Automation and Robotics Week 01 Theory Notes 20ME51I.pdf

Identify the possibilities of automation in a production system Discuss Hierarchy of Industrial Automation,
Industrial Automation pyramid. Present an Overview on the Levels of Automation-
• Device level
• Machine Level
• Cell Level
• Plant Level
• Enterprise Level

1. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Department of Mechanical [General]
Theory Interface

Subject : Automation and Robotics
Subject Code : 20ME51I
Semester : 5
th
Semester


Name of the Student: …………………………………………….

Register Number: …………………………………………….

2. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

APPENDIX 5 (Certificate issued by guide)
Name of the Institution: VIDYA VIKAS POLYTECHNIC
Address with pin code: 27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Department: MECHANICAL ENGINEERING (General)
CERTIFICATE
Certified that this Practical Record entitled “Automation and Robotics 20ME51I” which is being submitted
by Mr.………………………….……………………bearing Register Number…..………………………, is a
bonafide student of Mechanical Engineering Department, studying in Third Semester in our Institution and
has fulfilment the Theory Assignments prescribed by Department of Technical Education, Bangalore during
the year 2021-2021.
It is certified that all corrections/suggestions indicated for internal Assessment have been incorporated in the
Report.
Signature of the Staff In-charge


Signature of H.O.D

CIE (Internal Assessment Marks Obtained in Words):…………..……………………………………………

External Examiner 1:………………………………
Dept. …………………………College…….…………………

External Examiner 2:………………………………
Dept. …………………………College…….…………………

3. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore





Course Outcome




CIE and SEE Assessment Methodologies

4. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Assessment framework for CIE (1 to 5)
Note: Theory to be conducted for 1 hour and practice for 3 hours, total duration of exam – 4 hours
CIE 2- Model Question Paper




Scheme of Evaluations of Practical Questions-Section 2

5. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Assessment framework for SEE 1 (Theory)

6. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore




Scheme of Evaluation of SEE-2

7. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

WEEK 01
Day 01 Session
Conventional Production process

In a conventional production supply chain, it consists of all the steps involved in getting a product from a raw
material into the hands of the customer. Typically, the supply chain begins with the vendors or suppliers.
These are the businesses that provide raw materials. Next in the supply chain is manufacturing. This is the
process of converting the raw materials into products that are ready to sell. The final step is distribution which
can involve multiple different intermediaries. Some of these middle-men could be wholesalers, retailers,
distributors, and even the internet.
Often, different stages within the supply
chain are referred to as upstream or
downstream. Upstream operations are those in
which the materials flow into the
organization. Downstream operations are
those in which materials (mostly in the form
of finished products) flow away from the
organization to the customers. Similarly, the term logistics is used when talking about a business’s supply
chain. Inbound logistics are related to the upstream activities and include all of the movement of the product
before manufacturing. They involve receiving materials, storing them, and the manufacturing processes
required to produce the product. Of course, outbound logistics are related to the downstream operations
involving just about all of the movement of the product once it is a finished good.

What is Industrial Automation
Industrial automation is the use of various control devices like PC’s/PLC’s/DCS, used to have control on
various operations of an industry without significant intervention from humans and to provide automatic
control performance. In industries, control strategies use a set of technologies which are implemented to get
the desired performance or output, making the automation system most essential for industries.

8. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Industrial automation involves usage of advanced control strategies like cascade controls, modern control
hardware devices as PLC, sensors and other instruments for sensing the control variables, signal conditioning
equipment’s to connect the signals to the control devices, drives and other significant final control devices,
standalone computing systems, communication systems, alarming and HMI (Human Machine Interface)
systems.

Need of Automated Industry
a) To reduce Periodic or Manual checking
In some critical applications periodic checking of the process variable is necessary to perform industrial
operations. Automation equipment reduces the periodic or manual operations and establishes the automatic
working conditions.
b) To increase the Productivity
Automating the manufacturing and other production processes increases the production rate by producing
output at greater amounts for a given labour input
c) Reduce the Production Cost
Using the automatic machines and equipment’s, human intervention to control the processes abruptly falls.
This reduces the investment on the labor cost hence the production cost.
d) To improve Product Quality
Continuously doing the same work may not be perfect in all the cases in terms of quality specifications with
human efforts. With automation equipment, one can get reliable and uniform product quality by using real
time hardware control devices.
e) To increase the Flexibility
Using the automation equipment various, process is handled simply without getting any complex environment
particularly in manufacturing processes.
f) Operator Friendly and Improves the Safety
Complexity of operating the equipment’s or processes is reduced with industrial automation. It changes the
position of the operator as operator to the supervisory role.

Hierarchy of Industrial Automation [Industrial Automation pyramid].
Hierarchy or Structure of the industrial automation explains various levels of operation. These include
sensor level, automation control level (Unit, cell, process controls), supervision level and enterprise level.
Pyramid structure indicates that, as you go up the tip, the information is aggregated and while coming down
it is dissolved. This means we will get the detailed information for a particular variable at the bottom. Industrial
automation doesn’t mean that all the levels are automated like enterprise level need not be automated.

9. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore


Sensor level is also called as process layer. It uses the sensors and actuators to get the values of the process
variables in continuous or periodical manner. These act as eyes and arms of the industrial processes. Some of
these instruments include pneumatic instruments, smart instruments, etc.
Automation control level or control layer uses industrial control devices like PC’s/PLC’s/DCS, etc. This level
utilizes the various embedded processors, PID algorithms to control the process.
Supervising level or SCADA layer gets lots of channel information and stores the data in the system database.
It acquires data from various control devices and displays them on HMI’s (Human Machine Interface). It also
gives alarm to indicate the levels of the process and control variables. It uses special software to get the data
and communication protocols to interact with the field devices.
Enterprise level performs the tasks like scheduling, orders and sales, product planning, etc.

Overview on the Levels of Automation
There are various levels at which automation can be applied in the context of the enterprise. A temperature
sensor that feeds back information to a regular in a shower is a reasonably low level of automation. On the
other hand, a high-level automation system is required to run a train system in a city.

10. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Five levels of automation can be identified and are outlined. Automation can be examined at five different
levels, in a hierarchy that runs from the single device, the machine, the cell or system, the plant, to the
enterprise level.
Device level
The lowest level, it includes hardware components that comprise the machine
level, such as actuators and sensors. Control loop devices are predominant here.
Machine level
Hardware at the device level is assembled into individual machines. Control
functions at this level include performing the sequence of steps in the programmed
of instructions.
Cell or system level
This operates under instructions from the plant level. Consists of a group of
machines or workstations connected and supported by a material handling system,
computers and other appropriate equipment, including production lines.
Plant level
Factory or production systems level, it receives instruction from the corporate
information system and translates them into operational plans for production.
Enterprise level
The highest level, it consists of the corporate information system, and is concerned
with all the functions that are necessary to manage and coordinate the entire
company.

Types of Industrial Automations
Automation systems are classified into four basic types, based on the flexibility and level of integration in
manufacturing processes. Those are described below.

1. Fixed Automation
In this sequence of operations to be performed are fixed by the equipment configuration.
It is used in high volume production with dedicated equipment. Examples of this
automation system are automated assembly lines, distilled process, machine transfer
lines.

2. Programmable Automation
In this, sequence of operations can be changed by changing the program. Sequence of
operations is varied based on the different product configurations. Also new programs
can be entered into the programmable devices for the new products. This type of system
is used in batch processes, steel rolling mills, industrial robots, etc.

11. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

3. Flexible Automation
It is the extension for the programmable automation. This offers a greater
flexibility to deal with product design variations. Operators can give
commands in the form of codes in the computer program if wants to change
the sequence of the process. Lower level equipments receive the instructions
to operate at the field level without losing the production time. This type of
automation is used in manufacturing multipurpose CNC machines, automatic guided vehicles, etc.

4. Integrated Automation
In this type total system is fully automated under computer control. Starting from designing process to the
dispatching, whole system is completely automated. Even the equipment is handled by the robots. This system
is used in computer integrated manufacturing systems.

Types of Automation Equipment’s

a) Sensors and Actuators
A sensor senses the various process variables and converts them into the electrical or optical signals. These
sensors include temperature, pressure, velocity, flow, etc.
Actuators convert the electrical signals to the mechanical means to gain control over processes. These include
relays, magnets, servomotors, etc.
Some of the sensors and actuators have the capability to communicate with the industrial field communication
buses which comes under the smart devices.
b) Industrial computers
Programmable Logic controllers (PLC’s) also called as industrial computers are capable of being programmed
to perform certain control functions. It consists of a CPU or processor, I/O modules (both analog and digital)
to connect the various input/output devices and relay modules. These may be modular which is of fixed type

12. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

or integrated types to extend modules based on the inputs available. Along with the PLC’s, conventional PC’s
are used to control the process by online or by changing the programs. PLC’s comes with dedicated software
to program the control strategy.
c) HMI (Human Machine Interface)
HMI’s offers the facilities like, displaying the information on computer screens and other displays, logging
the results in the database, giving alarm signal, etc. It uses technologies like SCADA (Supervisory Control
and Data Acquisition) and other visual based technologies.
d) Communication system
In industries many sensors, actuators, controlling PC’s and other control devices are geographically distributed
and interacting with each other via several data buses. There are three types of buses used in the industrial
automation i.e., factory bus, process bus, and the field bus.
Field bus interacts between field instruments and the control devices while the process bus connects the
supervising level computers to the control devices like PLC’s. Factory bus connects the higher level of the
organization to the supervising level. Different protocols are used for the communications like RS-485,
profibus, CAN control modbus, etc.

13. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

WEEK 01
Day 02 Session
Design Thinking problem-solving process.
The design thinking process is a problem-solving design methodology that helps you tackle complex problems
by framing the issue in a human-centric way. The design thinking process works especially well for problems
that are not clearly defined or have a more ambiguous goal.

1. Empathize stage (Understanding stage)
The first stage of the design thinking process is to look at the problem you’re trying to solve in an practical
manner. To get an accurate representation of how the problem affects people, actively look for people who
encountered this problem previously. Asking them how they would have liked to have the issue resolved is a
good place to start, especially because of the human-centric nature of the design thinking process.
2. Define stage
Sometimes a designer has to clearly define and outline a problem, that is to create human-centric problem
statements. A problem statement helps frame a problem in a way that provides relevant context in an easy-to-
understand way. The main goal of a problem statement is to guide designers working on possible solutions for
this problem. A problem statement frames the problem in a way that easily highlights the gap between the
current state of things and the end goal.
3. Ideate stage
This is the stage where designers create potential solutions to solve the problem outlined in the problem
statement. Use of brainstorming techniques with a team to identify the human-centric solution to the problem
defined in step two. Here are a few brainstorming strategies you can use with your team to come up with a
solution:
a) Standard brainstorm session: Your team gathers together and verbally discusses different ideas out loud.
b) Brain writes: Everyone writes their ideas down on a piece of paper or a sticky note and each team member
puts their ideas up on the whiteboard.
c) Worst possible idea: The inverse of your end goal. Your team produces the most ridiculous idea so nobody
will look silly. This takes out the rigidity of other brainstorming techniques. This technique also helps
you identify areas that you can improve upon in your actual solution by looking at the worst parts of an
absurd solution.

14. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

4. Prototype stage
During the prototype phase, the team design a few different variations of inexpensive or scaled down versions
of the potential solution to the problem. Having different versions of the prototype gives your team
opportunities to test out the solution and make any refinements.
Prototypes are often tested by other designers, team members outside of the initial design department, and
trusted customers or members of the target audience. Having multiple versions of the product gives your team
the opportunity to tweak and refine the design before testing with real users.
5. Test
After testing different prototypes, team should have different solutions for how the product can be improved.
The testing and prototyping phase is an iterative process. After designers take the time to test, reiterate, and
redesign new products, they may find new problems, different solutions, and gain an overall better
understanding of the end-user.

Impact of design thinking on design, manufacturing and delivery
If you think like a designer, it can transform how your organisation develops products, services, processes,
and strategies. It brings together the desirability from the customer’s perspective with what is technologically
feasible and economically viable. It also provides various opportunities for people who aren’t trained as
designers to utilise creative tools so that they can tackle a vast range of problems/challenges.
There are also some essential aspects in which design thinking helps, and they are:
a) The main objective is to solve the customer’s requirements
b) Helps in tackling ambiguous and challenging problems
c) Drives people to create innovative solutions
d) It helps organisations to run faster with more efficiency

Describe the principles of Design Thinking
There are four universal principles of design thinking
1. The Human Rule: “All design is social in nature.” The problems must be solved by satisfying the
human requirements and recognizing the human element in all
technologies.
2. The Ambiguity Rule: “Ambiguity is inevitable.” We perform
experiments to the limits based on our knowledge, control events
based on our limits, and liberty to see things from different
perspectives.

15. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

3. The Redesign Rule: “All design is redesign.” In today’s world, technology and social events have been
consistently evolving. We must study and analyse how the requirements of humans were met in earlier
times.
4. The Tangibility Rule: “Making ideas tangible facilitates communication.” If we make our ideas
tangible for prototypes, it facilitates designers to communicate effectively.

Discuss the feasibility (possibility)of the operations that can be Automated in a Production system
here, automation can be defined as a technology concerned with the application of mechanical, electronic, and
computer-based systems to operate and control production.
The automated elements of the production system can be separated into two categories:
(1) automation of the manufacturing systems in the factory and
(2) computerization of the manufacturing support systems.

Automated manufacturing systems operate in the factory on the physical product. They perform operations
such as processing, assembly, inspection, or material handling, in some cases accomplishing more than one
of these operations in the same system. They are called automated because they perform their operations with
a reduced level of human participation compared with the corresponding manual process.
Examples of automated manufacturing systems include:
• automated machine tools that process parts
• transfer lines that perform a series of machining operations
• automated assembly systems
• manufacturing systems that use industrial robots to perform processing or assembly operations
• automatic material handling and storage systems to integrate manufacturing operations
• automatic inspection systems for quality control

Automated manufacturing systems can be classified into three basic types
(1) fixed automation,
(2) programmable automation, and
(3) flexible automation.

16. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

a) Fixed Automation Fixed automation is a system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration. Each of the operations in the sequence is usually
simple, involving perhaps a plain linear or rotational motion or an uncomplicated combination of the two;
for example, the feeding of a rotating spindle. It is the integration and coordination of many such
operations into one piece of equipment that makes the system complex. Typical features of fixed
automation are:
• high initial investment for custom engineered equipment
• high production rates
• relatively inflexible in accommodating product variety
b) Programmable Automation. In programmable automation, the production equipment is designed with
the capability to change the sequence of operations to accommodate different product configurations. The
operation sequence is controlled by a program, which is a set of instructions coded so that they can be
read and interpreted by the system. New programs can be prepared and entered into the equipment to
produce new products. Some of the features that characterize programmable automation include:
• high investment in general purpose equipment
• lower production rates than fixed automation
• flexibility to deal with variations and changes in product configuration
• most suitable for batch production
c) Flexible Automation. Flexible automation is an extension of programmable automation. A flexible
automated system is capable of producing a variety of parts (or products) with virtually no time lost for
changeovers from one part style to the next. There is no lost production time while reprogramming the system
and altering the physical setup (tooling, fixtures, machine settings). Consequently, the system can produce
various combinations and schedules of parts or products instead of requiring that they be made in batches.
• high investment for a custom engineered system
• continuous production of variable mixtures of products
• medium production rates
• flexibility to deal with product design variations

17. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Identify the operations that cannot be Automated in a Production system and requires human
intervention
Before identifying the operations, which are is not suitable for processes let us discuss the main factors that
influence:
• Need constant human oversight to monitor,
• Operations that are too complex to be automated,
• unstructured or incomplete or complicated data,
• yield of profits
• yet to reach perfections.
1. Processes that deal with unstructured data
Industries which use sorting and categorizing
2. Processes that need constant human involvement
Some processes, such as quality control (QC), customer care, sales, or customer feedback analysis
3. Processes that are too complex
From design to production if complications are present like chemicals, decompose, depreciation etc
4. Processes that will return a low profit after automation
The profit models of products are the first factor to consider in cost model. Other than this Maintenance
costs, infrastructure costs, and any future programming costs must be considered.
4. Processes that are yet to be mature
Companies that keep changing the product design that effects technical infrastructure, applications, employee
and department head turnover, governmental regulations, financial close season timing, and more.

Importance of Industrial automation in manufacturing industry
The major advantages of using automation are:
• To reduced direct human labour costs
• To Increased productivity
• To Enhanced consistency of processes or product
• To Delivery of quality product
Other major advantages are
• Improve quality and accuracy
• Increase productivity
• Greater product variety
• Complete control of the manufacturing process / system
• Consistency in manufacturing
• Safety in working
• Quick product change over

18. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Challenges and Limitations of industrial automations
There are advantages as well as disadvantages which are listed below, but these disadvantages are considered
as challenges
Advantages For Industrial Automation
a) Increased productivity: The rate of production and labour productivity increase when a manufacturing
operation is automated. This translates to more output per hour of labour.
b) Reduced labour cost: The trend in automation replaces manual operations and operators. This has become
economically justifiable. Machines are increasingly being used to replace human lahar to reduce unit costs.
c) Migrate the effects of labour shortages: Many advanced countries are experiencing a labour shortage,
which has prompted the development of automated operations as a labour replacement.
d) Reduce or eliminate routine manual and clerical tasks: There is social value in automating routine,
boring, fatiguing, and possibly annoying operations. Automating improve the general level of working
conditions.
e) Improve worker safety: Automating the operations make the work much safer. However, the workers get
active participation in a supervisory role.
f) Improve product quality: Automation achieves higher production rates than manual operations and
greater uniformity and conformity to quality specifications in the manufacturing process.
g) Reduce manufacturing lead time: Automation shortens the time between customer order and product
delivery, giving the manufacturer a competitive advantage for future orders.
h) Accomplish processes that cannot be done manually: Certain tasks are impossible to complete without
the assistance of a machine. Some examples are integrated circuit fabrication operations, rapid prototyping
and computer numerical control machining of complex surfaces. Computer-controlled systems can only
carry out these processes.
Disadvantages Of Industrial Automation
a) Higher start-up and operation costs: Automated equipment often includes high capital expenditures. The
design, fabrication, and installation can cost millions of dollars.
b) Higher cost of maintenance: When compared to a manually operated machine, a higher level of
maintenance is required in automation and spare parts for an automation system may be more expensive.
c) Obsolescence/depreciation cost: The gradual decrease in the value of physical assets is known as
obsolescence and depreciation. This is common with all physical assets, such as equipment and machinery.
It is unavoidable as a result of technological advancement.
d) Unemployment: A disadvantage often associated with automation is worker displacement. There is a mass
lay-off because manual laborers are being replaced by robots or other automated machinery. Many people
are losing their jobs, especially those who work in the manufacturing industry, such as a car factory.

19. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Week 01
Day 03 Session
Technologies adopted in Automation
The two major factors driving industrial automation are
a) the introduction of favourable policies towards the manufacturing sector and
b) increased focus on economic diversification in emerging markets.
The growth of this market can be attributed to the increasing use of enabling technologies in manufacturing.
Automation in the manufacturing industry uses intelligent machines in factories to carry out the manufacturing
processes with minimal human intervention and tasks that require endurance, speed, and precision. Some of
the top benefits of automation in manufacturing include -
• Productivity
• Accuracy
• Safety
• Quality
A few of the automation technologies used in the manufacturing industry are -
a) Industry 4.0
Industry 4.0 refers to a new phase in the Industrial Revolution that focuses heavily on interconnectivity,
automation, machine learning, and real-time data. Industry 4.0, which encompasses IIoT and smart
manufacturing, marries physical production and operations with smart digital technology, machine learning,
and big data to create a more holistic and better connected ecosystem for companies that focus on
manufacturing and supply chain management.
b) The Industrial Internet of Things
The Industrial Internet of Things is the use of connected smart devices in industrial applications for purposes
such as automation, remote monitoring and predictive maintenance. The IIoT is a more robust version of the
Internet of Things, or IoT which is the realm of connected devices in commercial and consumer applications.
In Industrial IoT use cases, smart devices may be deployed in construction vehicles, supply chain robotics,
solar and wind power, agricultural sensor systems, smart irrigation, and more. These IIoT applications tend to
have one thing in common: they are deployed in challenging environments.
c) Robotics
Robots are used in manufacturing to take on repetitive tasks, which streamlines the overall assembly
workflow. Robots also collaborate with humans for product production. Many jobs are dangerous or include
high volumes of materials, which can be harmful to human workers.
d) Artificial Intelligence
Artificial Intelligence refers to computer systems that can perform problem-solving and decision-making tasks
normally associated with human intelligence. These can include:

20. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

• Recognizing images and speech
• Making decisions
• Translating languages
• Providing recommendations
• And more
e) Big Data
Big data has been used in the industry to provide customer insights for transparent and simpler products, by
analysing and predicting customer behaviour through data derived from social media, GPS-enabled devices,
and CCTV footage. The Big Data also allows for better customer retention from insurance companies. Few
example industries using big data applications:
a) Banking and Securities
b) Communications, Media and Entertainment
c) Healthcare Providers
d) Education
e) Manufacturing and Natural Resources
f) Government
g) Insurance
h) Retail and Wholesale trade
i) Transportation
j) Energy and Utilities
f) The Industrial Cloud
Industrial cloud computing is a broad term for cloud technology used in asset-intensive industries such as
manufacturing, telecommunications, mining, construction, waste and water management, and energy
generation/distribution. Industrial cloud computing provides the infrastructure for the transmission of data to
the applications that operators are using on computers or mobile devices.
g) Cybersecurity
Cybersecurity for Industry enables continuously monitored and integrated security. Cover now all levels of
security simultaneously with Siemens. More information Defence in Depth. Industrial Security. Latest news
& alerts. Protecting productivity.
h) Advanced Materials and Additive Manufacturing
The Advanced Materials and Manufacturing research group specialises in materials science, applied
mechanics, bio-engineering, mechatronics, manufacturing systems, logistics and supply chain management.
Additive manufacturing (AM) or additive layer manufacturing (ALM) is the industrial production name for
3D printing, a computer controlled process that creates three dimensional objects by depositing materials,
usually in layers.
i) Modelling, Simulation, Visualization, And Immersion
Modelling provides a definite recommendation for action in a specific situation, while simulation allows users
to determine how a system responds to different inputs so as to better understand how it operates. Immersive
visualization is an accessible, easy-to-use technology that turns 3D BIM (Building Information Modelling)
models into engaging spatial experiences of design that participants can explore. These tools help architects
to refine and reshape their design—from initial concept to final design review.

21. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Demonstrate / Illustrate the following:

1) Sensors Technology
Sensors, sometimes referred to as” transducers,” help us interact with the world around us through an electrical
or a mechanical device. The technology measures or detects some property of the environment or changes to
that property over time. Sensors are classified broadly into two types:
a) Exteroceptive sensor
If the sensor captures data about the environment outside the system in which it is present, it is an
exteroceptive sensor. “Extero” means outside or from the surroundings, and some common examples are
camera, LiDAR, radar, and ultrasonic/sonar sensors.
b) proprioceptive Sensors:
A sensor is proprioceptive if it records data about the system itself. “Proprios” means internal or one’s own,
and some common examples include GPS, inertial measurement unit (IMU), and position sensors. Sensors
also categorize as digital or analog based on the type of output they provide.

2) Drives and Actuators
A drive is the electronic device that harnesses and controls the electrical energy sent to the motor. The drive
feeds electricity into the motor in varying amounts and at varying frequencies, thereby indirectly controlling
the motor's speed and torque.
An actuator is a part of a device or machine that helps it to achieve physical movements by converting energy,
often electrical, air, or hydraulic, into mechanical force. Simply put, it is the component in any machine that
enables movement.

3) Relays and Switches
Relays are electrically operated switches that open and close the circuits by receiving electrical signals from
outside sources. They receive an electrical signal and send the signal to other equipment by turning the switch
on and off. Relay is an electromechanical device used to make or break the circuits and can be controlled
electronically.
A switch is an electromechanical device used to make or break the circuits and it can be controlled
mechanically, it controls the flow of current by opening or closing of circuits. Switches are operated manually
by a lever or by pushing the buttons

4) PLC and Programming
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

22. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

the state of output devices. There are four basic steps in the operation of all PLCs, these steps continually take
place in a repeating loop.
a) Input Scan: Detects the state of all input devices that are connected to the PLC
b) Program Scan: Executes the user created program logic
c) Output Scan: Energizes or de-energize all output devices that are connected to the PLC.
d) Housekeeping: This step includes communications with programming terminals, internal diagnostics,
etc.
5) Communication Protocols
Communication protocols allow different network devices to communicate with each other. They are used in
both analog and digital communications and can be used for important processes, ranging from transferring
files between devices to accessing the internet.
Industrial Network Protocols are often referred to generically as SCADA and/or fieldbus protocols. SCADA
protocols are primarily used for the communication of supervisory systems, whereas fieldbus protocols are
used for the communication of industrial, automated control systems (ICS or IACS).

Modern tools used for Industrial Automation
A wide range of tools are required for industrial automation. They include various control systems that
incorporate different devices and systems impacting aspects of the manufacturing process. The key tools are
explained here.
1) Programmable Logic Controller (PLC)
A PLC is a ruggedized, digital industrial computer control system that is preprogramed to carry out automatic
operations in industrial processes. The PLC continuously monitors and receives information from input
devices or sensors, processes the information, and triggers the connected output devices, to complete the task
in the industrial process or machinery.
2) Supervisory Control and Data Acquisition (SCADA)
SCADA systems control and monitor industrial processes. The system acquires and processes real-time data
through direct interaction with devices, such as sensors and PLCs, and records events into a log file. SCADA
is important for data analysis, and enables effective decision-making for optimization in industrial processes.
3) Human Machine Interface (HMI)
An HMI is a software application that enables interaction and communication between a human operator and
the machine, or production system. It translates complex data into accessible information, enabling better
control of the production process and its various applications.
4) Artificial Neural Network (ANN)
An ANN is a computing system that is built like the human brain, a network of interconnected neuron nodes.
ANNs simulate the way a human brain analyses and processes information.

23. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

5) Distributed Control System (DCS)
A DCS is a central monitoring network that interconnects devices to control different elements within an
automated system.
6) Robotics
Robots can efficiently perform tasks in complicated or dangerous situations, improve production flow and
quality, and increase safety for employees. Additionally, robots can make daily life much more comfortable
or convenient.

Importance of IEC, ISO, NEMA, JIC standards used in automation.
a) IEC: The International Electrotechnical Commission (IEC) International Standards are essential for
quality and risk management; they help researchers understand the value of innovation and allow
manufacturers to produce products of consistent quality and performance.
b) ISO: An ISO standard is essentially an internationally recognized way of doing something. It means that
everyone follows the same set of guidelines no matter where they are based, resulting in a safer, more
consistent end result. This benefits both the organization and the customer or end user. Some of the most
popular standards include:
• ISO 9001: the standard for a quality management system
• ISO 27001: a system for managing information security
• ISO 45001: the occupational health and safety management standard
c) NEMA: The National Electrical Manufacturers Association (NEMA) defines standards used in North
America for various grades of electrical enclosures typically used in industrial applications. Each is rated
to protect against personal access to hazardous parts, and additional type-dependent designated
environmental conditions.
d) JIC: A joint industrial council (JIC) or national joint industrial council (NJIC), known as a Whitley
council in some fields, especially white-collar and government, is a statutory council of employers
and trade unions established in the United Kingdom and elsewhere. It is a workplace partnership, an
institution that serves for a forum of consultation between employees and employers. Councils were
established from 1919. They typically worked to determine wage rates, terms and conditions in a specific
industry.

24. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Week 01
Day 04 Session

Programmable Automation Controllers (PACs)
Programmable Automation Controller is a programmable microprocessor-based device used for
discrete manufacturing, process control, and remote monitoring applications. These computers are the brains
of a manufacturing operation as they control automation equipment with high reliability.
Programmable automation controllers are digital computers that hold and execute embedded programs.
These are seen in many different types of electromechanical processes and usually control the machinery in
factories. PAC also expand the capabilities of hardware you're using now by merging features of more
traditional PLC (programmable logic controller), DCS (Distributed control system), and RTU (remote
terminal unit) systems, plus adding some capabilities from PCs.
Programmable automation controllers are divided into these two categories:
a) PAC systems: A PAC system consists of one or more PAC modules, each performing a specific
function.
b) PAC modules: PAC modules are add-on devices that perform a specific control function in PAC
systems. Common types of PAC modules include analog I/O modules, digital I/O modules, relay
modules, counter modules, serial modules, servo or stepper controller modules, timer modules, and
data acquisition modules.
Many programmable automation controllers include watchdog timers, real-clock timers, visual indicators,
reset buttons, or surge protection. PACs with an integral power supply or built-in web server are also available.
Hot-swappable PACs can be installed or uninstalled during regular operation.

Role of PACs in modern industries.
PACs combine programmable logic controller (PLC) functions with the greater flexibility of a PC. The
key advantages of using PACs in industrial applications:
• A single controller with integrated software handles multiple functions across multiple domains.
• Modular designs make expansion easier.
• Networking and communication capabilities link systems and provide more accurate and timely data.
• Total system cost is lowered because integrated hardware and software are less expensive
• Modular design improves cash flow.
• Extensive analog control capabilities.
• PACs tend to be smaller in size and more durable.
• Runs in a scheduled cyclic mode

25. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Discuss Proportional Integral Derivative (PID)
Proportional-Integral-Derivative (PID) control is the most common control algorithm used in industry
and has been universally accepted in industrial control. The popularity of PID controllers can be attributed
partly to their robust performance in a wide range of operating conditions and partly to their functional
simplicity, which allows engineers to operate them in a simple, straightforward manner.
PID controller is to read a sensor, then compute the desired actuator output by calculating proportional,
integral, and derivative responses and
summing those three components to compute
the output. Before we start to define the
parameters of a PID controller, we shall see
what a closed loop system is and some of the
terminologies associated with it.
a) Proportional Response
The proportional component depends only on the difference between the set point and the process variable.
This difference is referred to as the Error term. The proportional gain (Kc) determines the ratio of output
response to the error signal. For instance, if the error term has a magnitude of 10, a proportional gain of 5
would produce a proportional response of 50. In general, increasing the proportional gain will increase the
speed of the control system response. However, if the proportional gain is too large, the process variable will
begin to oscillate. If Kc is increased further, the oscillations will become larger and the system will become
unstable and may even oscillate out of control.
b) Integral Response
The integral component sums the error term over time. The result is that even a small error term will cause
the integral component to increase slowly. The integral response will continually increase over time unless
the error is zero, so the effect is to drive the Steady-State error to zero. Steady-State error is the final difference
between the process variable and set point. A phenomenon called integral windup results when integral action
saturates a controller without the controller driving the error signal toward zero.
c) Derivative Response
The derivative component causes the output to decrease if the process variable is increasing rapidly. The
derivative response is proportional to the rate of change of the process variable. Increasing the derivative time
(Td) parameter will cause the control system to react more strongly to changes in the error term and will
increase the speed of the overall control system response. Most practical control systems use very small
derivative time (Td), because the Derivative Response is highly sensitive to noise in the process variable
signal. If the sensor feedback signal is noisy or if the control loop rate is too slow, the derivative response can
make the control system unstable

26. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

Programming with IEC 61131-3 Languages
In developing the IEC 61131 standard, the International Electrotechnical Commission identified five
programming languages as the most common for a variety of programmable controllers. The IEC 61131
standard’s languages have been adopted across industries in response to a larger field of automation vendors,
increased application complexity, and more diverse methods for implementing various control functions. The
IEC 61131’s five programming languages are Ladder Diagram, Instruction List, Function Block Diagram,
Structured Text, and Sequential Function Chart. Each language has advantages and disadvantages
depending on a control engineer’s desired application.
1. Ladder Diagram (LD)
Ladder Diagram was originally modeled from relay-
logic which used physical devices, such as switches
and mechanical relays to control processes. Ladder
Diagram utilizes internal logic to replace all, except
the physical devices that need an electrical signal to
activate them. The ladder diagram is the universal
programming language of PLC. It has a short
abbreviation as ‘LD’ and also known as ‘Ladder
Logic’. Ladder Diagram is built in the form of horizontal rungs with two vertical rails that represent the
electrical connection on relay-logic schematics. one can program all the necessary input conditions to affect
the output conditions, whether logical or physical. The main advantages of the Ladder Diagram language are:
a) The rungs allow it to be organized and easy to follow.
b) It also lets you document comments that are readily visible.
c) It supports online editing very successfully.
2. Sequential Function Charts (SFC)
This PLC Programming language is like construct a flowchart. In Sequential Function
Charts, you use steps and transitions to achieve your end results. Steps act as a major
function in your program. These steps house the actions that occur when you program
them to happen. This decision can be based on timing, a certain phase of the process,
or a physical state of an equipment. Transitions are the instructions that you use to
move from one step to another step by setting conditions of true or false. The Sequential
Function Charts can have multiple paths. You can use branches to initiate multiple
steps at one time. The advantages of Sequential Function Charts are:
a) Processes can be broken into major steps that can make troubleshooting faster.
b) You have direct access in the logic to see where a piece of equipment faulted.
c) It can be faster to design and write the logic.

27. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

3. Function Block Diagram (FBD)
The Function Block Diagram which is
also a graphical type of language. The
Function Block Diagram describes a
function between inputs and outputs
that are connected in blocks by
connection lines. Function Blocks were
originally developed to create a system
that you could set up many of the
common, repeatable tasks, such as
counters, timers, PID Loops, etc. One
can program the blocks onto sheets and then the PLC constantly scans the sheets in numerical order or is
determined by connections which you program between the blocks. Function Block Diagram Advantages
a) The Function Block Diagram does work well with motion controls.
b) The visual method is easier for some users.
c) The biggest advantage of Function Block Diagram is that you can take many lines of programming and
put it into one or several function blocks.

4. Structured Text (ST)
This language is a textual based language.
Structured Text is a high-level language that is like
Basic, Pascal and “C”. It is a very powerful tool
that can execute complex tasks utilizing algorithms
and mathematical functions along with repetitive
tasks. The code uses statements that are separated
by semicolons and then either inputs, outputs, or
variables are changed by these statements.one
must write out each line of code and it uses
functions such as FOR, WHILE, IF, ELSE,
ELSEIF AND CASE. If experience with Basic or C languages, this PLC Programming Language will come
easier than some of the other types of PLC languages. Some of the advantages of Structured Text are:
a) It is very organized and good at computing large mathematical calculations.
b) It will enable you to cover some instructions that are not available in some other languages like the
Ladder Diagram.

28. Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering VVETP, Mysore

5. Instruction List (IL)
The Instruction List is also a textual based language. The Instruction List language resembles Assembly
Language. When you use this PLC Programming Language, you will use mnemonic codes such as LD (Load),
AND, OR, etc. The Instruction List contains instructions with each instruction on a new line with any
comments you might want to annotate at the end of each line. The Instruction List language is valuable for
applications that need code that is compact and time critical.






Day 05 Session:
Developmental Weekly Assessment + Industry Assignment





Day 06 Session:
Industry Class on Sensors and Actuators+ Industry Assignment