ATM EXAM1
Automation is a set of technologies that results in operation of machines and
systems without significant human intervention and achieves performance
superior to manual operation.
Control is a set of technologies that achieves desired patterns of variations of
operational parameters and sequences for machines and systems by providing
the input signals necessary.
KEY COMPONENTS OF AUTOMATION
PLC is a computer based controller that uses inputs to monitor a process, and
uses outputs to control a process using a program. They are used to automate the
operation of machines and processes by executing a series of logic functions
based on input signals from sensors and other devices.
Human Machine Interfaces (HMIs): These are graphical interfaces that allow
operators to interact with the automation system. HMIs typically consist of
touchscreens or other displays that show real-time data and status information
about the machines and processes being monitored. Operators can use the HMI
to adjust settings, monitor performance, and respond to alarms and alerts.
Actuators: These are devices that are used to control the operation of machines
and processes. Actuators can be used to turn on and off motors, open and close
valves, and perform other actions that are necessary to control the process. Some
common types of actuators used in industrial automation include solenoid valves,
motor starters, and pneumatic cylinders.
Communication Networks: These are used to connect the various components of
the automation system together. Communication networks can be wired or
wireless, and they allow the PLCs, sensors, HMIs, and other devices to exchange
data and commands in real-time.
Sensors: These are devices that are used to detect and measure physical variables
such as temperature, pressure, flow rate, position, and proximity. Sensors provide
input signals to the PLCs, which use these signals to make decisions about the
operation of machines and processes.
Here is an overview of some commonly used sensors in industrial automation:
Photo sensors
These sensors use light to detect objects, either by transmitting a beam of light
and measuring the reflected light (through retro-reflective sensors), or by
detecting changes in the amount of light received (through diffuse and through-
beam sensors). Photo sensors are used in applications such as detecting the
presence of objects on a conveyor belt or measuring the position of a part in a
manufacturing process.
Inductive proximity sensors
These sensors use an electromagnetic field to detect the presence of metal
objects without physical contact. They are used in applications such as detecting
the position of metal components in a machine, or to prevent collisions between
two moving parts.
Capacitive proximity sensors
These sensors detect the presence of both metal and non-metal objects by
measuring changes in capacitance. They are used in applications such as detecting
the level of liquids in tanks or detecting the presence of objects in dusty
environments.
Ultrasonic sensors
These sensors use high-frequency sound waves to detect the presence of objects
and measure distance. They are used in applications such as measuring the level
of liquids in tanks or detecting the presence of objects in harsh environments.
Push buttons
These are simple switches that are manually operated to control the operation of
machines or processes. They are used in applications such as starting and
stopping a conveyor belt or controlling the movement of a machine.
Limit switches
These switches are used to detect the presence or absence of an object, usually at
the end of a travel or stroke. They are used in applications such as detecting the
position of a valve or detecting the end of a travel in a machine.
Pressure switches
These switches are used to detect changes in pressure and to control the
operation of machines or processes. They are used in applications such as
controlling the pressure of a hydraulic system or detecting leaks in a pneumatic
system.
Control transformers
These devices are used to convert voltage levels in industrial automation systems.
They are used to step up or step down voltage levels to match the requirements
of different devices or components in a system.
Signaling columns
These devices are used to provide visual and audible signals to operators in
industrial automation systems. They are used to indicate the status of machines
or processes or to provide warnings or alerts.
Fiber optic sensors
These sensors use optical fibers to detect changes in light intensity, phase, or
polarization. They are used in applications such as detecting the presence of small
objects or measuring temperature in high-temperature environments.
In summary, these sensors are used in a variety of industrial automation
applications to detect and measure physical variables and control the operation
of machines and processes. Each sensor has its own unique operating principle
and application, and the choice of sensor will depend on the specific
requirements of the system or process being automated.
Role of automation in industry
Firstly, automated machines have significantly lower production times.
Systems such as Automated Guided Vehicles, Industrial Robots, Automated
Crane and Conveyor Systems reduce material handling time.
Automation also reduces cost of production significantly by efficient usage
of energy, manpower and material.
The product quality that can be achieved with automated precision
machines and processes cannot be achieved with manual operations.
Moreover, since operation is automated, the same quality would be
achieved for thousands of parts with little variation.
Industrial Products go through their life cycles, which consists of various
stages. Automation also reduces the over-all product life cycle.
