CHAPTER 1:

Introduction to Automation
 Contents

1.1 Definition of ‘Automation’

1.2 Reasons & Goals of Automation
1.3 Types of automation
1.4 Comparisons: Fixed & Flexible Automation System
1.5 Computer Integrated Manufacturing
1.6 Structure of Automated System
1.7 Composition of Control System & Application

H.I. Jaafar DEKC3643 Chapter 1 2

Introduction to Automation

What is Automation?

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 Introduction to Automation

Definition of ‘Automation’
‘The process of following a predetermined
sequence of operation with little or no human
labor, using specialized equipment and
devices that perform and control
manufacturing processes. It is achieved
through the use of variety devices, sensors,
actuators, techniques and equipment that are
capable of observing the manufacturing
process, making decisions concerning the
changes that need to be made in the
operation and controlling all aspect of it.’

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 Introduction to Automation

• ‘is the technology by which a process or

procedure is accomplished without human Oh No!!!
assistance. It’s implemented using a
program of instructions combined with a
control system that executes the
instructions’ – book
• ‘as a technology concerned with the
application of mechanical, electronic, and
computer-based systems to operate and
control production’ - book
• ‘the control of an industrial process by
automatic’ - book
• ‘the use of machines instead of people to
do work’ - dictionary
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 Introduction to Automation

Reasons & Goals of Automation:

1. What is Automation?
To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical
tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating
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Introduction to Automation

Types of Automation: Oh No!!!

• Fixed Automation

• Programmable Automation

• Flexible automation

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 Introduction to Automation

• Fixed Automation
- This control system is designed to perform a
specific task.
- Functions of control circuit is fixed and
permanent.
- It will be complicated if we want to do other
task apart from the existing task.

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 Introduction to Automation

• Programmable Automation
- Production equipment is designed with the
capability to change the sequence of
operations to accommodate different
product configurations.
- Operation sequence is controlled by a
program, set of instructions coded.
- New programs can be prepared and entered
into the equipment to produce new
products.
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 Introduction to Automation

• Flexible Automation Oh No!!!

- Complex control system that can perform

several tasks.
- Functions of control circuit programmed by
the user and can be modified.
- When the task to be performed by machines
changed, changes only need to be done by
making modifications to the machine control
program.
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 Introduction to Automation
Comparison Between Fixed & Flexible Automation System
Type Fixed Flexible
What is Automation?
Automation Automation
Purpose Specific Variety
Ease of making Difficult Easy
changes / upgrade
Maintenance Hard Easy
Capability Depends on Very high
manufacturing and
design
Speed Slow Fast

Economy efficiency Suitable for small Suitable for

system all types of systems
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 CIM as Production Control System

Computer-integrated manufacturing (CIM) in

engineering is a method of manufacturing in
which the entire production process is controlled
by computer. The traditional separated process
methods are joined through a computer by CIM.

History : The idea of "digital manufacturing" was prominent the 1980s,

when computer-integrated manufacturing was developed and promoted
by machine tool manufacturers and the Computer and Automated
Systems Association and Society of Manufacturing Engineers (CASA/SME

Source : http://en.wikipedia.org/wiki/Computer_Integrated_Manufacturing

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CIM as Production Control System

Automation of the
Computerization of the
manufacturing systems in the
manufacturing support systems
factory

Computer–integrated
Manufacturing
(CIM)

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CIM as Production Control System

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 Structure of Automated System

• All automated system consist of:

– The Application or Operative Unit

– The Control System, which coordinates actions of the
‘Application’
Control commands

CONTROL
APPLICATION
SYSTEM
Data feedback

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 Structure of Automated System

Application

Worked on material and the product. It consist of:

i. Tooling
ii. Actuators intended

Control System

Sends order to the Application, then feeds signal back to the Control
System (actions are coordinated)
Based on programmable controllers or hard wire technology
Coordinates three (3) types of dialogue/communication:

i. Dialogue with the machine

ii. Man-Machine dialogue
iii. Communication machines with other machine 16
 General Structure of Automated System

sensors

Input interface

Processor (PLC) actuators

Output interface

Pre-actuators

Control part Application part

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 Composition of Control
System & Application
Control system & application compose of:

1. Actuators
Three types of actuator devices are used:
a. Pneumatics
b. Hydraulics
c. Electrical

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 Composition of Control
System & Application
a. Pneumatics

• Pneumatic control system is a system that uses compressed

air to produce power /energy to perform any task.
• Pneumatic systems found in many industrial systems such
as food industry, petrochemical and industrial involves
robotics.
• Pneumatic systems requires:
i. Compressed air supply
ii. Control valve
iii. Connecting tube
iv. Transducer
• Pneumatic control system can be controlled manually and
automatically.

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 Composition of Control
System & Application
b. Hydraulics

• Hydraulic control system is a system that uses fluid to

generate power/energy.
• The hydraulic system used in the automobile industry
such as power systems, braking systems, cranes, car
jack, satellite and others.
• Hydraulics systems requires:
i. Hydraulic fluid supply
ii. Control valve
iii. Cylinder
• Pneumatic control system can be controlled manually
and automatically.

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 Composition of Control
System & Application
c. Electrical

• A control system that uses an electric current; either direct

current (DC) or current shuttle (AC) as a source of supply.
• Electrical control systems requires:
i. Electricity (DC) or (AC)
ii. Input elements (switches, sensors,
transducer, valves, electronic components, etc.)
iii. Output elements (motor, lights, etc.)
iv. Extension cable

2. Pre-actuators
Associated with actuators energy either electrical,
pneumatic or hydraulic
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 Composition of Control
System & Application
3. Processors
Can be programmable controller, micro / mini
computer or electronic board
4. Sensors
Provide feedback information from actuators
to control system. Capable of sensing position,
pressure, temperature, speed, weight and etc.
5. Man-Machine dialogue devices
Enable machine operator and maintenance
personnel to intervene. Such as push button,
indicator light, keyboard, displays, hand
console, etc.

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 Advantages & Disadvantages
of Automation Control

The main ADVANTAGES of automation are:

• Replacing human operators What is Automation?
in tasks that involve hard
physical work.
• Replacing humans in tasks done in dangerous environments
• Performing tasks that are beyond human capabilities of
size, weight, speed, endurance, etc.
• Economy improvement: Automation may improve in
economy of enterprises, society or most of humanity.
• Reduces operation time and work handling time
significantly.

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 Advantages & Disadvantages
of Automation Control
The main DISADVANTAGES of automation are:
• Unemployment rate increasesWhat dueistoAutomation?
machines replacing
humans and putting those humans out of their jobs.
• Technical Limitation: Current technology is unable to
automate all the desired tasks
• Security Threats/Vulnerability: An automated system may
have limited level of intelligence, hence it is most likely
susceptible to commit error.
• Unpredictable development costs: The research and
development cost of automating a process may exceed the
cost saved by the automation itself.
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That’s all … TQ

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