ET-42053

INDUSTRIAL AUTOMATION
AND ROBOTICS

Prepared by : W.M.D. Kasun Chamikara Weerakoon

B.Sc.Eng.(Hons) USJP, M.Sc. In Industrial automation (Reading)
Course outline

Module code : ET 42053 – Industrial Automation and robotics

Credits :3

GPA/NGPA : GPA

Lectures : 2 hours per week

Lab/Assignments :2

Pre-requisites : None
Learning outcome

After completing this module, the students should be able to:

LO-1 : Displays knowledge of the application of the techniques of automation for the control of
manufacturing systems

LO-2 : Classifies types of robots and describes their constructional elements

LO-3 : Develops kinematic models of robots for analyzing robot mechanics

LO-4 : Manifests the knowledge of robotic control systems

LO-5 : Selects robots for the automation of industrial applications

Syllabus outline
1. Industrial Automation
Applications of automatic control systems and instrumentation, automated measurement and inspection,
elements and operation of vision systems and image processing, methods of illumination in vision systems for
shape and surface inspection, Application of PLCs and microcontrollers in manufacturing processes

2. Introduction to robots
Synthesis of elements with movability constraints; classification and specification of robots, Laws of Robotics,
Elements of robot anatomy

3. Kinematics of Manipulators
Hydraulic, pneumatic and electrical manipulators; End-effectors and their design

4. Robot Controllers
microprocessors or fluidics; Sensors – Tactile and non-tactile type

5. Management issues
Performance analysis of industrial robots and their manufacturing applications; Economics of robotics
Assessments

Continuous assessments : Laboratory practical assignments : Weightage 30%

End semester examination : LO-1 to LO-5 : Weightage 70%

Recommended Text

• Rehg, J Sand Kraebber, HW (2000),Computer Integrated Manufacturing, Prentice Hall

International.
• Jean, B W (1992), CIM Principles of Computer Integrated manufacturing, Wiley,
• David, D B, Mark, R H and Philip W (1991), Computer-integrated design and
manufacturing, McGraw-Hill.
• Groover, Mikell P., Automation production systems and computer integrated
manufacturing / Groover, Mikell P., New Delhi: Prentice-Hall, 1999.
• David, D B, Mark, R H and Philip W (1991), Computer-integrated design and
manufacturing, McGraw-Hill.
• Bedworth, D.D., Henderson, M.R., Wolfe, P.M. Computer Integrated Design and
Manufacturing, McGraw-Hill.
Automated control systems and instrumentations

What is automation?

Automation: To make a process in a factory operate by machines, in order to

reduce the amount of work done by humans and the time taken to do the work
Automated control systems and instrumentations

Automation- Ford-T Model (Year -1908)

https://www.youtube.com/watch?v=S4KrIMZpwCY
Automated control systems and instrumentations

Automation- Ford F150 Production Line (Year- 2020)

https://www.youtube.com/watch?v=xQVl4MhFUvc&t=3s
Automated control systems and instrumentations

Activity

Compare and contrast between the two systems (5 Minutes Exercise)

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Automated control systems and instrumentations

Why we need automation in the industry?

• Improvement of the productivity

• Accuracy of the production

• Saving the production cost

• Safety of the employees

Automated control systems and instrumentations

Control Systems
What is a control system?

Control system is a system provides an output or response for a given input

Automated control systems and instrumentations

Control Systems
The basic components of the control systems are,

1. Inputs – Inputs are the objectives of the control.

2. Control system –Components of the controller
3. Outputs-Outputs are the results /Response (Control Variable)
Automated control systems and instrumentations

Control Systems

Inputs Controller Output

• Maintain the systems

parameters(output) in • Motors
• Visual inputs the desired way • Pneumatic
• Position • Includes sets of
instructions, guidelines actuators
• Velocity etc. • Hydraulic
• Availability • Implemented as a
actuators
• Pressure software module in a
hardware (device) • Valves
• Temperature E.g.: PLC hardware and • Relays
program
Automated control systems and instrumentations

Control Systems

Inputs Controller Output

Sensors • Microcontrollers
• Digital signal Actuators
• Ultrasonic
processors(DSP) • Electric
• Inductive
• Programmable logic • Pneumatic
• Capacitive
devices(PLD) • Hydraulic
• Temperature
• Humidity • Programmable logic
controllers(PLC)
Automated control systems and instrumentations

Control Systems

Inputs Controller Output

Sensors • Microcontrollers
• Digital signal Actuators
• Ultrasonic
processors(DSP) • Electric
• Inductive
• Programmable logic • Pneumatic
• Capacitive
devices(PLD) • Hydraulic
• Temperature
• Humidity • Programmable logic
controllers(PLC)
Automated control systems and instrumentations

Control Systems
Sensors

• A sensor is a device that measures physical input from its environment and converts it into
data that can be interpreted by either a human or a machine.

• The input can be in the form of light, heat, motion, moisture, pressure or any other form
Automated control systems and instrumentations

Sensor Categorization

Sensors can be categorized as active sensors and passive sensors

Active sensors - Active sensors requires an external power source to respond environmental
input and generate output

(E.g. : Inductive sensors, Ultrasonic sensor , Infra-red sensor etc.)

Passive sensors –Passive sensors does not require external power source. They use environment
itself for the power

(E.g.: Temperature sensor(Thermocouple), Strain gauge, Humidity sensor, Light sensor etc.)
Automated control systems and instrumentations

Commonly used sensors in the industry

• Motion sensors -Motion sensors sense the physical motion of objects in a defined space.
These sensors may release energy in the form of microwaves, ultrasonic waves or light beams
• Pressure sensors – Pressure sensors can detect the pressure of the gases. They can also be
used to monitor the flow of gases or liquids as well
• Proximity sensors – Proximity sensors detect the presence of object and determine the
distance between the objects.
• Temperature sensors – Temperature sensors can be used to detect the temperature of solids,
liquids and gases
• Tactile/Touch sensors- Touch sensing devices can detect the contact on a monitored surface
Automated control systems and instrumentations

Commonly used sensors

General purpose sensors Industrial sensors

Automated control systems and instrumentations

Commonly used sensors in the industry

• Motion sensors -Motion sensors sense the physical motion of objects in a defined space.
These sensors may release energy in the form of microwaves, ultrasonic waves or light beams
• Pressure sensors – Pressure sensors can detect the pressure of the gases. They can also be
used to monitor the flow of gases or liquids as well
• Proximity sensors – Proximity sensors detect the presence of object and determine the
distance between the objects.
• Temperature sensors – Temperature sensors can be used to detect the temperature of solids,
liquids and gases
• Tactile/Touch sensors- Touch sensing devices can detect the contact on a monitored surface
Automated control systems and instrumentations

Control Systems

Inputs Controller Output

Sensors • Microcontrollers
• Digital signal Actuators
• Ultrasonic
processors(DSP) • Electric
• Inductive
• Programmable logic • Pneumatic
• Capacitive
devices(PLD) • Hydraulic
• Temperature
• Humidity • Programmable logic
controllers(PLC)
Automated control systems and instrumentations

Control Systems

Micro controllers

• Microcontroller is a small computer in a single IC containing a processor core, memory, and

programmable input and output peripherals
• Commonly used in the automated controlling systems and embedded systems
• Commonly used microcontrollers – PIC, ATMEL
Automated control systems and instrumentations
Control Systems
Digital signal processor (DSP)

• Specialized microprocessor with an architecture optimized for fast operational needs of digital
signal processing

• Large number of mathematical operations need to be performed quickly and repetitively on a

set of data for example processing of audio and video data

• E.g.: Texas instruments-C6000 series, DSPICSs-dsPIC33

Automated control systems and instrumentations
Control Systems
Digital signal processor (DSP)

ADC - Analog to Digital converter

DAC – Digital to Analog converter

Digital Signal Processing

Automated control systems and instrumentations
Control Systems
Programmable Logic controllers

• Digital computer used for industrial application such as automation, electromagnetic

processes, assembly lines in the factories etc.

• Designed for industrial conditions e.g. :Temperature ranges, Immunity to electrical noise,
resistance to vibrations etc.

• Can handle multiple inputs and outputs

• Used for discrete and continuous controls

E.g : Siemens, Rockwell Automation (Allen Bradley),Mitsubishi, Omron, Schneider , ABB,

Honeywell, Hitachi etc.
Automated control systems and instrumentations
Control Systems
Programmable Logic controllers

Siemens ABB Honeywell Omron

Mitsubishi Hitachi
Automated control systems and instrumentations
Control Systems

Programmable Logic controllers

Inputs Controller Output

Use of Programmable Logic

Controller (PLC)
Automated control systems and instrumentations
Control Systems
RECAP
Considering the control systems, we can basically categorize control systems as,
1. Open-loop control systems
2. Closed loop control systems

Open loop control systems

• The information relevant to controlled parameter is not used to adjust any of the system
inputs to compensate for the variation in the process variables
Automated control systems and instrumentations
Control Systems
RECAP

Closed loop control systems

Closed loop control system is a type of control system which the controlling action shows
dependency on the generated output of the system
Automated control systems and instrumentations
Control Systems
RECAP

Closed loop control systems

• Under closed loop control system, the feedback of the output can be given by a human
operator(Manual control) or by use of instruments (Automatic control)
• For automated systems, automatic control method is preferred.
Automated control systems and instrumentations
Control Systems

System control example 1- Governor

Automated control systems and instrumentations
Control Systems
System control example -1 Governor
Fuel amount
given into Speed of the
engine engine
Fuel Valve Engine
Desired
Engine
speed

Governor

Analog control
Automated control systems and instrumentations
Control Systems

System control example-2 (GITA)

Automated control systems and instrumentations
Control Systems
System control example-2 (GITA)-Closed loop control

Desired path
Controller Robot

Feedbacks from
the environment
e.g. Vision,
position , Speed
etc.
Digital control
Automated control systems and instrumentations
Control Systems
Control methods
Control

Continuous Sequential

Asynchronous Synchronous
Automated control systems and instrumentations
Control Systems
Continuous control

Inputs are sending information into the system all the time and outputs of the system are being
controlled at all the time. The change in the input directly change the output

(E.g. : Automatic street lights)

Switch Lamp
Light sensor
Light
level
Input Process Output Light

Set Level
Automated control systems and instrumentations
Control Systems
Sequential control

A series of different events takes place one after another. At the end of one event in the
sequence provides the signal to start the next event to start

E.g. : Traffic lights , Washing machines, Lifts/elevators