BOE 302_ UNIT - I Introduction to Automation

History of Automation
 Term Automation was coined in the automobile industry about 1946 to describe the increased use of
automatic devices and controls in mechanized production lines.
 Origin of the word is credited to D.S. Harder, an engineering manager at the Ford Motor Company at the
time.
Automation provides benefits to virtually all of industry. Here are some examples:

 Manufacturing, including food and pharmaceutical, chemical and petroleum, pulp and paper
 Transportation, including automotive, aerospace, and rail
 Utilities, including water and wastewater, oil and gas, electric power, and telecommunications
 Defense
 Facility operations, including security, environmental control, energy management, safety, and other
building automation
 and many others

Automation involves a very broad range of technologies including robotics and expert systems, telemetry
and communications, electro-optics, Cybersecurity, process measurement and control, sensors, wireless
applications, systems integration, test measurement, and many, many more.

Definition of Automation

The word ‘Automation’ is derived from greek words “Auto”(self) and “Matos” (moving). Automation
therefore is the mechanism for systems that “move by itself”.

Automation is the technique of making an apparatus, a process, or a system operate automatically.

Automation is the integration of machines into a self-governing system by replacement of human labor with
machines power of some form.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 1
BOE 302_ UNIT - I Introduction to Automation

Basic Elements of Automation

Why Automation?

Need of Automation

Advantages of Automation
Reduction in production time – having a machine that is automated definitely speeds up the production time
since the machine needs no thinking, there is better repeatability, and less human error.
Increase in accuracy and repeatability – when an automated machine is programmed to perform a task over
and over again, the accuracy and repeatability compared to an employee is far greater.
Less human error – no one is perfect, and we are all prone to making mistakes. Which is why a machine that
performs repeated tasks is less likely to make mistakes than an employee.
Less employee costs – by adding automated machines to an operation, means less employees are needed to get
the job done. It also indicates less safety issues, which leads to financial savings. With having less employees,
there are numerous costs that are diminished or reduced such as payroll, benefits, sick days, etcetera.
Increased safety – having automated machines means having less employees who perform tasks that can be
dangerous and prone to injury, which can make the work environment safer.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 2
BOE 302_ UNIT - I Introduction to Automation

Higher volume production – investing in automated equipment creates a valuable resource for large production
volumes, which in turn, will increase profitability

Disadvantages of Automation
Less versatility – by having a machine that can perform a certain task limits to the flexibility and variety of tasks
that an employee could do.
More pollution – different types of machines operate using motor which may require gases or chemicals in order
to operate. This can cause an increase in pollution in the workplace.
Large initial investment – automated machines can be one of the most costly operating costs for a company.
With automated machines running anywhere between thousands and millions of dollars depending on the type
and degree of automation.
Increase in unemployment – by increasing the amount of automation, there are less employees required causing
high unemployment rates.
Unpredictable costs – there can be several unpredictable costs that may exceed the actual cost saved by the
automation itself. Some of these costs could include research and development costs of automating a process,
preventative maintenance costs, and the cost of training employees to operate automated machines.

Automation Vs Mechanization

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 3
BOE 302_ UNIT - I Introduction to Automation

Types of Automation

Fixed Automation

Process Automation Flexible Automation

Programmable
Automation
Industrial
Automation
Automation
Fixed Automation
Home or Building
Automation

Discrete / Manufacturing
Flexible Automation
Automation

Programmable
Automation

 In process industries, the product results from  The manufacturing industries make the product
many chemical processes based on some raw out of materials using machines/robotics.
materials.  Some of these manufacturing industries include
 Some of the industries are pharmaceuticals, textile and clothing, glass and ceramic, food and
petrochemical, cement industry, paper industry, beverages, paper making, etc.
etc.  New trends in manufacturing systems have been
 Thus the overall process plant is automated to using automation systems at every stage such as
produce the high quality, more productive, high material handling, machining, assembling,
Automation of production
reliable control systems
of the physical can be
process inspection,
classified into three basic
variables. types:and packaging.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 4
BOE 302_ UNIT - I Introduction to Automation

1. Fixed automation (Hard Automation)

2. Programmable automation (Soft Automation)
3. Flexible automation.

1. Fixed automation (Hard automation): Fixed

automation refers to the use of special purpose
equipment to automate a fixed sequence of processing or
assembly operations. Each of the operation in the
sequence is usually simple, involving perhaps a plain
linear or rotational motion or an uncomplicated
combination of two. It is relatively difficult to
accomodate changes in the product design. This is called
hard automation.

Advantages:
1. Low unit cost
2. Automated material handling
3. High production rate.

Disadvantages:
1. High initial Investment
2. Relatively inflexible in accommodating product changes.

2. Programmable automation (Soft 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.

Advantages:
1. Flexible to deal with design variations.
2. Suitable for batch production.

Disadvantages:
1. High investment in general purpose equipment
2. Lower production rate than fixed automation.
Example: Numerical controlled machine tools, industrial robots and programmable logic controller.

3. Flexible automation: Flexible automation is an extension of programmable automation. A flexible automation system
is capable of producing a variety of parts 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 set up.

Advantages:
1. Continuous production of variable mixtures of product.
2. Flexible to deal with product design variation.

Disadvantages:
1. Medium production rate
2. High investment.
3. High ‘unit cost relative to fixed automation.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 5
BOE 302_ UNIT - I Introduction to Automation

Difference Between Fixed, Programmable and Flexible Automation

Levels of Automation

1. Device level – actuators, sensors, and other

hardware components to form individual
control loops for the next level
2. Machine level – CNC machine tools and similar
production equipment, industrial robots,
material handling equipment
3. Cell or system level – manufacturing cell or
system
4. Plant level – factory or production systems level
5. Enterprise level – corporate information system

Difference between Open-Loop Control System and Closed-Loop Control System

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 6
BOE 302_ UNIT - I Introduction to Automation

Control System is a system in which the behavior of the system is determined by a differential equation. It manages the
devices and the systems using control loops. There are Open-Loop Control System and Closed-Loop Control System.

Open-Loop Control System is used in applications in which no feedback and error handling are required. It is simple
and economical but optimization is not possible. Maintenance of OPCS is easier.

Advantages of Open-Loop Control System:

Simple to design and implement.
Low cost and maintenance.
High speed of operation.
Can be used for systems that don’t require precise control.
Disadvantages of Open-Loop Control System:
Lack of accuracy and precision.
Susceptible to external disturbances and variations.
Not suitable for systems that require a high degree of accuracy and precision.
Closed-Loop Control System is used in applications where feedback and error handling are required. It is a complex
system and not economical but optimization is possible. Maintenance of CLCS is
difficult.

Advantages of Closed-Loop Control System:

High accuracy and precision.
Robust against external disturbances and variations.
Suitable for systems that require a high degree of accuracy and precision.
Disadvantages of Closed-Loop Control System:
Complex to design and implement.
High cost and maintenance.
Slower speed of operation compared to open-loop control systems

Similarities between Open-Loop Control System and Closed-Loop Control System:

 Both types of control systems aim to achieve a specific output or goal.
 Both types of control systems use sensors and actuators to measure and control the output.
 Both types of control systems rely on a feedback mechanism to monitor and adjust the output.
 Both types of control systems use mathematical models or algorithms to calculate the output.
 Both types of control systems can be used in various applications, such as industrial control, robotics, and
automation.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 7
BOE 302_ UNIT - I Introduction to Automation

The following table differentiates Open-Loop Control System and Closed-Loop Control System:

Role of Industrial Automation in Industry 4.0?

Industry 4.0 automation now places a greater emphasis on task margins of error reduction than just efficiency and
profitability. It also increases flexibility and significantly improves the quality of manufacturing processes. Some
of the roles which were automated under 4.0 include:
IoT: The Internet of Things (IoT) is a term that refers to the links between actual physical objects, such as
machinery or sensors, and the Internet.
IIoT: The term “Industrial Internet of Things” (IIoT) describes how people, data, and machines are connected to
manufacturing.
Artificial intelligence (AI): It is the term used to describe a computer’s capacity to carry out operations and make
decisions that, in the past, would have required some degree of human intelligence.
Cloud computing: Utilizing networked remote computers hosted on the Internet to store, manage and process
data.
Smart Factory: A smart factory invests in and uses Industry 4.0 tools, techniques, and strategies.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 8
BOE 302_ UNIT - I Introduction to Automation

Advantages of automation in Industry 4.0

The main benefits of automation in Industry 4.0 are the following:

 Cost efficiency: Reduces labour costs, automating portions of processes that do not require human
judgment to leverage human creativity in obtaining new skills and activities where required. In
addition, Virtual and/or Augmented reality technologies facilitate learning processes and improve
productive organisation models.
 Competitive advantages: Standardisation and automatic redesign of procedures, making them
constant and accurate, being able to operate 24/7. As a result, increased productivity, capacity and
process quality, minimising inaccuracies and the cost of downtime.
 Scalability and flexibility: Adding or changing tasks requires training for a human operator, while
Robots and devices are reconfigurable and can be accurately programmed in a tight time frame, thus
reducing process execution and response time.
 Time reduction: Reduced information processing times. The platforms with which automation works
have a large capacity for the storage and management of data derived from processes.
 Utmost safety: The production line can assign machines and/or robots to hazardous tasks that pose a
high risk to staff. In addition, advanced comprehensive security controls can be implemented for
equipment, components, people, and systems. Cybersecurity is one of the essential technologies to
safeguard companies’ privacy.
 Improved control: These types of processes are monitored and recorded, which generates ‘Big Data’;
valuable information to identify patterns, improve processes, and implement changes to prevent future
events. In addition, process optimisation opens the door to ‘insourcing’. This infrastructure
centralisation improves data quality and consistency and leads to analytical improvements.

Automation challenges in Industry 4.0

Although automation 4.0 has a high potential for companies, it is necessary to be aware and assess the challenges
posed by this new business model:

 Investment and infrastructure: Adapting the existing infrastructure to the new one can be a big
challenge for companies, who will have to invest large sums of money and in many cases get access
to financing in order to acquire the necessary infrastructure and decide which solutions will be the most
profitable.
 Strategic Plan: The transition not only depends on investment in machinery and hardware, but
requires time, a change of mind set, an intelligent analysis and a detailed strategy that maximises
implementation and capitalises on the investment.
 Human factor: Smart devices are no longer working tools but have become an intelligent workforce,
so millions of jobs are predicted to be lost as a result of automation processes. Society and large
enterprises should therefore encourage continuous training for workers to develop relevant digital skills
that complement with this new type of industry.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 9
BOE 302_ UNIT - I Introduction to Automation

Define the role of Industrial Automation in Industry 4.0. What are the Advantages and
Challenges of automation in Industry 4.0?
Industry 4.0 automation now places a greater emphasis on task margins of error reduction than just efficiency and
profitability. It also increases flexibility and significantly improves the quality of manufacturing processes. Some
of the roles which were automated under 4.0 include:

 IoT: The Internet of Things (IoT) is a term that refers to the links between actual physical objects, such
as machinery or sensors, and the Internet.
 IIoT: The term “Industrial Internet of Things” (IIoT) describes how people, data, and machines are
connected to manufacturing.
 Artificial intelligence (AI): It is the term used to describe a computer’s capacity to carry out operations
and make decisions that, in the past, would have required some degree of human intelligence.
 Cloud computing: Utilizing networked remote computers hosted on the Internet to store, manage and
process data.
 Smart Factory: A smart factory invests in and uses Industry 4.0 tools, techniques, and strategies.

Advantages of automation in Industry 4.0

The main benefits of automation in Industry 4.0 are the following:

Cost efficiency: Reduces labour costs, automating portions of processes that do not require human judgment to
leverage human creativity in obtaining new skills and activities where required. In addition, Virtual and/or
Augmented reality technologies facilitate learning processes and improve productive organisation models.

Competitive advantages: Standardization and automatic redesign of procedures, making them constant and
accurate, being able to operate 24/7. As a result, increased productivity, capacity and process quality, minimising
inaccuracies and the cost of downtime.

Scalability and flexibility: Adding or changing tasks requires training for a human operator, while Robots and
devices are reconfigurable and can be accurately programmed in a tight time frame, thus reducing process
execution and response time.

Time reduction: Reduced information processing times. The platforms with which automation works have a
large capacity for the storage and management of data derived from processes.

Utmost safety: The production line can assign machines and/or robots to hazardous tasks that pose a high risk to
staff. In addition, advanced comprehensive security controls can be implemented for equipment, components,
people, and systems. Cybersecurity is one of the essential technologies to safeguard companies’
privacy.

Improved control: These types of processes are monitored and recorded, which generates ‘Big Data’; valuable
information to identify patterns, improve processes, and implement changes to prevent future events. In addition,
process optimisation opens the door to ‘insourcing’. This infrastructure centralisation improves data quality and
consistency and lead to analytical improvements.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 10
BOE 302_ UNIT - I Introduction to Automation

Automation challenges in Industry 4.0

Although automation 4.0 has a high potential for companies, it is necessary to be aware and assess the challenges
posed by this new business model:

Investment and infrastructure: Adapting the existing infrastructure to the new one can be a big challenge for
companies, who will have to invest large sums of money and in many cases get access to financing in order to
acquire the necessary infrastructure and decide which solutions will be the most profitable.
Strategic Plan: The transition not only depends on investment in machinery and hardware, but requires time, a
change of mind set, an intelligent analysis and a detailed strategy that maximises implementation and capitalises
on the investment.
Human factor: Smart devices are no longer working tools but have become an intelligent workforce, so millions
of jobs are predicted to be lost because of automation processes. Society and large enterprises should therefore
encourage continuous training for workers to develop relevant digital skills that complement with this new type
of industry.

Define industrial automation and its classification.

Automation is the technique of making an apparatus, a process, or a system operate automatically. It can be also
defined as that Automation is the integration of machines into a self-governing system by replacement of human
labor with machines power of some form.

Industrial Automation refers to the use of control systems, such as computers or robots, and information
technologies for handling different processes and machinery in an industry to replace human intervention. It is a
step beyond mechanization, where human operators control machinery, and automation significantly increases
production efficiency, consistency, and quality while reducing human error and operational costs.
Industrial automation encompasses a variety of technologies including robotics, computer-aided manufacturing
(CAM), and computer numerical control (CNC). It involves the integration of various control systems to ensure
that manufacturing processes are efficient, reliable, and flexible.

Vikash Kumar, Asst. Prof, Mech. Engg Deptt., Ajay Kumar Garg Engineering College 11