LEARNING GUIDE

Week No.: __10__

TOPIC/S

Overview of DCS
- DCS software configuration
- DCS communication

I. EXPECTED COMPETENCIES
At the end of the lesson, you must have:
a. enumerated the different levels of DCS
b. enumerated the different communication used in DCS; and
c. discussed the architecture and feature of DCS.

II. CONTENT

An Overview of Distributed Control Systems (DCS)

Distributed Control Systems (DCS) plays a vital role in manufacturing industries

as they are used to control and manage the processes. The networking capabilities of
DCS are useful in the process management and the inputs or resulted outputs can be an
analog signal or discrete signal.

Distributed Control Systems are used merely in the innovative emerging process
industries as an extension of traditional controllers. The major concept of distributed
control systems application is derived from the idea of decentralizing the control unit
and establishing a common network between the engineering stations.

Figure 10.0 Overview of DCS Market Size and Forecast

(Source: https://www.plantautomation-technology.com/)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Individually controlling, reporting, and monitoring the components are enabled
using integrating distributed control systems with process plants. To manage the
database, control logic, graphics, and system security, DCS uses a set of configuration
tools. Moreover, it supports modification, upgrade, and integration to the existing
architecture of any industry.

What is Distributed Control Systems (DCS)?

Distributed Control Systems (DCS) is a computerized control system for a

process or plant that consists of a large number of control loops, in which autonomous
controllers are distributed throughout the system, but there is central operator
supervisory control.

DCS can be used to enhance reliability and reduce installation costs by localizing
control functions near the process plant, with remote monitoring and supervision.

These systems are used on large continuous process plants where high reliability
and security is required.

Structure of DCS:

As DCS contains the distribution of the control processing around nodes in the
system, the complete system is reliable and mitigates a single processor failure. It will
affect one section of the plant process; if a processor fails and the whole process will
be affected when the central computer fails. This distribution of computing power to
the field Input / Output (I/O) field connection racks also ensures fast controller
processing times by removing possible network and central processing delays.

The below diagram showcases the functional manufacturing levels using

computerized control:

Figure 10.1 Structure of DCS

(Source: https://www.plantautomation-technology.com/)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
Referring to the diagram;

Level 0: It consists of the field devices such as temperature sensors, flow, and
final control elements such as control valves.

Level 1: It consists of the industrialized Input / Output (I/O) modules, and their
associated distributed electronic processors.

Level 2: It is included with supervisory computers that help to gather information

from processor nodes on the system and provide the operator control screens.

Level 3: It is the production control level, which does not directly control the
process, but is concerned with monitoring production and monitoring targets.

Level 4: It is the production scheduling level

On the other hand, Level 1 and Level 2 are the functional levels of a traditional
DCS, in which all equipment are part of integrated systems from a single manufacturer.

Levels 3 and 4 do not strictly process control in the traditional sense, but where
production control and scheduling take place.

Examples of DCS:

Figure 10.2 Examples of DCS

(Source: https://www.plantautomation-technology.com/)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
The architecture of DCS:

Distribution Control Systems (DCS) consists of three major qualities.

1) Various control functions can be distributed into small sets of subsystems that
are of semiautonomous. These are interconnected by a high-speed communication bus
and their functions include data presentation, data acquisition, process control, process
supervision, reporting information, storing and retrieval of information.

2) The second characteristic is the automation of manufacturing process by

integrating advanced control strategies.

3) The third characteristic is arranging the things as a system.

The organizing of the entire control structure as a single automation system can
be done with DCS as it unites sub-systems through a proper command structure and
information flow. DCS is included with basic elements such as engineering
workstation, operating station or HMI, process control unit, smart devices, and
communication system.

Figure 10.3 The architecture of DCS

(Source: https://www.plantautomation-technology.com/)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
Features:

Distribution Control Systems (DCS) can be used in various control applications

with more number of I/O’s with dedicated controllers. These systems are used in
manufacturing processes where designing of multiple products in multiple procedures
such a batch process control.

Features of DCS are:

• System redundancy
• More sophisticated HMI
• Scalable platform
• System security

Applications:

Distributed control systems (DCS) are majorly used in manufacturing processes

that are continuous or batch oriented.

Applications of DCS include:

• Chemical plants • Sewage treatment plants

• Petrochemical (oil) and • Food and food processing
refineries • Agrochemical and fertilizer
• Pulp and Paper Mills • Metal and mines
• Boiler controls and power • Automobile manufacturing
plant systems • Metallurgical process plants
• Nuclear power plants • Pharmaceutical
• Environmental control manufacturing
systems • Sugar refining plants
• Water management systems • Agriculture Applications
• Water treatment plants

Benefits of DCS

Benefits of using DCS include:

• It requires minimal troubleshooting

• It contains HMI graphics and faceplates
• Alarms
• Lends itself to better organization and consistency than a PLC/HMI
combo
• Batch management is possible
• OPC server

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 • Reduced engineering time
• Redundant operator system servers

How is DCS different from PLC?

To perform advanced regulatory control on a plant-wide scale, DCSs contain the

built-in infrastructure. Slower processes typically require coordination across various
production units. Superior speed makes PLCs a better choice for applications involving
fast production startup using discrete I/O. They also offer range in I/O granularity and
maintainability.

At the same time, the DCS is hybridized to incorporate PLCs and PCs to control
certain functions and to provide reporting services.

Below mentioned are the differences between DCS & PLC:

Table 10.1 Differences between DCS & PLC

(Source: https://www.plantautomation-technology.com)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
Distributed Control System (DCS) Software

DCS software includes embedded controller software as well as some, but not all,
software sold bundled with a system. DCS software includes control, HMI, systems
management software, engineering and configuration software, and plant information
management (PIM) software such as bundled data historians in addition to performing
HMI functions, DCS HMI software can also perform functions such as I/O
communication. HMI software typically resides in the DCS workstation or PC. Control
software typically resides embedded in controllers and performs basic control
functions. Programming software, used to program and configure the various
functions of the control system at startup, accounts for a small part of the total DCS
software business.

The DCS definition excludes optional supervisory software that performs

production management (MES) and advanced control functions and typically
resides in a supervisory DCS server. Supervisory software includes categories such
as advanced process control (APC), model-predictive control (MPC), real-time
process optimization (RPO), process simulation and optimization (PSO), and plant
asset management (PAM) applications.

Communication System

The communication medium plays a major role in the entire distributed control
system. It interconnects the engineering station, operating station, process station and
smart devices with one another. It carries the information from one station to another.
The common communication protocols used in DCS include Ethernet, Profibus,
Foundation Field Bus, DeviceNet, Modbus, etc.

It is not mandatory to use one protocol for entire DCS, some levels can use one
network whereas some levels use different network. For instance, consider that field
devices, distributed I/Os and process station are interconnected with Profibus while the
communication among engineering station, HMI and process station carried though
Ethernet as shown in the figure below.

Communication Protocols in DCS

In Distributed control systems there are multiple communication protocols are

used based on instruments, controller and environmental Zone. So here we will see
some of very important communication protocols which are widely used to establish
DCS network. So, these are the communication protocols used in Industrial
networking.

• Profinet/Industrial Ethernet
• Profibus
• AS-I
• Modbus

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 • HARTc
• CAN
• Fieldbus

1. Profinet /Industrial Ethernet

PROFINET IO uses traditional Ethernet hardware and software to define a

network that structures the task of exchanging data, alarms and diagnostics with
Programmable Controllers and other automation controllers. PROFINET is
communicating fastest up to 100MBPS speed.

Industrial Ethernet is just as it sounds – Ethernet applied to an industrial setting,

which often requires more rugged connectors, cables and – most importantly – better
determinism. Industrial Ethernet uses specialized protocols inconjunction with
Ethernet. The more popular Industrial Ethernet protocols are PROFINET, EtherNet/IP,
EtherCAT, SERCOS III and POWERLINK. With Industrial Ethernet, data
transmission rates range from10 Mbits/s to 1GBPS. However, 100 Mbit/s is the most
popular speed used in Industrial Ethernet applications.

Figure 10.4 Profinet/Industrial Ethernet Cable

(Source: https://www.plctutorialpoint.com/2017/08/)

2. Profibus

The PROFIBUS (Process Field Bus) is qualified for the networking of complex
devices with its multi master protocol. The PROFIBUS is named after DIN 19245,
where it extends its user range from the field level to the process control level. In
principle it is applicable with its protocol profile PROFIBUS-DP (Distributed I/O)
down to the sensor/actor level.

PROFIBUS has two type protocols

• Profibus DP (Decentralize Peripherals) 9.6Kbps to 12 Mbps Speed

• Profibus PA (Process Automation) 32 Kbps

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Figure 10.5 Profibus DP cable
(Source: https://www.plctutorialpoint.com/2017/08/)

3. AS-I

The AS-I (Actuator Sensor Interface) is matched to the requirements in the lowest
level. AS-I operates actors and sensors with the first control level and replaces them
with cable harnesses, distributor cabinets and connecting terminal plates. Since then,
the AS-I is an open standard. In the meantime, many manufacturers offer intelligent,
AS-I compatible actors and sensors in order to be able to transfer more information
than only 1/0. AS-I is especially easy in data manipulation. Field devices are simply
clamped into cut terminal technology on an unprotected 2-way conductive flat cable.
As a result, the installation can then be accomplished by people without any expertise.

4. Modbus

MODBUS is a Master/Slave communications protocol. The protocol provides

for one master device and up to 247 slave devices on a common line. Each device is
assigned an address to distinguish it from all other connected devices. The MODBUS
protocol comes in 2 versions

• ASCII transmission mod- Each eight-bit byte in a message is sent as 2

ASCII characters.
• RTU transmission mode – Each eight-bit byte in a message is sent as two
four-bit hexadecimal characters.

The main advantage of the RTU mode is that it achieves higher throughput.
ASCII mode allows time intervals of up to 1 second to occur between characters
without causing an error.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Figure 10.6 Modbus Cable
(Source: https://www.plctutorialpoint.com/2017/08/)

5. HART

Highway Addressable Remote Transducer. HART is a hybrid communications

technology in which a modulated, two-way digital signal is imposed on the industry-
standard 4–20 mA analog signal carrying the primary process variable.

The digital signal conveys additional process variables, device status and
diagnostics information that can be routed to asset management, process control and
safety systems. This means that HART provides two simultaneous communication
channels on the same wire–the industry standard 4–20 mA channel for fast, reliable
and robust control (PV) and a digital channel for real-time communication of additional
process/device information. HART (Hiway Addressable Remote Transducer) protocol
enhances these operations by transmitting digital data along with the 4-20 ma signal –
without interfering with it.

Figure 10.7 HART Modem Cable

(Source: https://www.plctutorialpoint.com/2017/08/)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 6. CAN

The CAN bus system (Controller Area Network) was primarily developed by
Bosch in cooperation with Intel, in order to reduce cable harnesses in automobile
building. CAN is therefore very well suited for the networking of intelligent sensors
and actors within machines. In the CAN physical layer uses differential transmission
on a twisted pair wire.

Figure 10.8 CAN Cable

(Source: https://www.plctutorialpoint.com/2017/08/)

7. FieldBus

FieldBus is a bi-directional digital communication that interconnects smart field

devices to control system or to instrument located in the control room. Field Bus is
based on the OSI (Open System Interconnect), which was developed by the ISO
(International Standard Organization) to represent the various functions required in any
Communication network. It was discovered by Indian Engineer Mr. Ram Ramchandran
(M.S in Com Tech- Texas) The OSI model consists of seven layers. However, for real
time application layers 3 to 6 are not considered since they deal with transference of
data among networks.

For such application following layers are used:

• LAYER 1 – PHYSICAL LAYER- Defines the type of signal, transmitting

medium, data transmission speed, etc.
• LAYER 2 – DATALINK LAYER- Define the interface between the
physical layer and the application layer. It establishes how the messages
shall be structured and normalizes the use of multiple masters.
• LAYER 3 – APPLICATION LAYER- Defines how data is specified, its
addresses and its representation

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Figure 10.9 Fieldbus Cable
(Source: https://www.plctutorialpoint.com/2017/08/)

III. PROGRESS CHECK

TRUE/FALSE Directions: Read each statement below carefully. Place a T on the line
if you think a statement it TRUE. Place an F on the line if you think the
statement is FALSE.
_____ 1. Industrialized Input/Output (I/O) modules and their distributed electronic
processors make up Level 2.
_____ 2. For the entire DCS, only one protocol must be used; some levels can use
the same network, while others must use a different network.
_____ 3. Different communication protocols for instruments, controllers, and
environmental zones are used in distributed control systems.
_____ 4. MODBUS is a bi-directional digital communication protocol that connects
smart field devices to a control system or a control room instrument.
_____ 5. Level 0 includes field instruments like temperature sensors and flow, as well
as final control components like control valves.
_____ 6. DCS is a safer option for applications requiring quick production startup
using discrete I/O due to its superior speed.
_____ 7. With its multi master protocol, the Process Field Bus is qualified for the
communication of complex devices.
_____ 8. In some cases, HART communications can be used to represent two or more
signals.
_____ 9. PROFIBUS DP is a Profibus standard for field equipment as well as bus
cables.
_____ 10. PROFIBUS PA is a PROFIBUS standard that is based on the PROFIBUS
protocol. Controllers are used.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
IV. REFERENCES:
An Overview Of Distributed Control Systems (DCS). (2021). Retrieved from Plant
Automation Technology: https://www.plantautomation-
technology.com/articles/an-overview-of-distributed-control-systems-dcs
KUMBHAR, V. (2017, August 11). Communication Protocols in DCS. Retrieved from
PLCtutorialpoint: https://www.plctutorialpoint.com/2017/08/communication-
protocols-in-dcs.html
O'BRIEN, L. (2017, December 26). What is a Distributed Control System (DCS)?
Retrieved from ARC: https://www.arcweb.com/blog/what-distributed-
control-system dcs#:~:text=Distributed%20Control%20System%20(DCS)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 LEARNING GUIDE

Week No.: __11__

TOPIC

DCS Supervisory Computer Tasks

DCS integration with PLC and Computers

I. EXPECTED COMPETENCIES
At the end of the lesson, you must have:
a) understand the DCS Supervisory Computer Tasks;
b) enumerated the differences of PLD and DCS; and
c) discussed how to integrate DCS to PLC.

II. CONTENT

INTRODUCTION
Supervisory control is what we actually see in the PLC, SCADA, DCS systems.
Which is controlling whole plant or more than one field devices through a master
system.
There will many types of field devices in a plant, each of the devices will have
controllers to control the control action. We can’t install a signal controller to control
the whole plant, it’s logic less. But can connect all the controller to a single master
device. So, a human can verify the process variable and set the setpoint to each
controller distinctly.
In a manually controlled process, a human operator directly actuates some form
of final control element (usually a valve) to influence a process variable. Simple
automatic (“regulatory”) control relieves human operators of the need to continually
adjust final control elements by hand, replacing this task with the occasional adjustment
of setpoint values. The controller then manipulates the final control element to hold the
process variable at the setpoint value determined by the operator. The next step in
complexity after simple automatic control is to automate the adjustment of the setpoint
for a process controller. A common implementation of this concept is the automatic
cycling of setpoint values according to a timed schedule. An example of this is a
temperature controller for a heat-treatment furnace used to temper metal samples:

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Figure 11.0 Temperature controller
(Source: https://forumautomation.com/t/what-is-supervisory-control/2844)

Here, a computer “supervises” the furnace’s temperature by communicating

setpoint values to the temperature indicating controller (TIC) over a digital network
interface such as Ethernet. From the temperature controller’s perspective, this is a
remote setpoint signal, as opposed to a local setpoint value which would be set by a
human operator at the controller faceplate. Since the heat-treatment of metals requires
particular temperature ranges and rates of change over time, this control system relieves
the human operator of having to manually adjust setpoint values again and again during
heat-treatment cycles. Instead, the computer sets different setpoint at different stages
according to the needs.
There are many communication protocols used in industries, which can be used
for the communication between computer and controller.
Process controllers configured for supervisory setpoint control typically have
three operating modes:
• Manual mode: Controller takes no automatic action. Output value set by
a human operator.
• Automatic mode with local SP: Controller automatically adjusts its output
to try to keep PV = SP. Setpoint value set “locally” by human operator.
• Automatic mode with remote SP: Controller automatically adjusts its
output to try to keep PV = SP. Setpoint value set “remotely” by
supervising computer.
The supervisory control system can include many such controllers and can be
connected to a single master computer or supervisory computer.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Figure 11.1 Supervisory Control
(Source: https://forumautomation.com/t/what-is-supervisory-control/2844)

The master computer or supervisor makes the setpoint and gives to the
controllers. Controllers adjust the PV with respect to the setpoint using PID controller.
This forms a two-layer process control system: the “base” or “regulatory” layer of
control (PID loop controllers) and the “high” or “supervisory” level of control (the
powerful computer with the mathematical process models).
A single cable can’t do the setpoint changes at once or much frequently, so a
series of digital data lines are implemented to transfer setpoint from supervisor to
controller. but it may also carry process variable information from those controllers
back to the supervisory computer, so it has data for its optimization algorithms to
operate on:

Figure 11.2 Supervisory Control

(Source: https://forumautomation.com/t/what-is-supervisory-control/2844)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
DCS stands for “Distributed Control System”
DCS’s were designed to control processes, not discrete operations. As such, a
large number of the inputs and outputs are analog like a 4-20mA signal or 0-10V signal.
In Literary meaning, a Distributed Control System (DCS) refers to a control
system usually of a process or manufacturing system, in which the controller elements
are not central in location (like the brain) but are distributed throughout the system with
each component sub-system controlled by one or more controllers. Process plants used
to have long series of panel mounted Single Loop Controllers (Analog/PID controllers).
PLC stands for “Programmable Logic Controller”
Historically a PLC was in discrete control of manufacturing processes. Whole
discrete logic used to be implemented with relay circuitry. Most of the inputs and
outputs for discrete control are binary, meaning they have only two states: On and Off.
What are attributes and characteristics which differentiate the PLC system from
the DCS. There have been claims and counter claims from different manufacturers that
their system is DCS or PLC.
Table 11.1 Differences between DCS & PLC

(Source: https://www.plantautomation-technology.com)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 The topic has remained under debate for long, and especially today when we
have already entered into new era of Hybrid Distributed Control Systems, it has become
increasingly difficult to select and differentiate the advantages and drawbacks one can
get from different systems.
There are few similarities and dissimilarities:
1) DCS are designed or made available to the user in a way that only
configuration in form of a Functional Block has to be carried out unlike PLC, where
complete programming has to be implemented using any one of the different languages
available in the system. Now, Functional Blocks are also available in the PLC systems,
which really makes it comparable to DCS.
2) When DCS started emerging in the market, idea was to supply DCS with
whole bunch of hardware and software packages including for Human Interface,
necessary for the complete automation of the plant, thus facilitating Single Point
Configuration in terms of database and communication possible in general
Additionally, Human Interface does not need separate communication package
i.e DDE server, to communicate with the controller. DCS includes higher levels of
application software for regulatory and batch control.
In case of PLC systems, PLC were not supposed to be in packages but
competition with DCS vendors forced the PLC manufacturers to offer necessary all
other softwares and packages.
3) Many DCS are designed such that it is possible to configure cycle time for
each Functional Block. Thus, DCS system takes care of cycle time scheduling of the
Functional Blocks which are the basic execution units.
This is one of the reasons that overall scan time of the DCS is comparatively
higher than the PLC system. This functionality has been introduced in PLC systems(s)
in some form as well.
4) A DCS has inherently multiple processor capability thus making the
functionality distributed across a network.
In a typical multi-processors (multi-node) DCS architecture, Engineer has to
put in less efforts for inter-communication of the processors or one controller can easily
access the Tag(s) from the database of the other .i.e the input of FB in one controller
can be output of FB of the other controller. This is possible now in PLC but more efforts
have to be put in.
5) DCS programming is centered around configuration of Functional Blocks
and discrete logic is implemented in DCS using FBs, thus making the DCS inherently
an analog control system (although ladder programming is also possible in some of the
DCS also).

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 PLCs were programmed using Ladder/Relay language before arrival of IEC
1131-3 standard and Analog control was incorporated inside Ladder inside Ladder
Logic using special FBs. This is probably the reason we look at some of the process
plants that process (Analog) control is done by the DCS, while emergency control
(Discrete Control) is implemented by PLC based systems.
6) PLCs are still being used at RTU stations because of their simple, small and
cheaper architecture as well as engineering (typically the RTU application) instead of
big DCS.
DCS have been used as the central system in a SCADA network. In a typical
SCADA scenario, one DCS is connected to many PLCs systems.
7) Being Discrete in nature, PLC was natural choice of manufacturer and end-
user to apply it for safety system. This led to production of specialized safety system
conforming to SIL3 certification in accordance with ANSI / ISA 84.00.01-2004.
Today, a lot has changed, it is difficult to distinguish between two systems in
terms of its main features. Differences between the two has virtually vanished due to
Programming / Configuration language standard IEC-61131.
The functionality of the PLC has evolved over the years to include sequential
relay control, motion control, process control, distributed control systems and
networking.
However, in major industrial areas and structure markets, it is practice to deploy
DCS for process control and PLC based system for safety control.
Perhaps, for a large install base like more than 1000 I/Os system, cost of
installation, addition and maintenance per I/O is less in case of DCS system.
Now, more important is cost, application, system integrity, reliability,
maintainability, historical logging / intelligent statistics and learning / training. How
much support is available from the vendor for the operation matters most to the operator
now.
This has resulted into ‘Solutions Packages’ by vendors to their customers
instead of simply offering individual products. It is DCS or PLC, must come in a
solution package.
More and improved System functionalities have made these systems more
complex which require strong integration between the operator/user and the
manufacturer.
Reasons for conversion to DCS I/O
Although the existing I/O was adequate at one time, the need for its
replacement became more apparent as the technology changed. While the existing I/O
was readily available in the 1990s, more recently parts for repair and replacement were
difficult to find. An upgrade to the new replacement PLC I/O was available, but it

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
provided none of the benefits of the DCS I/O. The DCS I/O had much faster speed and
a “quality status,” which was not available on a Modbus RTU serial link with a
transmission rate of 19,200 baud. The choice was to either replace the entire PLC
system with the DCS system at one time, which required massive logic conversion and
testing, or perform a two-phase implementation approach. The first phase would
replace the PLC I/O with the DCS I/O. Then the second phase would involve
converting PLC logic to DCS logic. The split approach was chosen to minimize
downtime and prevent a complicated check-out process.
Hardware installation
The components for this application include a new DCS controller, a DCS I/O,
and new 24-V dual-redundant power supplies for the I/O. The PLC processor remains
and communicates strictly to the old DCS controller, which in turn communicates to
the new DCS controller that talks to the new DCS I/O. As with the old system, the
primary function of the new system is to provide process control of the equipment via
the DCS, which is made available to operators at a remote location. The basic system
architecture is shown in figure below.

Figure 11.3 Basic system architecture

(Source: https://blog.isa.org/integrating-dcs-io-existing-plc)

In all cases, existing wiring could be reused as part of the new scheme. The new
I/O was mounted in the existing I/O space. The old field wires were terminated on the
new I/O. The 24-V I/O power supplies were installed in an existing cabinet. A new
DCS controller, connected to the new DCS I/O via fiber, was installed in the same
cabinet as the old DCS controller. The new DCS controller communicates to the old

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
DCS controller via a backplane that provided a local control highway within the
cabinet.
Software installation
The software for this application includes DCS controller software that allows
communication between the old DCS controller and the new DCS controller. The PLC
receives the necessary data for sequence logic from the new DCS controller. No field
I/O connects to the PLC. All PID algorithms are processed in the new DCS controller
and pressure and surge controllers, which communicate to the old DCS controller via
Modbus.
System architecture
The new DCS I/O is installed in the current PLC I/O location. Wires from the
field were removed from the PLC I/O and terminated on the new DCS I/O. The new
DCS I/O connects to the new DCS controller via a fiber optics network. The old DCS
controller utilizes a custom foreign device interface “C” program and Modbus RTU
protocol to communicate to the PLC. The old and new DCS controllers communicate
with the operator console via a proprietary data highway.
Testing of new I/O
Some problems were encountered while commissioning the new I/O
installation. One of these involved minor wiring errors on the drawings, which made it
hard to find the field devices for HMI screen-to-field device point testing. This was a
relatively easy fix. Verification of the drawings before demolition, although time
consuming, would have lessened downtime and would have resulted in a net saving of
time. Having the same PLC logic reduced troubleshooting, by isolating errors to the
I/O cabinet.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
III. PROGRESS CHECK

1. Why supervisory computer important in manufacturing industry?

2. Give few similarities and dissimilarities of DCS and PLC
3. Draw a sample diagram that uses a Supervisory Computer for Tank level by
communicating High and Low set point values to Level Indicating controller over
a digital network interface such as Ethernet.

IV. REFERENCES:

Sadhukhan, D. (n.d.). Integrating DCS I/O to an Existing PLC. Retrieved from ISA
Interchange: https://blog.isa.org/integrating-dcs-io-existing-plc
sivaranjith. (2017, December). Industrial Automation. Retrieved from Forum
Automation: https://forumautomation.com/t/what-is-supervisory-control/2844
Areej. (2018, April 23). What is supervisory control? Retrieved from
AutomationForum.Co: https://automationforum.co/what-is-supervisory-
control/

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 LEARNING GUIDE

Week No.: __12__

TOPIC

Features of DCS
Advantages of DCS

I. EXPECTED COMPETENCIES
At the end of the lesson, you must have:
a) Enumerated the basic elements of Distributed Control System;
b) know the proper selection and installation of PLC; and
c) discussed the advantages of using PLC for industrial automation.

II. CONTENT

4 Basic Elements of Distributed Control System

Distributed Control System continuously interacts with the processes in process
control applications ones it gets instruction from the operator. It also facilitates
variable set points and opening and closing of valves for manual control by the
operator. Its human-machine interface (HMI), faceplates, and trend display give the
effective monitoring of industrial processes.

Figure 12.0 Elements of DCS

(Source: https://www.elprocus.com/distributed-control-system-)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
Engineering PC or controller
This controller is the supervisory controller over all the distributed processing
controllers. Control algorithms and configuration of various devices are executed in
this controller. Network communication between processing and engineering PC can
be implemented by a simplex or redundant configuration.
Distributed controller or Local control unit
It can be placed near to field devices (sensors and actuators) or certain locations
where these field devices are connected via the communication link. It receives the
instructions from the engineering station like set point and other parameters and
directly controls field devices.
It can sense and control both analog and digital inputs/outputs by analog and
digital I/O modules. These modules are extendable according to the number of inputs
and outputs. It collects the information from discrete field devices and sends this
information to operating and engineering stations.
In the above figure, AC 700F and AC 800Fcontrollers act as a communication
interface between field devices and engineering stations. Most of the cases these act
as local control for field instruments.
Operating station or HMI
It is used to monitor entire plant parameters graphically and to log the data in
plant database systems. The trend display of various process parameters provides
effective display and easy monitoring.
These operating stations are of different types such as some operating stations
(PCs) used to monitor only parameters, some for only trend display, some for data
logging, and alarming requirements. These can also be configured to have control
capabilities.
Communication media and protocol
Communication media consists of transmission cables to transmit the data such
as coaxial cables, copper wires, fiber optic cables and sometimes it might be wireless.
Communication protocols selected depend on the number of devices to be connected
to this network.
For example, RS232 supports only for 2 devices and Profibus for 126 devices
or nodes. Some of these protocols include Ethernet, DeviceNet, the foundation filed
bus, Modbus, CAN, etc.
In DCS, two or more communication protocols are used between two or more
areas such as between field control devices and distributed controllers and another one
between distributed controllers and supervisory control stations such as operating and
engineering stations.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
7 Important Features of DCS

1. To handle complex processes:

In the factory automation structure, PLC-Programming Logic Controller is used
to control and monitor the process parameters at high-speed requirements. However,
due to the limitation of a number of I/O devices, PLCs cannot handle complex
structures.

Figure 12.1 Handling Complex Processes

(Source: https://www.elprocus.com/distributed-control-system-)

Hence DCS is preferred for complex control applications with a greater number
of I/O’s with dedicated controllers. These are used in manufacturing processes where
designing of multiple products are in multiple procedures such as batch process
control.
2. System redundancy:
DCS facilitates system availability when needed by redundant features at every
level. Resuming the steady-state operation after any outages, whether planned or
unplanned is somewhat better compared to other automation control devices.
Redundancy raises the system reliability by maintaining system operation
continuously even in some abnormalities while the system is in operation.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Figure 12.2 System Redundancy
(Source: https://www.elprocus.com/distributed-control-system-)

3. A lot of Predefined function blocks:

DCS offers many algorithms, more standard application libraries, pre-tested
and pre-defined functions to deal with large complex systems. This makes
programming to control various applications being easy and consuming less time to
program and control.

Figure 12.3 Predefined Function block

(Source: https://www.elprocus.com/distributed-control-system-)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
4. Powerful programming languages:
It provides more number of programming languages like a ladder, function
block, sequential, etc for creating custom programming based on user interest.

5. More sophisticated HMI:

Similar to the SCADA system, DCS can also monitor and control through
HMI’s (Human Machine Interface) which provides sufficient data to the operator to
charge over various processes and it acts as the heart of the system. But this type of
industrial control system covers large geographical areas whereas DCS covers the
confined areas.

Figure 12.4 Sophisticated HMI

(Source: https://www.elprocus.com/distributed-control-system-)

DCS completely takes the entire process plant to the control room as a PC
window. Trending, logging, and graphical representation of the HMI’s give an
effective user interface. Powerful alarming system of DCS helps operators to respond
more quickly to the plant conditions

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
6. Scalable platform:
The structure of DCS can be scalable based on the number I/O’s from small to
large server systems by adding more clients and servers in the communication system
and also by adding more I/O modules in distributed controllers.
7. System security:
Access to control various processes leads to plant safety. DCS design offers a
perfect secured system to handle system functions for better factory automation
control. Security is also provided at different levels such as engineer level,
entrepreneur level, operator level, etc.
Application of Distributed Control System
DCS system can be implemented in a simple application like load management
using a network of microcontrollers.
Here the input is given from a keypad to a microcontroller, which
communicates with the other two microcontrollers. One of the microcontrollers is
used to display the status of the process as well as the loads, while the other
microcontroller controls the relay driver. The relay driver, in turn, drives the relay to
operate the load.
I hope you have understood the concept of the distributed control system and
its importance. Here is a basic question for you – Give any application of a DCS, you
are aware of.

Figure 12.5 Application of DCS

(Source: https://www.elprocus.com/distributed-control-system-)

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
Advantages of Distributed Control Systems
A distributed control system (DCS) centralizes plant operations to provide
flexibility and simplicity by allowing central control, monitoring and reporting of
individual components and processes. A DCS is designed to control complex
processes that can be geographically disseminated using networked control elements
that are distributed throughout the system. These features, along with redundancy that
is designed into the overall structure to facilitate high system availability and
reliability, drive operators of large, complex facilities and processes, such as those
used in nuclear power plants, to choose DCS.
Unlike programmable logic controllers, DCS use a suite of configuration tools
to set up the database, control logic, graphics and system security. Control applications
are distributed to system controllers that are dedicated to specific plant processes
utilizing field devices. Control logic can be created and dispersed across the system
controllers. This allows changes that must be made to meet new requirements and/or
the addition of new controllers or field devices, to be made efficiently and accurately,
easing and simplifying updates and new equipment integration.
The controllers and associated inputs/outputs are connected through a
redundant communications network to operating and engineering stations. The
stations have graphical, easy-to-use displays for data monitoring, data logging,
alarming and control. Field devices, such as actuators and sensors, are directly
connected to input/output modules that communicate with assigned controllers while
reading and reporting real world information, such as pressure and temperature.
DCS are scalable. A DCS can be deployed in an initial installation as a large,
integrated system, or as a standalone system that can be added to as planned or needed.
New controllers and inputs/outputs can be added throughout a plant. When new
systems are added, they become part of the integrated DCS and are automatically
updated by the controlling database.
The DCS automate the process by integrating advanced regulatory control,
logic and sequential control. The “control” aspect of the modern DCS has expanded
to include information that is capable of supporting such manufacturing enterprise
applications as:
• activity-based cost accounting
• production scheduling and dispatching
• preventative or predictive maintenance scheduling
• validation of employee job certification and readiness
• information exchange with business, logistics, and transportation
applications

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 On the other hand, using feedback can have several disadvantages:
• The system is complicated by the increased number of components,
such as sensors and error detectors.
• The overall gain of the system is reduced and must be compensated for
in the design.
• The system may not be stable (it may oscillate or depart greatly from
the desired output), even though the comparable open-loop system is
stable.
• The error detector is necessary in order to compare two states.
• If there is a change in an Output, it will affect the system input.

III. PROGRESS CHECK

FILL IN THE BLANKS. ✓ Directions: Read each statement or question below carefully
and fill in the blank(s) with the correct answer.

1. This is used to display the trend of different process parameters which allows for
simple tracking. _____
2. Allows for central supervision, monitoring, and reporting of specific components
and procedures, allowing for greater flexibility and convenience. _____
3. The interface between the control module and the field instrument is the _____.
4. Transmission cables, such as coaxial cables, copper wires, fiber optic cables, and
wireless transmission, are used to transmit data in _____.
5. _____ improves device stability by allowing the system to continue operating even
though any causing interference while it is in use.
6. ____ is often offered at various level, such as engineer, entrepreneur, and operator.
To have a perfect protected system to ensure system functions for better factory
automation control, the design was developed.
7. The communication ____ being used are determined by the number of devices that
will be connecting to the network.
8. _____ oversees all of the distributed processor controllers and serves as the
supervisory controller. This system executes control algorithms and interface setup
for a variety of applications.
9. Field instruments, such as actuators and sensors, are wired directly to_____, which
connect with assigned controllers when interpreting and reporting actual information
including temperature and pressure.
10. A _____ is a compilation of commands, instructions, and other syntax that is used to
develop software.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
IV. REFERENCES:

Everything You Need to Know About Distributed Control System. (2021). Retrieved
from Electronics Project Focus: https://www.elprocus.com/distributed-control-
system-features-and-elements/
Advantages of Distributed Control Systems. (2016, August). Retrieved from Power
Engineering: https://www.power-eng.com/nuclear/advantages-of-distributed-
control-systems/#gref
sivaranjith. (2018, September). Advantages of DCS system. Retrieved from Forum
Automation: https://forumautomation.com/t/advantages-of-dcs-system/4560
https://electricalacademia.com/control-systems/feedback-control-system-advantages-
and-disadvantages/

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 LEARNING GUIDE
Week No.: __13__
TOPIC/S

-Basic construction and configuration

of robot Pick and place robot
-Welding robot.

I. EXPECTED COMPETENCIES
At the end of the lesson, you must have:
a. identified the parts of Pick and Place Robot;
b. discussed how Pick and Place Robot work; and
c. discussed what is Welding Robot

II. CONTENT

Pick and Place Robot

A pick and place robot is the one which is used to pick up an object and place
it in the desired location. It can be a cylindrical robot providing movement in
horizontal, vertical and rotational axes, a spherical robot providing two rotational and
one linear movement, an articulate robot or a scara robot (fixed robots with 3 vertical
axes rotary arms).
Advantages
Before moving further, let us see few reasons why pick and place robots are
preferred:
• They are faster and can get the work done in seconds compared to their
human counterparts.
• They are flexible and have the appropriate design.
• They are accurate.
• They increase the safety of the working environment and actually never get
tired.
Parts of a Pick and Place Robot
Let us see what the pick and place robot actually consists of:
• Rover: It is the main body of the robot consisting of several rigid bodies
like a cylinder or a sphere, joints and links. It is also known as a
manipulator.
• End Effector: It is the body connected to the last joint of the rover which
is used for the purpose of gripping or handling objects. It can be an analogy
to the arm of a human being.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 • Actuators: They are the drivers of the robot. It actually actuates the robot.
It can be any motor like servo motor, stepper motor or pneumatic or
hydraulic cylinders.
• Sensors: They are used to sense the internal as well as the external state to
make sure the robot functions smoothly as a whole. Sensors involve touch
sensors, IR sensor etc.
• Controller: It is used to control the actuators based on the sensor feedback
and thus control the motion of each and every joint and eventually the
movement of the end effector.

Figure 13.0 Pick and Place Robot

(Source: https://www.elprocus.com/pick-n-place-robot/)

Working of a Basic Pick and Place Robot:

The basic function of a pick and place robot is done by its joints. Joints are
analogous to human joints and are used to join the two consecutive rigid bodies in the
robot. They can be rotary joint or linear joint. To add a joint to any link of a robot, we
need to know about the degrees of freedom and degrees of movement for that body part.
Degrees of freedom implement the linear and rotational movement of the body and
Degrees of movement imply the number of axis the body can move.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Figure 13.1 A Simple Pick and Place Robot
(Source: https://www.elprocus.com/pick-n-place-robot/)

A simple pick and place robot consists of two rigid bodies on a moving base,
connected together with rotary joint. A rotary joint is a one which provides rotation in
360 degrees around any one of the axes.
• The bottom or the base is attached with wheels which provide linear movement.
• The 1st rigid body is fixed and supports the second rigid body to which the end
effector is provided.
• The 2nd rigid body is provided with movement in all 3 axes and has 3 degrees
of freedom. It is connected to the 1st body with a rotational joint.
• The end effector should accommodate all 6 degrees of freedom, in order to
reach all sides of the component, to take up position to any height.
On a whole, the basic pick and place robot works as follows:
• The wheels underneath the base help to move the robot to the desired location.
• The rigid body supporting the end effector bends or straightens up to reach the
position where the object is placed.
• The end effector picks up the object with a strong grip and places it at the
desired position.
Now that we have got a brief idea of the pick and place robot, the basic question
is how it is actually controlled.
A simple pick and place robot can be controlled by controlling the movement of
its end effector. The motion can be using hydraulic motion, i.e. using hydraulic fluid
under pressure to the drive the robot, or using pneumatic motion, i.e. using pressurized
air to cause mechanical motion. However, the most effective way is using motors to

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
provide the required motion. The motors have to be controlled in order to provide
required motion to the robot and the end effector.
Working Example of Controlling a Pick and Place Robot
How about controlling the robot with a just a few buttons on the keypad? Yes, it
is possible! Just pressing the required button, we can transmit command to the robot to
make it move in any direction to achieve our task. Moreover, this can be achieved using
simple wireless communication.
Let’s see how this actually works:
The transmitter part consists of the keypad interfaced to the microcontroller. Any
button number in decimal format is converted to 4-digit binary by the microcontroller
and the parallel output at one of its port is applied to the encoder. The encoder converts
this parallel data to serial data, and this is fed to the transmitter, fitted with an antenna
to transmit the serial data.

Figure 13.2 Block Diagram Showing Transmitter of a Pick and Place Robot
(Source: https://www.elprocus.com/pick-n-place-robot/)

The system consists of two motors for providing motion to the whole robot and
two other motors to provide the arm motion. The end effector or the gripper needs to be
controlled to apply proper pressure on the object to handle it effectively, to give it a soft
grip. This is ensured by controlling the arm motors through proper command. The output
from the arm motors is connected to a 10Ohms/2W resistor and at the time of motor
over load or locked condition, a high voltage is developed across the resistor, which
causes a logic high level at the output of the optoisolator and the interrupt pin of the
microcontroller connected to the optoisolator output through a pnp transistor gets logic
low signal, which halts all other operations of the gripper.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Figure 13.3 Block Diagram Showing Receiver of a Pick and Place Robot
(Source: https://www.elprocus.com/pick-n-place-robot/)

The system consists of two motors for providing motion to the whole robot and two
other motors to provide the arm motion. The end effector or the gripper needs to be
controlled to apply proper pressure on the object to handle it effectly, to give it a soft
grip. This is ensured by controlling the arm motors through proper command. The output
from the arm motors is connected to a 10Ohms/2W resistor and at the time of motor over
load or locked condition, a high voltage is developed across the resistor, which causes a
logic high level at the output of the optoisolator and the interrupt pin of the
microcontroller connected to the optoisolator output through a pnp transistor gets logic
low signal, which halts all other operations of the gripper.

Practical Applications of Pick and Place Robot:

Defense Applications: It can be used for surveillance and also to pick up harmful
objects like bombs and diffuse them safely.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Industrial Applications: These robots are used in manufacturing, to pick up the
required parts and place it in correct position to complete the machinery fixture. It can be
also used to place objects on the conveyer belt as well as pick up defective products from
the conveyer belt.
Medical Applications: These robots can be used in various surgical operations like
in joint replacement operations, orthopedic and internal surgery operations. It performs
the operations with more precision and accuracy.
Other than these applications, these robots can also be used in various other
applications suitable to mankind.
FACTORS TO BE CONSIDERED
The various factors to be considered while designing of pick and place mechanical
arm are been discussed as follows. The factors are all important while designing
procedure of the mechanical arm.
Controls
The mechanical structure of a mechanical arm must be controlled to perform tasks.
The control of a mechanical arm involves three distinct phases - perception, processing,
and action. human knows information about the environment (e.g. the position of its
joints or its end effector). This information is then processed to calculate the appropriate
power to the actuators (motors) which move the mechanical.
The processing phase can range in complexity. At a reactive level, it may translate
raw information directly into actuator power. human sense fusion may first be used to
estimate parameters of interest (e.g. the position of the robot's gripper) . An immediate
task (such as moving the gripper in a certain direction) is done from these estimates.
Techniques from control theory convert the task into commands that drive the actuators.
At longer time scales or with more sophisticated tasks, the mechanical arm may
need to build and reason with a "cognitive" model. Cognitive models try to represent the
mechanical arm, the world, and how they interact. Pattern recognition and computer
vision can be used to track objects. Mapping techniques can be used to build maps of the
world. Finally, motion planning and other artificial intelligence techniques may be used
to figure out how to act. For example, a planner may figure out how to achieve a task
without hitting obstacles, falling over, etc.
Autonomy Levels
Control systems may also have varying levels of autonomy.
• Direct interaction is used for hap tic or tale-operated devices, and the human has
nearly complete control over the mechanical arm motion.
• Operator-assist modes have the operator commanding medium-to-highlevel tasks,
with the mechanical arm figuring out how to achieve them.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 • An autonomous mechanical arm may go for extended periods of time without human
interaction. Higher levels of autonomy do not necessarily require more complex
cognitive capabilities. For example, mechanical arm in assembly plants are
completely autonomous, but operate in a fixed pattern.
Another classification takes into account the interaction between human control and
the machine motions.
1. Teleportation: - A human controls each movement; each machine
2. actuator change is specified by the operator.
3. Supervisory: - A human specifies general moves or position changes
4. and the machine decides specific movements of its actuators.
5. Task-level autonomy: - The operator specifies only the task and the mechanical
arm manages itself to complete it.
6. Full autonomy: - The machine will create and complete all its tasks without
human interaction.

Safety Requirements
The various safety requirements which were considered while designing the
mechanical arm are decided as follows:
• The mechanical arm should not be programmed such that it should damage the
Battery while holding it in its gripper.
• Correct holding position should be set as if it not set then while movement of
the mechanical arm it may drop the Lead Batteries which can arise a Hazardous
situation in the industry.
• The mechanical arm should be interfaced properly with the sensors been placed
near the Belt conveyor so as to know when the belt conveyor is to be stopped
or to be started to move the batteries ahead.
• Load carrying capacity should be maintained as it should be always more than
the default load which is to be shifted.

ROBOTIC WELDING PROCESSES

Robotic welding automates the welding process to increase accuracy, enhance
safety and reduce the time needed to complete each project. These benefits make the
robotic welding process a popular alternative to manual metal joining. Several industries
take advantage of this automated process to get the results they need as quickly as
possible.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
HOW ROBOTIC WELDING WORKS
When using robots for any process, the method requires amending to accommodate
automation. The same is true of welding, which uses several tools not found in its manual
equivalent. People don’t need programming the way robotic welders do.
The robot itself has an arm that can move in three dimensions for rectilinear types
and through more planes with articulating versions. A wire feeder sends the filler wire to
the robot as it needs it for a welding job. A high-heat torch at the end of the arm melts
metal to enable the welding process. Because the temperatures reach thousands of
degrees, using robots for this process keeps people safer.
Certified human operators still need to remain close to the robots. These workers
should hold certification from the American Welding Society, AWS, which certify not
only manual welders but also robotic welding arm operators. The operators program the
controller using a teach pendant. This device sets new programs, moves the arm and
changes parameters for the process. To start the welding, the operator uses the buttons
on the operation box.
The tool in the robotic arm heats to melt metal to conjoin the desired pieces. As
needed, a wire feeder delivers more metal wire to the arm and torch. When awaiting the
next parts to weld, the arm moves the torch to the cleaner to clean any metal splatters
from the arm, which could solidify in place without this process.
Because one of the primary reasons to have robotic welders is protecting human
workers, these automated systems come with multiple safety features. Arc shields
prevent the high-heat arc from mixing with oxygen. Enclosed areas protect operators
from the temperatures and bright light.
ROBOTIC WELDING PROCESSES
Welding requires a high level of education and skill. However, the number of
professional welders does not meet the needs of the industry. According to the American
Welding Society, by 2022, the industry will experience a shortage of 450,000 welders.
Instead of letting critical projects these workers would complete fall behind, robots can
pick up the slack.
Robots automate the process, which ensures higher accuracy, less waste and faster
operation. With the range of machinery available, robots adapt to a wide variety of
welding processes including arc, resistance, spot, TIG and more.
1. ARC WELDING
One of the most common types of robotic welding is the arc process. In this method,
an electric arc generates extreme heat, up to 6,500 degrees Fahrenheit, which melts the
metal. Molten metal joins parts together, solidifying into a stable connection after
cooling. When a project requires a large volume of accurately conjoined metals, arc
welding serves as an ideal application.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
2. RESISTANCE WELDING
When projects need heat-treating or a way to lower costs, robots may use resistance
welding. During this process, a current of electricity creates a pool of molten metal as it
passes between the two metal bases. This molten metal joins the pieces of metal together.
3. SPOT WELDING
Some materials resist electrical currents, precluding them from other forms of
welding. This situation frequently occurs in the automotive industry for piecing together
parts of an automobile body. To overcome the issue, robotic welders use a variation of
resistance welding to connect a pair of thin metal sheets in a single spot.
4. TIG WELDING
Robot welding applications requiring high levels of precision may require TIG
welding. This method also goes by the term gas tungsten arc welding or GTAW. An
electric arc passes between a tungsten electrode and the metal base.
5. MIG WELDING
Gas metal arc welding, also known as GMAW or MIG, is a fast and straightforward
method that uses a high level of deposition. A wire moves continuously to the heated tip
of the welder, which melts the wire, allowing for a large amount of molten metal to drip
onto the base for joining the base to another piece.
6. LASER WELDING
When welding projects require accuracy for a high volume of parts, laser welding
is the preferred method of metal joining. Small parts, such as jewelry or medical
components often use laser welding.
7. PLASMA WELDING
Plasma welding offers the most significant degree of flexibility because the
operator can easily change both the speed of gas passing through the nozzle and the
temperature.
ROBOTIC VS. MANUAL WELDING
Manual welding still has a place in modern manufacturing. For projects in which
you need an expert to quickly change the styles of welding used, manual welding will be
your best choice. A professional welder can promptly change what he’s doing, but robots
do not adapt as quickly to uncertain situations.
Because manual welding remains a process that many companies still need,
professional welders will not disappear any time soon. In fact, with the shortage of expert
welders mentioned above, those who hold certification will easily find work, even with
multiple businesses investing in robots.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Replacing manual welders with robots will not put the AWS out of its certification
business. Most robot welder operators need to hold certification in the robotics side of
this field, for which the AWS also offers certifications. Having robotics experts who
know about welding ensures the projects get properly programmed to finish as quickly
and cost-effectively as possible.
SHOULD YOU USE ROBOTIC WELDING?
Whether or not you use robotic welding depends largely on the type of project
you’re working on. Let’s take a look at some of the pros and cons of robotic welding to
help you determine whether this method is right for your project.
PROS OF ROBOTIC WELDING
Robotic welding has many positive attributes that convince businesses to select this
process for their projects. These benefits can boost productivity and the bottom line for
both the welding company and the companies it delivers to.
1. INCREASED EFFICIENCY
Unlike human workers who require breaks and time off, a robot can operate on a
24-hour shift. Longer working hours and quicker speeds allow robotic welding machines
to complete their projects much faster than people could. Thanks to the faster completion
times, the output from robotic welders far surpasses anything possible from a human.
2. ENHANCED SAFETY
Robotic welders come equipped with a range of safety features to protect people
from the welding arc, its temperature and its brightness. These safety features help keep
the work area safe. When workers have a safer workplace, there will be more productive
and have improved job satisfaction. Injuries and damaged equipment are also expensive
for companies, so these safety features can also save them money.
3. BETTER ACCURACY
The ideal project for a robot involves repetitive motions applied to a large volume
of parts. When engaged in this type of work, even the most experienced worker will
eventually make errors. Robots will finish the project with a higher degree of accuracy
because the machine will keep working with the same level of attentiveness until the
project is complete.
4. LESS WASTE
Due to their increased precision, robots generate less waste due to mistakes. Manual
welders may have to discard parts mistakenly welded together or those with weak
junctions. Since robots operate with a higher degree of accuracy, they make fewer
mistakes. Without as much material discarded from errors, a facility that uses robotic
welders operates more efficiently and produces less waste.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
5. LOWER DELIVERY COST
Once installed, robots can weld large numbers of parts together. Though upfront
costs to the company using the robotic welder may be high, the high productivity of the
machine will eventually recoup the loss. Since automatic welders have high levels of
production, projects done with them may cost less than those employing a team of human
workers.
Robotic welders can also cut delivery costs. The company doing the welding can
use one operator instead of a team of human welders to accomplish the same amount of
work. By trimming overhead, the company you hire for welding work can offer lower
prices or additional services.
CONS OF ROBOTIC WELDING
Robotic welding, while helpful, has some drawbacks that could outweigh the
advantages in some situations.
1. HIGHER UPFRONT COST
Yes, your delivery costs will likely be lower when you use a company with robotic
welders. However, if you were to invest in the machinery and trained operators yourself,
you would probably find the investment a loss. Individual companies that don’t
professionally offer welding services may not use robotic welders enough to justify the
high purchase price of the machinery.
If you want your business to take advantage of the benefits of robotic welding,
outsourcing the job will be the most fiscally responsible option for your company. You’ll
get the fast turnaround for a high volume without having to dedicate a significant portion
of your budget to machinery.
2. LESS FLEXIBILITY
The benefit of robots performing more accurately than people also comes with a
downside. People can react to unexpected situations in a way that robots can’t. When a
robotic welder needs to make a change, the operator must stop its process and reprogram
it. For complex projects, this increases the amount of time required.
3. NOT FEASIBLE FOR SMALL PROJECTS
For smaller projects, the time needed to program the robotic arm may be longer
than the welding process. For smaller projects, a human welder could finish the task
faster, but this timing depends on the project size and the operator’s programming speed.
THE FUTURE OF ROBOTIC WELDING
Today, robotic welding accounts for only a small portion of the welding projects in
the industry, but this will likely change with emerging technologies. Future innovations
will lead to welding robots that are easier to use, work with other machines and increase
in popularity.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
1. MIND-CONTROLLED WELDING ROBOTS
Currently, operators must program welding robots to start them on a process.
However, instead of a computer terminal or teach pendant, future operators may only
have to think about what they want the robot to do.
At the University of Illinois Urbana-Champaign, researchers have created a cap that
transfers brain waves into operations for a robotic welding arm. If applied to the industry,
such a process could reduce the amount of training existing manual welders need to
become robotic operators. Professionals could put on a cap and look over plans to tell the
robot how to properly weld the pieces together instead of plugging in a computer
program.
Since these arms would not require separate computer programs, robotic arms could
execute even small projects for which the programming time needed is currently too long
for using robots to make sense.
This technology likely won’t appear any time soon. Despite the success of the
research team’s prototype, developing the cap for commercial use will require at least a
couple of years, according to researcher’s estimates.
2. COLLABORATIVE ROBOTS
Imagine having your partner at work be a robot instead of a human. Some
businesses already use collaborative robots. These machines have a people-friendly
design that allows for easy interfacing with humans. Sensors make these robots capable
of gathering information and reacting to changing situations.
Industrial robots have traditionally required prior programming to execute large-
scale tasks. These durable, but expensive and unwieldy devices take up too much space
and money to be viable options for smaller businesses.
To solve this problem, engineers have created increasingly more durable
collaborative robots that could work with people in industrial applications. The designers
of these machines hope to reduce the number of 90% of tasks that could be done
automatically and aren’t.
Collaborative robots could integrate into manual welding areas to supplement the
work of human welders. With such changes, expect to see even more growth than the
market already exhibits.
3. A GROWING MARKET
Both the transportation and automotive markets continue to embrace technological
innovations that improve productivity. Welding robots are critical parts of these
industries’ operations. Due to growth in these sectors, over the five years from 2018 to
2023, the use of robotic welders will increase at a compound annual growth rate of
8.91%.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 Increasing demand for cars around the world puts pressure on the transportation
industry and automotive sector to raise production. More production will require
investing in machinery, such as robotic welding arms, that increases the speed and
accuracy of the vehicle-building process.

III. PROGRESS CHECK

FILL IN THE BLANKS. ✓ Directions: Read each statement or question below carefully
and fill in the blank(s) with the correct answer.
1. It's used to monitor the actuators based on sensor input, allowing it to control the
motion of each joint and, ultimately, the end effector's movement.
2. A _____ picks up an item and places it in the desired position.
3. It is the robot's main body, made up of solid bodies such as a cube or a sphere,
joints, and connections. It's often referred to as a manipulator. _____
4. _____ automates the welding process to improve accuracy, maximize safety, and
shorten project completion times.
5. The robot is actuated by it. Any engine, such as a servo motor, stepper motor, or
pneumatic or hydraulic cylinders, can be used. ____

TRUE/FALSE Directions: Read each statement below carefully. Place a T on the line
if you think a statement it TRUE. Place an F on the line if you think the statement is
FALSE.
_____ 6. The end effector is attached to the second rigid body, which is locked and
supported by the first rigid body.
_____ 7. To reach the position where the object is mounted, the rigid body
supporting the wheels or straightens up.
_____ 8. The robotic arm's tool heats up to melt metal and join the parts together.
_____ 9. Robots automate the procedure, resulting in increased accuracy, reduced
waste, and quicker operations.
_____ 10. When keeping the Battery in its gripper, the mechanical arm should be
designed to damage it.
_____ 11. The target is picked up by the rigid body with a firm grip and placed in
the desired location.
_____ 12. The robot can be moved to the target position due to the rigid body under
the platform.
_____ 13. It is the robot's main body, made up of multiple solid bodies, such as a
cylinder or a sphere, as well as joints and connections.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 _____ 14. The end effector or gripper should not need to be controlled in order to
apply sufficient pressure to the target in order to handle it efficiently and softly.
_____ 15. Robots make less errors than humans because they work with greater
precision.

IV. REFERENCES:

Pick N Place Robot. (n.d.). Retrieved from Electronics Project Focus:

https://www.elprocus.com/pick-n-place-robot/
ROBOTIC WELDING PROCESSES. (2019, August 21). Retrieved from Summit Steel
Manufacturing: https://www.summitsteelinc.com/resources/blog/robotic-
welding-processes/
https://www.slideshare.net/suchitmoon/pickandplacerobot?from_action=save

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.