Centro industrial de las empresas y los servicios

Industrial Automation System

Presentado por:
Carlos Andrés Ossa Castañeda
Hector Ivan Lozano Sanchez

Instructora:
Adriana

Neiva-Huila
22/04/2024
 MECHATRONIC DESING
A. The V model is a graphical representation of the systems development life cycle, used to
produce rigorous development life cycle models and project management models. the main
steps of the V model for the design of mechatronic systems:

1. Identification of needs and requirements: In this phase, the needs of the system are
analyzed and the functional and non-functional requirements are defined.

2. Conceptual design: the main functions, key components and the interactions between them.
The goal is to establish a solid foundation for detailed design.

3. Detail design: At this stage, diagrams, plans and technical specifications are created.

4. Test Implementation: Extensive testing is carried out to verify that the system meets the
established requirements.

B. Using the Functional Analysis System Technique (FAST), perform the analysis of a robotic
lawnmower (present minimum 3 sub-functions and specifications).

The Functional Analysis System Technique (FAST) is a valuable tool for breaking down and
understanding the functional structure of a technical system. We will apply this technique to the
analysis of a lawnmower robot, presenting at least three subfunctions and their specifications:

1. Subfunction: Lawn Cutting

• Description: The robotic lawnmower must be able to cut the grass efficiently and evenly.
Specifications:

• Cutting Height: The cutting height range, generally adjustable, can vary between 20 mm and
60 mm.
• Battery Life: Battery life determines how long the robot can operate before needing to
recharge. For example, some models offer up to 80 minutes of continuous operation.
• Cutting Technology: Some robots use rotating blades or discs for efficient and uniform
cutting
2. Subfunction: Navigation and Obstacle Avoidance
• Description: The robot must move autonomously through the cutting area without colliding
with obstacles.
Specifications:

• Collision sensors: The robot must be equipped with sensors that detect obstacles (such as
trees, garden furniture, etc.) and avoid collisions.
• Navigation System: Use technologies such as GPS, infrared sensors or ultrasound to trace
your route and avoid obstacles.

3. Subfunction: Cutting Area Management.

• Description: The robot must be able to cover the entire grass area efficiently.
 Specifications:
• Coverage Area: The ability of the robot to cut a specific area, which can vary from 300 m² to
1,500 m² depending on the model.
• Perimeter Cable: Some robots use a perimeter cable to define the limits of the cutting area
and prevent them from leaving the desired area.

C. Using the Functional Analysis System Technique (FAST), perform the analysis of the
Festo MPS solution used in lab sessions.
Festo MPS is a modular production system designed for teaching mechatronics and factory
automation. Let's see how it can be analyzed using the FAST technique:

1. Functions (F):
• Identification and classification of sample holders: The system allows the manipulation and
classification of different types of samples in the laboratory.
• Opening and closing sample containers: MPS modules can simulate the opening and closing
of sample bottles or containers.
• Dispensing fluids into microtiter plates: The system can accurately dispense minimum
volumes of liquids into assay plates.

2. Actions (A):
• Gripping and Handling: MPS modules are equipped with grippers and clamping systems for
gripping and handling samples.
• Opening and Closing: Rotating components and tongs enable opening and closing of sample
bottles.
• Contactless dosing: The dosing head provides precise dosing of liquids.

3. Outputs (S):
• Accurate and reproducible results: The MPS system ensures that automated processes are
traceable and consistent.
• Adaptability: The modularity of the system allows the degree of automation to be adjusted
according to the specific needs of the laboratory.
• Reduced development time: Using standard components and custom solutions accelerates
time to market

ROBOTIC

1. For stationary robots (robotic arms), define the following elements: link, joint, degree of
freedom, orientation, position, workspace, and payload.

• Link: Each rigid piece that connects two consecutive joints in a robotic arm.
• Joint: Point where two links come together and allow relative movement
between them.
• Degree of freedom: The number of independent movements a robot can make
in a given space.
• Orientation: The spatial arrangement of an object or tool, usually defined by
angles of tilt or rotation.
 • Position: Coordinates that describe the location of a point or the position of an
object in three-dimensional space.
• Workspace: Volume or area within which a robot can perform its movements.
• Payload: Maximum mass that a robot can safely and efficiently transport or
manipulate.

2. State the difference between linear and joint interpolation.

• Linear Interpolation:
• Definition: Linear interpolation involves moving the end-effector of the robot in
a straight line from one point to another.
• Method: The robot moves each joint simultaneously, maintaining a constant
speed for each joint.
• Result: The end-effector follows a straight-line path between the initial and final
points.
• Advantage: Simple to implement and provides smooth motion.

• Joint Interpolation:
• Definition: Joint interpolation involves moving each joint of the robot
individually from its initial position to its final position.
• Method: The robot moves each joint sequentially, with each joint reaching its
final position before the next joint starts to move.
• Result: The end-effector follows a path determined by the configuration of the
robot's joints.
• Advantage: Allows for more complex trajectories and control over the robot's
motion.

3. For the following stationary robot configurations, give an application for which
they are the most suitable choice: gantry, SCARA, and articulated.

1. Gantry Robot:
• Application:Pick-and-place operations in manufacturing,
packaging, and material handling industries.
• CNC (Computer Numerical Control) machining.
• Automated warehouse systems.
• Reasoning: Gantry robots are well-suited for applications
that require high-speed and high-precision movements
over a large workspace. They are particularly effective for
tasks that involve moving heavy payloads over large
distances with accuracy.

2. SCARA Robot (Selective Compliance Assembly Robot Arm):

• Application:
 • Assembly tasks in electronics, automotive, and consumer
goods industries.
• Material handling and sorting.
• Packaging and palletizing.
• Reasoning: SCARA robots are ideal for tasks that require
fast and precise horizontal movements. They excel in
applications that involve pick-and-place operations and
assembly tasks where high speed and repeatability are
critical

• 3. Articulated Robot:
• Application:
• Welding, painting, and sealing in automotive and
aerospace industries.
• Material handling and machine tending.
• Inspection and testing.
• Reasoning: Articulated robots offer versatility and
flexibility, making them suitable for a wide range of
applications. They are capable of reaching into confined
spaces and can perform complex movements with high
accuracy, making them ideal for tasks that require a high
degree of flexibility and dexterity.

MACHINE VISION
A. Mention what the steps in the machine vision process are.
1. Image Acquisition: Capturing images using cameras or other devices.
2. Preprocessing: Improving image quality through lighting correction, noise
removal, etc.
3. Segmentation: Identification and separation of regions of interest in the image.
4. Feature Extraction: Obtaining relevant features from the identified regions.
5. Recognition/Classification: Identification or classification of objects based on
extracted features.
6. Interpretation/Decision: Decision making based on the information obtained
from the recognition.
7. Post-processing: Refinement of results or correction of errors using additional
techniques.

B. What is an image processing operation? Mention three examples.

An image processing operation is any action performed on an image to modify its
appearance, extract useful information, or improve its quality. Three common examples
include:
1. Image Filtering: Application of filters to improve quality, eliminate noise or highlight
features. Example: smoothing filter to reduce noise.
 2. Geometric Transformations: Changes in the geometry or position of elements in the
image, such as rotation or scaling.
3. Thresholding: Conversion of an image into a binary image based on a threshold,
useful for segmenting objects. Example: global or local thresholding.

C. What is image segmentation? In addition, describe how this technique/process is

useful in industrial automation applications.

Image segmentation is a process in which an image is divided into meaningful regions or

segments for the purpose of identifying and isolating objects of interest within the image.
In industrial automation applications, image segmentation is essential to:
1. Quality Inspection: Allows you to detect defects in manufactured products, such as
cracks, dents or imperfections, guaranteeing the quality of the final product.
2. Object Classification: Facilitates the separation of different types of products or
components in production lines, based on criteria such as size, shape or visual
characteristics.
3. Robot Guidance: Helps industrial robots identify the location and orientation of
objects, allowing them to perform tasks such as picking, placing or assembling
components precisely and efficiently.
4. Process Control: Allows you to monitor the status of materials in the manufacturing
process, ensuring that operations are carried out according to the required
standards.

D. Explain the differences between backlighting and toplighting and give two examples
where each could be used.

Backlighting and toplighting are lighting techniques used in different contexts to optimize
the visual inspection of objects in computer vision applications, each with their own specific
advantages and applications.
1. Backlight: In backlighting, the light source is placed behind the object being
inspected. This creates a contrast between the object and the background, making it
easier to detect edges and features.

Examples of use:
• Inspection of defects in electronic components: Backlighting can reveal
imperfections such as cracks or inclusions in printed circuit boards.

• Inspection of packaged foods: Backlighting can identify contaminants or defects

in transparent or semi-transparent containers.

2. Superior Lighting:
 • In overhead lighting, the light source is placed above the object being inspected,
projecting light directly onto it. This provides uniform lighting and reduces
shadows.
Examples of use:

• Inspecting reflective surfaces: Overhead lighting can minimize unwanted

reflections on shiny surfaces, such as polished metals or plastics.

• Fruit and Vegetable Sorting: Overhead lighting can highlight characteristics such
as color, shape and ripeness in produce for automatic sorting.

INDUSTRIAL NETWORKS

1. Define network topology and give two examples of standard

topologies

Network topology refers to the arrangement of nodes and the interconnections

between them in a computer network. It describes how devices are connected
and how data flows between them.

Examples of Standard Network Topologies:

1. Bus Topology:
▪ Description: In a bus topology, all devices are connected to a single communication
line, often referred to as a "bus" or "backbone."
▪ Characteristics:
▪ All devices share the same communication line.
▪ Data is transmitted in both directions.
▪ If the main communication line fails, the entire network may become inoperable.
▪ Example:
▪ Small networks like small office/home office (SOHO) networks.
▪ Industrial control systems.
2. Star Topology:
▪ Description: In a star topology, each device on the network is connected to a central
hub or switch.
▪ Characteristics:
▪ All communication between devices must pass through the central hub or switch.
▪ Failure of one connection does not affect the rest of the network.
▪ Easy to add or remove devices without disrupting the network.
▪ Example:
▪ Ethernet LANs (Local Area Networks).
▪ WLANs (Wireless Local Area Networks).
2. For each layer of the ’five-layer internet protocol’ architecture, describe the main
characteristics of the layer and state at least an example of their
responsibilities/activities

1. Application Layer:
• Main Characteristics:
▪ The top layer of the TCP/IP model.
▪ Interacts directly with end-users and applications.
▪ Responsible for providing network services to user applications.
• Example of Responsibilities/Activities:
▪ Providing interfaces for email (SMTP), file transfer (FTP), web browsing
(HTTP), and remote login (SSH).
▪ Encoding, formatting, and encrypting data for transmission.

2. Transport Layer:
• Main Characteristics:
▪ Ensures end-to-end communication.
▪ Responsible for reliable data delivery and error recovery.
▪ Manages data flow and controls data congestion.
• Example of Responsibilities/Activities:
▪ Segmentation and reassembly of data.
▪ Error detection and correction (using protocols like TCP).
▪ Flow control and congestion control.

3. Network Layer:
• Main Characteristics:
▪ Responsible for logical addressing and routing.
▪ Determines the best path for data packets through the network.
▪ Handles addressing, routing, and traffic control.
• Example of Responsibilities/Activities:
▪ Logical addressing (IP addresses).
▪ Routing packets between networks.
▪ Fragmentation and reassembly of packets.

4. Data Link Layer:

• Main Characteristics:
▪ Transmits data frames from one node to another within the same
network segment.
▪ Provides error detection and correction at the physical layer.
▪ Ensures data integrity and controls access to the physical medium.
• Example of Responsibilities/Activities:
▪ Framing: Dividing data into frames.
▪ Error detection and correction (using protocols like Ethernet).
 ▪ Media access control (MAC addressing).

5. Physical Layer:
• Main Characteristics:
▪ The lowest layer of the TCP/IP model.
▪ Transmits raw bit streams over physical medium.
▪ Deals with the physical connection between devices.
• Example of Responsibilities/Activities:
▪ Transmitting and receiving raw data bits over a physical medium (e.g.,
copper wire, fiber optic cable, or wireless transmission).
▪ Signal modulation and demodulation.
▪ Bit synchronization and multiplexing.

3. What is multiplexing and demultiplexing?

Multiplexing:
• Definition: Multiplexing is the process of combining multiple data streams into a
single, high-speed data stream for transmission over a shared communication
channel.
• Purpose: Allows multiple signals to share a single transmission medium
simultaneously.
• Example: In telecommunications, multiple telephone conversations can be
multiplexed onto a single optical fiber using techniques like Time Division
Multiplexing (TDM) or Frequency Division Multiplexing (FDM).

Demultiplexing:
• Definition: Demultiplexing is the process of separating the combined,
multiplexed data stream back into its original individual data streams.
• Purpose: Reverses the process of multiplexing, allowing each data stream to be
directed to its intended recipient.
• Example: In a network router, demultiplexing is used to separate incoming data
packets based on their destination IP addresses, directing each packet to the
appropriate outbound interface for transmission to its intended destination.

4. Mention and describe three industrial network protocols, and mention three
industrial network
Applications.

1. Modbus
• Description: Modbus is a widely used serial communication protocol originally
developed by Modicon (now Schneider Electric) in 1979. It is a simple, robust,
and widely supported protocol that is used for communication between various
industrial electronic devices.
• Applications:
 • SCADA Systems (Supervisory Control and Data Acquisition): Modbus
is commonly used to connect remote terminal units (RTUs) and
programmable logic controllers (PLCs) to a SCADA system for monitoring
and control of industrial processes.
• Building Automation Systems: Modbus is used to connect sensors,
actuators, and other building automation devices to a centralized control
system for HVAC (Heating, Ventilation, and Air Conditioning), lighting,
and security.
• Industrial Automation and Control: Modbus is widely used for
communication between various industrial automation devices such as
PLCs, motor drives, and HMI (Human Machine Interface) devices.

2. PROFINET (Process Field Network)

• Description: PROFINET is an industrial Ethernet-based communication protocol
developed by PROFIBUS International. It is widely used in factory automation,
process automation, and motion control applications.
• Applications:
• Factory Automation: PROFINET is used for real-time communication
between programmable logic controllers (PLCs), I/O devices, and other
automation components in manufacturing plants.
• Process Automation: PROFINET is used to connect distributed control
systems (DCS), field devices, and supervisory systems in process
industries such as oil and gas, chemical, and pharmaceutical.
• Motion Control: PROFINET is used for high-speed communication
between motion controllers, servo drives, and other motion control
devices in applications such as robotics and CNC machines.

3. EtherNet/IP (Ethernet Industrial Protocol)

• Description: EtherNet/IP is an industrial Ethernet-based communication
protocol developed by Rockwell Automation. It is an open protocol that is widely
used in industrial automation and control applications.
• Applications:
• Integrated Manufacturing Systems: EtherNet/IP is used to connect
various automation devices such as PLCs, HMI devices, motor drives, and
sensors in integrated manufacturing systems.
• Machine-to-Machine Communication: EtherNet/IP enables real-time
communication between machines and devices on the factory floor,
allowing for seamless coordination and control of manufacturing
processes.
• Remote Monitoring and Diagnostics: EtherNet/IP allows for remote
monitoring and diagnostics of industrial equipment and processes,
enabling predictive maintenance and optimization of production
processes.
 5. Discuss the motivations and challenges for industrial wireless networks
implementation.

Motivations for Industrial Wireless Networks Implementation:

1. Flexibility and Mobility:

▪ Motivation: Wireless networks provide flexibility by eliminating the need for
physical cabling, allowing for easier reconfiguration and mobility of industrial devices
and equipment.
2. Cost Savings:
▪ Motivation: Wireless networks can reduce installation costs associated with running
cables, conduits, and cable trays, especially in large industrial facilities.
3. Scalability:
▪ Motivation: Wireless networks can easily scale to accommodate changes in the
industrial environment, allowing for the addition of new devices and equipment
without the need for extensive rewiring.
4. Remote Monitoring and Control:
▪ Motivation: Wireless networks enable remote monitoring and control of industrial
equipment and processes, allowing for real-time data collection, analysis, and
decision-making.
5. Increased Productivity and Efficiency:
▪ Motivation: Wireless networks can improve productivity and efficiency by providing
faster communication and response times, reducing downtime, and enabling
predictive maintenance.

Challenges for Industrial Wireless Networks Implementation:

6. Reliability and Security:
▪ Challenge: Industrial wireless networks must be reliable and secure to ensure
continuous operation and protect sensitive data from unauthorized access or
interference.
7. Interference and Signal Attenuation:
▪ Challenge: Industrial environments are often characterized by high levels of
electromagnetic interference (EMI) and signal attenuation, which can degrade
wireless signal quality and reliability.
8. Latency and Determinism:
▪ Challenge: Some industrial applications require low latency and deterministic
communication, which can be challenging to achieve in wireless networks, especially
in environments with high network congestion or interference.
9. Quality of Service (QoS):
▪ Challenge: Industrial wireless networks must provide adequate Quality of Service
(QoS) to meet the performance requirements of critical applications such as real-time
control and monitoring.
10. Compatibility and Interoperability:
▪ Challenge: Industrial wireless networks must be compatible with existing wired
networks and industrial protocols to ensure seamless integration and
interoperability with legacy systems.
11. Range and Coverage:
▪ Challenge: Industrial wireless networks must provide sufficient range and coverage
to support communication across large industrial facilities, including areas with
obstacles or harsh environmental conditions.
12. Regulatory Compliance:
▪ Challenge: Industrial wireless networks must comply with regulatory requirements
and standards related to wireless communication, electromagnetic compatibility
(EMC), and safety.

6. What are the main challenges regarding industrial networks security system.

1. Legacy Systems and Equipment:

• Challenge: Many industrial control systems (ICS) and operational technology
(OT) devices were not designed with security in mind and may lack built-in
security features.
• Impact: Legacy systems may be more vulnerable to cyber threats and may
require additional security measures to protect against modern cyber attacks.

2. Connectivity and Interoperability:

• Challenge: Industrial networks often consist of a mix of legacy and modern
devices from different vendors, making it challenging to ensure seamless
connectivity and interoperability while maintaining security.
• Impact: Incompatible or poorly integrated security solutions can create
vulnerabilities and gaps in the security posture of industrial networks.

3. Remote Access and Third-Party Connections:

• Challenge: The need for remote monitoring, maintenance, and support often
requires external parties, such as vendors and contractors, to have remote access
to industrial networks.
• Impact: Unauthorized or insecure remote access can provide entry points for
cyber attackers, leading to potential breaches and compromise of industrial
systems and data.

4. Lack of Segmentation and Access Control:

• Challenge: Industrial networks are often flat and lack proper segmentation and
access controls, making it easier for attackers to move laterally within the
network once they gain access.
• Impact: Without adequate segmentation and access controls, attackers can
easily escalate privileges, access critical systems, and cause widespread damage.
5. Operational Technology (OT) vs. Information Technology (IT) Divide:
• Challenge: There is often a disconnect between IT and OT teams regarding
security practices, priorities, and technologies, leading to gaps in security
management and enforcement.
• Impact: Misalignment between IT and OT security strategies can result in
inadequate protection of industrial networks and systems against cyber threats.

6. Lack of Security Awareness and Training:

• Challenge: Many industrial organizations lack security awareness and training
programs for employees and staff working with industrial control systems.
• Impact: Human error, such as clicking on malicious links or falling victim to
social engineering attacks, can lead to security breaches and compromise
industrial networks and systems.

7. Complexity and Scale:

• Challenge: Industrial networks are often large and complex, with a diverse
range of devices, protocols, and systems that need to be secured.
• Impact: Managing security across large and complex industrial networks can be
challenging, requiring robust security policies, procedures, and technologies to
effectively detect, prevent, and respond to cyber threats.