What Is Industrial Automation

IA
§ 1 What is Industrial Automation?
1.1 Definition of Several Basic Terms

1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical representation of Technical Processes
1.8 Effects of Industrial Automation on People, Society and
Environment
© 2004 IAS, Universität Stuttgart 9

Chapter 1: What is Industrial Automation? IA
Chapter 1 - Learning targets
– to know what Industrial Automation is

– to understand what a real-time system is
– to know what is meant by the „degree of automation“
– to recognize the different kinds of computer deployment
– to be able to differ between product automation and plant automation
– to know the components of an industrial automation system
– to know the different levels of an industrial automation system and their
requirements
– to be able to classify processes in technical systems
– to know the different kinds of graphical representation of technical
processes
– to become aware of the responsibility of an automation engineer

IA

1.1 Definition of Several Basic Terms
1.2 Degree of Automation and Computer Deployment
1.3 Automation of Technical Products and Technical Plants
1.4 Components of an Industrial Automation System
1.5 Levels of Process Management and Automation Functions
1.6 Technical Systems
1.7 Graphical Representation of Technical Processes
1.8 Effects of Industrial Automation on People, Society and Environment

1.1 Definition of Several Basic Terms IA
Definition 1:
A technical process is a process during which material, energy or
information is altered in its state. This modification of state can imply
the transition from an initial state to a final state.
process, procedure, event
TECHNICAL
Initial state of Final state of
PROCESS
material, energy material, energy
or information or information
in a technical system
transformation
transport storage
Technical process means flow of material, energy or information

Examples
Initial State Technical Process Technical System Final State
Low ambient
Heating of a house Oil-fueled heating system Higher ambient temperature
temperature
Dirty
Washing process Washing machine Fresh laundry
laundry
Transportation and distribution

Unsorted parcels Parcel distribution system Parcels sorted by destinations
processes
Energy of fossil or Energy transformation and

Power plant Electric energy
nuclear fuels energy generation processes
Parts to be
Storage process High bay warehouse Parts compiled for commissions
stored
Train at location A Traffic process Train Train at location B
Monomere substance Chemical reaction Chemical reactor Polymeric substance
Untested device Test process Test laboratory Tested device

Parts without a drill-
Drilling process Drilling machine Parts with drill-hole
hole
Information on pollution
System for air
Pollutants Pollution monitoring concentrations are indicated
pollution monitoring
in monitoring center

Definition 2: DIN 66201

A process is the entirety of all interacting processes within a
system that transforms and stores material, energy or information.
A technical process is a process in which its physical parameters
are recorded and influenced by technical means.
effecting output
variables quantities
material,
material, energy
energy or
or information
information
TECHNICAL PROCESS outflow
inflow
in a technical system
– from simple to highly complex washing machine, power plant

– different partial processes are combined to an overall process
car with automotive electronics

Technical system with technical process
actuating measured
signals signals
material, energy material, energy

or information or information
inflow Technical System outflow
(device,machine
or technical plant)
process
influencing process
information outcome
information
the technical
Technical process runs on
Process
technical system
process process
input output

Example
actuating signals measured signals
Technical Plant
substance A
substance B
substance C
Technical Process
feed
substance A outflow
reac- empty
fill reactions
feed tion
product
substance B substance C
– technical plant: chemical reactor

– technical process: 3 sub-processes (fill, reaction, empty)

Industrial automation
= process + automation
automat = independently
cigarette vending machine operating
technical systems
ticket vending machine
automation = to enable machines,

office automation, installations and facilities
to operate independently
traffic automation,
railway automation,
industrial automation

Industrial automation
= the automation of a technical process
Industrial automation system
= technical system with technical process

+ computer and communication system
+ process operators

Structure of an industrial automation system
People
(process operators)
for managing and operating
the technical
process as well as
intervening in
exceptional situations
process process
influence outcome
computer and
communication system
consisting of e.g.,
programmable logic
controllers (PLC), industrials PCs,
micro controllers,
bus systems, etc.
control signals
signals to the from the
technical technical
process process
technical system
(technical product or
technical plant), in which
a technical process
takes place

Industrial automation system

– Goal is the automation of operations in the technical process with the
help of appropriate information processing units
– Human operators only place requests on the operating results

automation of the technical
process in the foreground
Process control system

– Goal is the management of the procedure of the technical process by
human operators, supported by the automation of individual
operations
operation in the
– Managing refers to controlling and regulating
foreground
Process computer sciences
– Goal is an automation software system
– Real-time system computer and communication
system in the foreground

Definition: Real-time operation (DIN 44300)

Real-time operation is the operation of a computer system, in which
programs required for the handling of incoming data are in constant
operation so that the processing results are available within a given
period of time.
This data may appear according to a random time distribution or at
regular intervals.
Features of a real-time system
– Hardware/software system
– Data reception, data processing, data delivery to the process within a

given time interval
– External events
– Processing priority
Real-time system allows real-time operation

Requirements on real-time systems
– Timeliness
reaction right on time
not too soon, not too late
– Simultaneousness
simultaneous reaction to various events
parallel processes
– Dependability
reliable, safe, available
important reason for purchase
– Predictability
all reactions must be predictable and deterministic
comprehensible in case errors occur

Industrial automation system as real-time systems
people external
influences
time time
sensor signals
computer and technical process
communication in a
system control signals technical plant
operating personnel
computer and communication

system
technical process

Features
Processors applicable in a process automation system are freely

programmable digital processors (computers) that have to show
mainly 3 features:
– Compliance of real-time operation requirements, that are:

recording, processing and output of process data in a timely
manner
– Possibilities for input/output of process signals (directly or via a
communication system) for process connection
– Processing of numbers, characters and bits
In 60th and 70th years specific „process computers“

- Antiquated term, because differences have disappeared
IA

1.1 Definition of several basic terms
1.2 Degree of automation and computer deployment

1.3 Automation of technical products and technical plants
1.4 Components of an industrial automation system
1.5 Levels of process management and automation functions
1.6 Technical systems
1.7 Graphical representation of technical processes
1.8 Effects of industrial automation on people, society and environment

1.2 Degree of automation and computer deployment IA
Degree of automation
The sense and benefit of an automation depends on the technical process

(accessible / inaccessible) and the general conditions (economically
reasonable / senseless). The degree of automation describes the extend of
the processes included in the automation.
bandwidth: from zero up to fully automated operation
Caution! - Also with fully automated operation the human being can
make interventions (set point default or malfunction)!
Types of operation
– Off-line operation (operation with indirect process connection) with the

lowest degree of automation
– On-line / open-loop operation (open on-line operation) for a medium
degree of automation
– On-line / closed-loop operation (closed on-line operation) for a high
degree of automation

Operation without computer use

general management
orders
operation
accounting
operation
protocol process
management
applications
process
personnel
no automation
control and
regulation devices
display device and
graphical recorder
manual
device
technical plant

Off-line operation (indirectly connected operation)

input,
operation modes
instructions
General management orders
operation operation
protocol input protocoll
Off-line
computer process
management
instructions
process
personnel low degree of
control and automation, no
regulation devices display and connection to
grapical recorder
the technical
process
manual
device
technical plant

On-line/ open-loop operation of a computer system
general management orders
operation
monitoring operation
protocol
medium degree
control board instructions of automation,
data acquisition
open-loop from the
process-
technical process
control and personnel
regulation devices
computer
system
manual
on-line
device
technical plant

On-line-/ closed-loop operation of a computer system
operation management
and control
orders
on-line and
closed-loop
operation
protocol high degree of
automation, data
recording and
computer and communication system
influence of the
emergency
emergency instruments technical process
control
technical plant

IA



1.3 Automation of technical products and technical plants IA
Product automation
industrial automation systems, in which the technical process takes place

within a device or within a single machine
large quantities
Plant automation
industrial automation systems, in which the technical process is composed of

single partial processes that take place on greater, often geographically wide
spread plants
unique systems

Examples
Examples of products in Examples of technical plants
product automation in plant automation
heating systems power plants (steam generators,
washing machines turbines, generators)
sewing machines energy grid
kitchen appliances (e.g., dish washer, high bay warehouse
microwave, etc.) parcel distribution installations
TVs, radios chemical reactors
cameras process engineering installations
alarm systems steel production plants
toys milling installations
navigation systems railway traffic system (long distance
trains, commuter railways, metros)
answering machines
traffic light installations
musical instruments
gas supply installations
machine tools
purification and water plants
measuring devices
building system installations
automobiles with sub-systems:
motor control, ABS, distance warning laboratories and test fields
system, route planning, environmental measurement installations
etc. etc.

Characteristic criteria regarding product automation

– Technical process in a device or machine (embedded systems)
– Dedicated automation functions simple
– Automation computer in the form of a micro controller or PLC
– Few sensors and actuators
– Degree of automation 100%, on-line/closed-loop operation
– High quantities (serial or mass products)
– Engineering and software costs of inferior importance since they are

distributed among large unit numbers

Structure with simple product automation
user
or
operator
set values
display
example:
manipulated variables
micro controller
kitchen appliance
process results
technical product

Example of a simple product automation (chalkboard writing)

Structure with complex product automation
user
or
operator
micro-
controller
bus-system example:
automotive
electronics
micro- micro- micro-
controller controller controller
1 2 n
subsystem subsystem subsystem

1 2 n
technical product

Characteristic criteria regarding plant automation

Technical process in an industrial plant, often geographically wide spread
Extensive and complex automation functions
PLCs, PCs and process control systems are used as automation computer
systems
Large number of sensors and actuators
Medium to high degree of automation
Unique system
Engineering and software costs are critical for overall costs

Structure for a larger technical plant

factory bus
monitoring,
operating, level 3
protocolling
master
computer PC PC
pant bus
level 2
PLC PLC PLC
field bus field bus

level 1
sub- sub- sub-

system system system
technical plant

IA


1.4 Components of an industrial automation system IA
technical components
Overview of an industrial
automation system
technical system to facilities necessary for

be automated automation
(automation object) (automation system)
technical technical facilities for

product plant user - process
communication
interface to the hardwired

technical process: individual
sensors and actuators devices
communication automation
system computer system
communication bus system for the

system close to the hardware system automation
communication between
process (field bus) (device system) software system
automation computers
computer process user system

hardware periphery software software

Sensors
– Acquisition of information on the progression of process variables

– Sensors, detection devices, measuring devices
– Conversion into electrical or optical signals
examples: temperature,
pressure ,
velocity
Actuators
– Conversion of control information in order to influence process variables

– Actuators (correcting element)
examples : relays,
magnets,
servomotors

Communication system in product automation

Simple products user
or
operator
set values
– few sensors and actuators
display
manipulated variables
– short line distances micro controller
process results
technical product
Complex products
– communication between subsystems via bus system

– examples: CAN bus, Interbus-S user
or
operator
micro-
controller
bus system
micro- micro- micro-

controller controller controller
1 2 n
subsystem subsystem subsystem

1 2 n
technical product

Communication system in plant automation
– Many sensors and actuators, geographically distributed

– Many automation computers, geographically distributed
Communication tasks on several levels

factory bus
observation, level 3
– Factory bus master
operating,
protocolling
computer PC PC
plant bus
– Plant bus (process bus) level2
PLC PLC PLC
field bus field bus

– Field bus level1
sub- sub- sub-

system system system
technical plant

Different forms of automation computers
– Programmable logic controller (PLC)
– Micro controller
– Personal computer (PC)
– Process control system

Automation software system

– Set of all programs necessary for the execution of automation tasks,
including their documentation
– Differentiation between executive and organizational/administrational

tasks
Executive programs Organizing and administrating

(application software) programs (operating software
or system software)
input measured values
software device drivers
calculation of control
variables operating system

Application software System software

programs for
programs for
organizing of
acquisition of
application
process variables
programs
programs for
operating system
programs for managing
process
peripherical devices
monitoring
programs for programs for

process organizing data traffic
control with
external memories
programs for programs for the

process dialogue between
regulation human and computer
programs for
process
compilation programs
optimization and
management
programs for
run-time
process safety
programs
and security

IA


1.5 Levels of Process Management and Automation Functions IA
Model of levels in the management of a technical process
levels of
hierarchy levels of distribution levels of a company
long-term business management

strategic distribution policy level
level
production and operation

dispositive distribution planning management level
level
tactical
distribution tactics process control level
level
level of measuring
operative controlling and regulating
sales process variables
level
(process variable level)
technical process in a
field of action market technical system

Time requirements on the different levels

business management level: Effects ranging between
months-years
production and operation Effects ranging between

management level: days-weeks-months
process control level:

Effects ranging between
minutes-hours
process variable level: Effects ranging between

microseconds-seconds

Automation functions
Levels of a company Automation functions
business cost analysis,

management level statistical evaluations
production and work sequence planning,

operation capacity optimization,
management level evaluation of process results
process monitoring,
process control start-up and shut-down,
level malfunction handling, process
guidance, process security
measuring, controlling,
manipulating, regulating
process variable
interlocking, emergency
level
handling of process variables,
shut-down, protection
recording and influencing

field level process variables with sensors
and actuators

IA


1.6 Technical systems IA
Types of occurring process variables (1)
– Process variables, that are allocated to the course of physical

state-variables with a continuous or piecewise continuous range of values
example: temperatures in a heating system
– Process variables, that are allocated to certain discrete process states

• physical variables with a continuous range of values that characterize
the process states
• binary process variables that are allocated to state transitions i.e., to
events that cause the change of state
example: switch setting: 0/off - 1/on

Types of occurring process variables (2)
– Process variables that are allocated to individually identifiable objects

• physical variables with a continuous range of values
example: temperature of a slab in a clogging mill,
size of a part in a store
• non-physical variables
example: type, design, application, depot number

Definition of three process types in technical systems
– continuous processes
– sequential processes, discrete event type processes
– object-oriented processes
Caution! - a clear distinction is not always possible !
example: transportation as a continuous and object-oriented process

Continuous processes in technical systems
processes containing time-dependent continuous

Characteristics
process variables
Process variables physical variables with a (at least piecewise)

continuous range of values
Examples generation processes,

transformation processes,
movements, etc.
Mathematic differential equations (time as an independent

models variable), transfer functions

Sequential processes in technical systems
processes containing sequences of

Characteristics
different, distinguishable process states
Process variables binary signals that cause or indicate discrete process

states as well as continuous physical variables
allocated to process states
Examples sequences of process states during start-up or
shut-down of a turbine, sequence of states during the
operation of an elevator, sequence of states during
production using a machine tool
Models flow charts, function plans according to DIN 40719,
state models, Petri nets

Object-oriented processes in technical systems
Characteristics processes during which individually identifiable

objects are transformed, transported or stored
Process variables physical variables with a continuous range of values

or non-physical variables (e.g., type, design, application,
bay number) that are allocated to the objects, as well
as binary variables, that cause or indicate state changes
of objects
Examples processes during the manufacturing of parts,
traffic processes, storage processes,
information processes in computers
Models simulation models, queue-models, state models,

Petri nets, OO-models

Classification methods
Classification according to the kind of...

– transformed or transported medium
material related processes, energy related processes,
information related processes
– effect
generation processes, distribution processes, storage processes
– material-related transformation
chemical processes, production processes
– dominating process type

flow processes (continuous), successive processes (sequential),
piece-related processes (object-related)

Assignment of technical production processes to process types
Technical processes Process types
Energy-related continuous processes,

processes sequential processes
chemical continuous processes,
processes sequential processes
production continuous processes,
processes sequential processes,
object-related processes
material-handling continuous processes,
processes sequential processes,
object-related processes
Technical processes can contain processes of different types,

on the other hand a process in turn can be a technical process.

Examples:
– Generation of electric energy in a turbo generator

• continuous process
• sequential process (start-up sequence of plant)
Energy-related processes
– Batch processes
• single process steps are continuous processes
• sequence of steps is a sequential process
Chemical processes
– Manufacturing a swivel
• transportation of the machine’ parts is an object-related process
• manufacturing process consists of a sequence of steps (“mount part”,
“drive machine to position “ etc.), thus it is a sequential process
• cutting process is a continuous process
Production process

IA



1.7 Graphical representation of technical processes IA
Flowchart
– Similar to block diagrams used in control engineering
– Processes and process steps are represented as rectangles
– Arrows represent the information or material flow
– Bundles of connections are shown as double lines with arrow
Example:
additive
crush
additive solvent
crushed
raw
material
dissolve reaction separate
inter- final product
material mediate
solvent dissolved product

Information/material-oriented representation
– Information/materials as circles
– Processes/functions as linking arrows
Example:
additive crus
h
additive
crushed
re tio
n solvent
ac a
tio
n p ar
se
intermediate
material diss
olve
product se
pa
n rat
tio i
material eac on
final
r
dissolved product
o lve
diss
solvent

Phase model representation
– Mixture of flowchart and information/material-oriented representation
Example:
sub
additive process additive solvent
crushed
„crush“
inter-
reaction mediate separate
product
raw
material
sub material
final
process dis-
product
„dissolving“ solved
solvent

Examples for the flowchart representation

additive
crushing
raw material
final product
solvent dissolving reaction separation
solvent
simple flow chart
additive solvent
heating steam
350 kg/h 700 kg/h
3 bar
x z1
M1 M2
raw material
M M W1
800 kg/h
solvent
1000 kg/h heating 1 bar
steam 108° C
B1 B2
1 bar 1 bar final product
20° C 20° C 1450 kg/h
depot
P1 P2
process flow chart

heating steam
solvent
5 bar
700 kg/h
V301
F1
additive
350 kg/h V302 V304
V206
V303
X
M TRC
FRC 3h
M1 Z1
raw material 1.02
1.01
800 kg/h
M2 M W1
V101 V102 V103 3h
V201 V202 V203 V105 V112 LRC
V111 1.04
K1
solvent FRC
V305
1000 kg/h 2.01 M
V204 3h
B1 B2 A1
TRC
1.02
W3
LRC LRC
1.03 1.04 V306 V301
M
3h LRC+
M M
W2 V302 V116
3h 3h 1.04
P1 P2 V303
V106 V107 V106 V110
final product
1450 kg/h
condensate
Pipes and instrumentation flow diagram

IA


1.8 Effects of industrial automation on people, society and
environment

1.8 Effects of Industrial Automation on People, Society and Environment IA
Intentional (positive) effects

– Simplified and more convenient operation
• automation of a washing machine
• automation of a heating system
– Production of better, cheaper products of equal quality with lowered

production costs
• automation of chemical production processes
– Reduction of hazards to people

• ABS system
• traffic system automation (like inductive train security, automatic
barrier close)
– Better, more humane working conditions

• automation of painting or foundry work
– Securing jobs through higher competitiveness

• use of robots in automobile manufacturing

Unintentional (negative) effects

– Redundancy of workers may lead to unemployment
• use of robots in manufacturing
– Restructuring of jobs due to changes in work flow and fields of work

• lower/ higher qualified jobs
• drop of ancillary tasks
• increase of jobs in the service sector
– Reduction of human relationships

• introduction of ticket vending machines and information systems
– Increase of stress and reduction of relaxing tasks

• automation of testing systems
– Overtaxing in difficult situations

• safety-critical decision in a nuclear power plant

–Industrial automation has effects on:

people
society
environment
energy and resources
The automation engineer is responsible for the effects of

industrial automation!
Direct, immediate responsibility

– damages in industrial automation systems designed by him
– violations of generally accepted guidelines and regulations
(regulations of the VDE, etc.)
– safety of automation systems
Indirect, collateral responsibility

– unintentional side effects
Dilemma: trade-off between benefits and damage

Question referring to Chapter 1.1
In addition to the correctness of the data the timeliness of data is of high

relevance in industrial automation. Which of the following statements do
you agree?
Answer
ü Early data is bad data

¨
ü Late data is bad data
¨
f ¨ As fast as possible data is correct data
f ¨ Precise data is bad data
ü No data is bad data
¨

A company wants to automate the production of refrigerators. For this

purpose, a new production line shall be constructed. In this production
line, the coolant will be filled in and the rear will be screwed to the case.
Which kind of automation system is this ?
Answer
The given system is a plant automation system. The production process

(assembly line) shall be automated and not the product itself.

For the control computer of a production line of refrigerators (described in

the last question) the company received two offers:
• „ordinary“ PC 3000,- €
• industrial PC with the same performance 5000,- €
Which computer would you choose ?
Give reasons for your choice and explain the difference in price.
Answer
There is no difference in the performance range of the two computers. The

main difference between an „ordinary“ PC and an industrial PC is that the
industrial PC is especially built to endure the higher stress in industrial
environments (temperature variations, EMI, vibrations, etc.)
In this case, therefore, the choice would be an industrial PC.

The IAS modular production system is shown below.

Which kind of processes do you identify in this system?
sequential processes (all

Answer
individual assembly stations are
passed through sequentially)
Object-related processes
(all work steps are done at
the barrels)
Continuous processes
(e.g. transportation)

Crosswords to Chapter 1

Crosswords to Chapter 1
Across
3 Denomination of systems which have to be in synchrony with
activities happening in an external system. (4,4,6)
5 Process type of manufacturing of parts. (6,8)
7 Simultaneous reaction to various events (16)
9 Process in which the physical parameters are recorded and
influenced by technical means. (9,7)
10 Automation technical analog to "tactical level". (7,7,5)
Down
1 Device used to influence process variables. (8)
2 Term describing the extent in which a process is automated.
(6,2,10)
4 Graphical representation of technical processes, similar to block
diagram. (9)
6 Reaction to an event right on time (10)
8 Device used to measure process variables. (6)

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IA

§ 1 What is Industrial Automation?

1.1 Definition of Several Basic Terms

© 2004 IAS, Universität Stuttgart 9

Chapter 1 - Learning targets

– to know what Industrial Automation is

© 2004 IAS, Universität Stuttgart 10

§ 1 What is Industrial Automation?

© 2004 IAS, Universität Stuttgart 11

process, procedure, event

Technical process means flow of material, energy or information

© 2004 IAS, Universität Stuttgart 12

Transportation and distribution

Energy of fossil or Energy transformation and

Train at location A Traffic process Train Train at location B

Monomere substance Chemical reaction Chemical reactor Polymeric substance

Untested device Test process Test laboratory Tested device

© 2004 IAS, Universität Stuttgart 13

Definition 2: DIN 66201

– from simple to highly complex washing machine, power plant

© 2004 IAS, Universität Stuttgart 14

Technical system with technical process

material, energy material, energy

© 2004 IAS, Universität Stuttgart 15

– technical plant: chemical reactor

© 2004 IAS, Universität Stuttgart 16

automation = to enable machines,

© 2004 IAS, Universität Stuttgart 17

= the automation of a technical process

Industrial automation system

= technical system with technical process

© 2004 IAS, Universität Stuttgart 18

Structure of an industrial automation system

© 2004 IAS, Universität Stuttgart 19

Industrial automation system

– Human operators only place requests on the operating results

Process control system

© 2004 IAS, Universität Stuttgart 20

Definition: Real-time operation (DIN 44300)

Features of a real-time system

– Data reception, data processing, data delivery to the process within a

Real-time system allows real-time operation

© 2004 IAS, Universität Stuttgart 21

Requirements on real-time systems

not too soon, not too late

comprehensible in case errors occur

© 2004 IAS, Universität Stuttgart 22

Industrial automation system as real-time systems

computer and communication

© 2004 IAS, Universität Stuttgart 23

Processors applicable in a process automation system are freely

– Compliance of real-time operation requirements, that are:

– Processing of numbers, characters and bits

In 60th and 70th years specific „process computers“

§ 1 What is Industrial Automation?

1.2 Degree of automation and computer deployment

© 2004 IAS, Universität Stuttgart 25

The sense and benefit of an automation depends on the technical process

– Off-line operation (operation with indirect process connection) with the