerative converter available from 5kW to 370kW Low power supply harmonics ensuring less input current distortion with unity power factor at rated load Multi drives can be connected to single D1000 ensuring saving of regenerated energy and low harmonics at improved power factor Multi drives combination useful for overhead cranes, escalator, automatic parking system, weaving machines, HVAC apps & many other Overload of 150% for 1min&200% for 3sec Brake opening command by Drive under following condition Inverter Output Frequency > Brake Release Frequency AND Inverter Output Current > Brake Release Current AND Inverter Torque > Torque Compensation Value Ensures Slip prevention Different settings possible for Hoisting & Lowering Motion Special “S” parameter group only for crane drives PLC & HMI V1000 Range from 7.5 to 110kW Range from 18A to 220A Control voltage: 110 V - 240VAC : 380V - 440VAC Time based start & stop ramp EMX3 World’s smallest drive V/f Control Built-in braking transistor High Flux Braking Unique maintenance monitor RS-485 MODBUS Communication (Optional) Low-noise technology Tree Program Structure 5 DI, 1 DO, 1 AI, 1 AO Features Compact Design Built-in bypass contactor Time based start & stop ramp Complements existing motor protection Programming through trim pot Flexible soft starting profiles (CSXi) Safety AC Inverter Drives Safe disable inputs Built-in RS-485 port @ 115.2 kbps Last 10 faults stored Peak current @ frequency recorded Fault trace of last fault Application presets 200 V class: 1.5 to 110 kW 400 V class: 1.5 to 110 kW CSX and CSXi Series- Specifications D1000 V1000 Series Applications Soft Starter Smooth & Comfortable Ride J1000 Series- Specifications A1000 Range 23 Models 23A ~ 1600A 7.5 ~ 800kW 2 Voltage Ranges 200 ~ 440V AC 380 ~ 690V AC Protection IP20 EMX-0023B EMX3-0105B IP00 EMX-0145B EMX3-1600C 18.5 D1000 A1000 Power-through Servo & Motion Control V1000 Series- Compact & Powerful V/f , V/f with feedback, OLV & Flux vector 200% starting torque @ 0 RPM in closed loop Speed range 1:1500 Swing PWM for low motor noise for all ND Built-in braking transistor upto 30kW Detachable terminal block with memory Standard conformal coating in all ratings CSX & CSXi Runs Induction and Synchronous Motors Compatible with a Wide Range of Encoders Loaded with Auto-Tuning Features Designed Compact for Tight Machine Rooms Reduced Operation Time and More Powerful Braking Extensive Product Lineup LX Series PLC 10 to 8192 I/Os Embedded Ethernet, USB, SD Card RoHS, CE, CULuS certification Embedded Web Server Modular Micro PLC J1000 Series Applications Robust control terminals Real time metering and monitoring Adjustable bus-bars Serial programming and control Suitable for Asynchronous & PM motor Designed for 10 years of performance life Rated for 50ºC without derating Unique maintenance monitor function Intelligent detachable control terminals Adapted to tropical conditions (conformal coating) Features a USB port for easier communication Key features of Crane Algorithm A1000 Series- High Performance EMX3- Key features EMX3- Key features Rescue Operation Light Load Search Detection Function Safe Disable Function Fault Detection During Run Preventative Warnings Long-life Performance Range 400 V, 3-phase power supply, 1.2 - 1200A (0.4kW to 630kW, ND) Overload Capacity 150% (HD) or 120% (ND) for 60 sec Power Supply 380~480 V 3-phase 50/60 Hz *Allowable voltage fluctuation -15%/+10% Matching Every Need Smooth Operation Overshoot and Anti-Vibration Control Variety of Braking Functions High Performance Starting Torque w/o Sensors (Anti-rollback) Range 200 V, single-phase power supply, 1.2 - 9.6A (0.4 – 2.2kW, ND) 400 V, 3-phase power supply, 1.2 – 11.1A (0.4 – 5.5kW, ND) Overload Capacity 150% (HD) or 120% (ND) for 60 sec Power Supply 200~240 V single-phase 50/60 Hz 380~480 V 3-phase 50/60 Hz *Allowable voltage fluctuation -15% to +10% V/f and Open loop control 200% starting torque at 0.5 Hz Dual Microprocessor Built-in braking transistor Online auto tuning Application preset Built-in MODBUS communication port No deration required upto 8kHz carrier freq 7 DI , 3 DO, 2 AI, 1 AO 5.5 Industrial

Industrial Automation

Transcript: INDUSTRIAL AUTOMATION Automation Automation Industrial automation can be defined as the use of set technologies and automatic control devices that results the automatic operation and control of industrial processes without significant human intervention and achieving superior performance than manual control. Auto means "Self" and matos means "moving". Example Example Levels of Automation Levels of Automation Increased throughput or productivity. Improved quality or increased predictability of quality. Improved robustness (consistency), of processes or product. Increased consistency of output. Reduced direct human labor costs and expenses. Advantages Advantages and Disadvantages Disadvantages Security Threats/Vulnerability Unpredictable/excessive development costs High initial cost Advantages and Disadvantages ANN - Artificial neural network DCS - Distributed Control System HMI - Human Machine Interface SCADA - Supervisory Control and Data Aquisition PLC - Programmable Logic Controller Instrumentation Motion control Robotics Sensors Actuators Tools for Automation Tools for Automation Programmable Logic Controller Programmable Logic Controller A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control system that continuously monitors the state of input devices and makes decisions based upon a custom program to control the state of output devices. There is a broad range of PLCs available. We can classify them as Siemens PLC and Non- Siemens PLC. Some of the Siemens PLCs are :- SIMATIC S7-300 Series SIMATIC S7-400 Series SIMATIC S7-1200 Series SIMATIC S7-1500 Series Some of the Non-Siemens PLC that we use are :- Allen Bradley(Rockwell Automation) Mitsubishi Omron Modicon (Schneider Electric) Brands of PLCs Brands of PLCs Advantages Advanatages and Disadvantages Advanatages and Disadvantages Disadvantages Rugged and designed to withstand vibrations, temperature, humidity, and noise. Have interfacing for inputs and outputs already inside the controller. PLCs are easily programmed and have an easily understood programming language. There's too much work required in connecting wires. There's difficulty with changes or replacements. It's always difficult to find errors; And require skillful work force. When a problem occurs, hold-up time is indefinite, usually long. The PLC receives information from connected sensors or input devices, processes the data, and triggers outputs based on pre-programmed parameters. Depending on the inputs and outputs, a PLC can monitor and record run-time data such as machine productivity or operating temperature, automatically start and stop processes, generate alarms if a machine malfunctions, and more. Programmable Logic Controllers are a flexible and robust control solution, adaptable to almost any application. How does a PLC work? How does a PLC work? The graphical user interface between human/operator and machine in a manufacturing or process control system to visualize, monitor and operate highly complex process. To achieve the above operations it communicates with specialized computers in the plant such as a programmable automation controller (PAC), programmable logic controller (PLC) or distributed control system (DCS). Human Machine Interface Human Machine Interface Human Machine Interface is classified into following types: Key Panels Basic Panels Comfort Panels Mobile Panels Classification Classification SIMATIC HMI Key Panels can be used for creating con-ventional operator panels according to the principle of "plug and control": They are ready for installation and pre-assembled. In this way, time-consuming individual assembly and wiring, as required for conventional operator panels, is not necessary. This reduces the time required for wiring by up to 90% compared to conventional wiring. Requirements are installation cutout and a PROFINET cable. E.g.- SIMATIC HMI KP8/KP8F PN and SIMATIC HMI KP32F etc. Simatic Key Panels Simatic Key Panels SIMATIC HMI Basic Panels 2nd generation are the ideal entry-level series for simple HMI applications. The device series offers panels with 4", 7", 9" and 12" displays, and combined key or touch operation Displays with high resolution They can be installed in portrait mode and are especially energy-efficient due to their 100% dimmable brightness. The user interface opens up a wide range of operations with improved usability and allows you to connect a keyboard, mouse and barcode scanner and supports archiving of data on a USB stick. Simatic Basic Panels Simatic Basic Panels Simatic Comfort Panel Simatic Comfort Panel Extremely flexible across all sizes Brilliant displays in widescreen format Application and data protection Optimum convenience, even during commissioning Precise diagnostics made easy Easy to operate More interfaces – less hardware costs Fast application recovery in case of device damage Intelligent energy management with PROFIenergy SIMATIC HMI Mobile Panels 2nd generation offer even more performance, flexibility,

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