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LECTURE NOTES AT074.07

AUTOMATION TECHNOLOGY

Dr Nitin Afzulpurkar Industrial Systems Engineering Program

Asian Institute of Technology

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AT74.07 Automation Technology 3(2-3) Semester:

Rationale: To impart knowledge and practical experience in advanced control and programming of automation systems. The principles of advanced automation technology are presented and then applied in lab sessions. Catalog Description: Principles of Automation Technology. Programmable Logic Controllers (PLC). Digital Communication. Feedback Control. Man-Machine Communication. Pre-requisite(s): Consent of Instructor Course Outline:

I Principles of Automation Technology 1. Automation System Components 2. Discrete Manufacturing Automation 3. Continuous Process Automation 4. Strategy for Automation

II Programmable Logic Controllers (PLC) 1. Industrial Control Overview 2. Structure of PLC 3. Programming Languages for PLC4. Boolean Logic for Process Control5. Timers, Counters and Other Functions 6. Application Examples

III Digital Communication 1. Evolution of Factory Communication 2. Communication Architectures 3. Open Systems Interconnection 4. Communication over Public

IV Feedback Control 1. Continuous and Time-Discrete Control 2. On/Off Control 3. PID Control 4. Distributed System Control (DCS)

V Man-Machine Communication 1. Definition 2. Psychological Considerations 3. Interface Design Principles 4. Supervisory Control and Data Acquisition (SCADA)

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Networks 5. Description of Selected Automation Buses 6. Fieldbus: Architecture and Protocol 7. Intelligent Sensors and Actuators

Laboratory Sessions:

Lab 1: System Introduction Lab 2: Timers and Counters Lab 3: Edge Rising and Falling Lab 4: Jump Operations Lab 5: Load and Transfer Operations Lab 6: Functions, Function Blocks and Data Blocks Lab 7: WINCC Introduction Lab 8: Application Project

Textbook(s):

Lecture Notes

References:

T-C. Chang, R.A. Wysk, and H-P. Wang: Computer Aided Manufacturing, Prentice-Hall Inc., 1991. D. Collins, and E. Lane: Programmable Controllers A Practical Guide, McGraw-Hill, 1995. A.J. Crispin: Programmable Logic Controllers and their Engineering Applications, McGraw-Hill, 1997. S. B. Mossis: Programmable Logic Controllers, Prentice Hall, 2000 G. Olsson, and G. Piani: Systems for Automation and Control, Prentice Hall, 1992. E.A. Parr: Programmable Controllers An Engineer’ s Guide, Part of Reed International Books, 1993. J. Webb: Programmable Logic Controllers Principles and Applications,

4 Maxwell Macmillan, 1992. Journals:

International Journal of Computer-Integrated Manufacturing Journal of Manufacturing Systems Manufacturing Engineering Simulation

Grading System:

The final grade will be computed according to the following weight distribution: Midsem Exam 30%; Laboratory projects and Assignments 30%; Final Exam 40%. Closed-book exams are given in both the midsem and final.

Instructor(s):

5 Introduction Manufacturing industry has played a key role in the rapid economic growth of Southeast Asia in general and Thailand in particular. For example, Thailand is home for one of the largest disk drive manufacturing activity in the world. One of the key solutions, offering many benefits to manufacturing productivities, is the adaptation of flexible and intelligent automation technology. Industrial automation involves use of automated transfer lines, PLC and computer controlled machines, use of automated inspection techniques, distributed control systems, use of robots, flexible assembly lines and greater use of Information Technology. Market changes are forcing product changeovers at unprecedented rates. As manufacturing industry comes out of recession, it is going to face intense competition in terms of quality, price and delivery times, while at the same time producers are going to have to reduce their operating costs. The only way forward is the use of automation and robotics technology which lends itself admirably to automotive, electronics, computer components, and other industries.