COT: 06210

Industrial Automation Systems

Tutor: Eng. Stanley Mkolwe
Department of Computer Studies
Email: mkolwestanley@gmail.com
+255768660660
Introduction
 What is Automation?
• Is the delegation of human control function to
technical equipment for increasing
productivity, increasing quality, reducing cost
and increasing safety in working conditions
 What is Industrial Automation??
• Industrial automation refers to the use of various
control systems, such as computers or robots, and
information technologies for handling different
processes and machineries in an industrial
environment with minimal human intervention.
The main objective of industrial automation is to
improve efficiency, productivity, and safety by
reducing errors and minimizing the need for
human intervention in the manufacturing or
production process.
Types of Industrial Automation
 Defn
• Industrial Automation Systems refer to the
use of technology and control systems to
automate industrial processes and improve
efficiency, productivity, and safety. These
systems typically use advanced technologies
such as robotics, sensors, artificial intelligence,
and the Internet of Things (IoT) to monitor
and control various industrial processes and
machines.
 Uses
• Industrial automation systems can be used in
a variety of industries, including
manufacturing, energy, transportation, and
healthcare. These systems can automate
tasks such as assembly, material handling,
quality control, and machine maintenance.
By automating these processes, organizations
can reduce costs, increase productivity, and
improve safety.
 Components of Industrial Automation
Systems
• Industrial automation systems typically involve various components
such as sensors, actuators, programmable logic controllers (PLCs),
human-machine interfaces (HMIs), supervisory control and data
acquisition (SCADA) systems, and other specialized software and
hardware solutions. These systems work together to control and
optimize different processes in industrial settings, ranging from
assembly lines to chemical plants and beyond.
• Examples of industrial automation applications include robotic
assembly lines, automated material handling systems, CNC machines,
automated inspection and quality control systems, and more. Industrial
automation has revolutionized modern manufacturing and production,
allowing for higher levels of precision, speed, and efficiency, while
reducing waste and minimizing errors.
Features of SCADA (cont)
 Features of SCADA Software
• Dynamic process graphic
• Real-time and historical trending
• Alarms
• Recipe Management
• Security
• Device Connectivity
• Script for logic development
• Database connectivity
 Components of Industrial Automation
Systems (cont)
• Industrial automation systems typically consis t of several key components, including
hardware, software, and communication networks. The hardware component
includes the physical devices and sensors used to monitor and control industrial
processes, such as programmable logic controllers (PLCs), robots, and sensors. The
software component includes the programs and algorithms used to control the
hardware and analyze data, such as control software, data analytics software, and
machine learning algorithms. The communication network component includes the
infrastructure used to transmit data between devices and systems, such as local area
networks (LANs), wide area networks (WANs), and the internet.
• Effective implementation of industrial automation systems requires careful planning,
design, and testing. Organizations must identify the specific processes and tasks that
can benefit from automation and develop a clear understanding of the technology and
hardware requirements. They must also establish effective communication networks
and implement appropriate security measures to protect against cyber threats.
• Overall, industrial automation systems offer significant benefits to organizations in
terms of improved efficiency, productivity, and safety. However, successful
implementation requires a thorough understanding of the technology and a strategic
approach to implementation and maintenance
 Industrial Automation concepts in
Engineering
• Sensors and Actuators: Sensors are used to collect data about various process
parameters, such as temperature, pressure, and humidity, while actuators are used
to control the operation of machinery or equipment based on the sensor data.
• Control Systems: These systems are responsible for processing the data collected
by sensors and using it to control the operation of machinery or equipment. The
control system can be a computer-based system or a programmable logic
controller (PLC).
• Human-Machine Interface (HMI): The HMI is a graphical user interface that
enables operators to interact with the control system and monitor the operation of
the machinery or equipment.
• Robotics: Industrial robots are used for tasks such as assembly, material handling,
and packaging. They are programmable machines that can perform repetitive tasks
with a high degree of accuracy and speed.
• Supervisory Control and Data Acquisition (SCADA): This is a control system
architecture that uses computers, networked data communications, and graphical
user interfaces to manage complex industrial processes.
 Types of Industrial Automation
• Fixed Automation: This type of automation is designed to perform a specific task
repeatedly, such as assembly line production in a factory.
• Programmable Automation: In this type of automation, machines and
equipment can be programmed to perform different tasks. This type of
automation is commonly used in industries where multiple products are
produced in smaller quantities.
• Flexible Automation: This type of automation is similar to programmable
automation, but with the added ability to adapt to changes in the manufacturing
process. This makes it a good fit for industries with changing production needs.
• Integrated Automation: This type of automation brings together different
automation technologies, such as robotics, sensors, and controllers, to form a
single system that can be managed from a central location.
• Collaborative Automation: In this type of automation, humans work alongside
machines to perform tasks. This is becoming increasingly popular in industries
where machines are not able to replace human intuition or decision-making.
 Automation Equipment
• Robots: These are programmable machines that can perform a
wide range of tasks, such as assembly, welding, painting, and
material handling.
• Programmable Logic Controllers (PLCs): These are small computers
that are used to control and monitor industrial processes, such as
assembly lines, power plants, and water treatment systems.
• Motion Control Systems: These systems are used to control the
movement of machines or equipment, such as servo motors, linear
actuators, and hydraulic cylinders.
• Human-Machine Interfaces (HMIs): These are graphical user
interfaces that allow operators to interact with machines or
equipment, such as touchscreens, keyboards, and control panels.
• Sensors and Actuators: These are devices that can detect changes
in the environment, such as temperature, pressure, or motion, and
then trigger a response, such as turning on a motor or opening a
PROGRAMMABLE LOGIC CONTROLLER

PLC consist of Input Module, CPU with

Processor and Program memory, Output
module, Bus System, Power Supply
PLC System
 PROGRAMMABLE LOGIC CONTROLLER
• A Programmable Logic Controller (PLC) is a type of industrial
control system used in manufacturing and industrial
applications to automate various processes. PLCs are designed
to control electromechanical processes such as assembly lines,
conveyor systems, robotic devices, and more.
• A PLC works by receiving inputs from sensors and switches,
processing the input data using a program, and then controlling
outputs such as motors, valves, and other devices. The PLC's
program is written in ladder logic, a graphical programming
language that allows engineers to create complex automation
sequences in a visual and intuitive manner.
 PROGRAMMABLE LOGIC CONTROLLER
(cont)
• PLCs are known for their reliability and durability,
and are often used in harsh industrial environments
where traditional computers and electronics may
not be able to operate. They are also highly flexible
and can be easily reprogrammed or reconfigured to
adapt to changes in the manufacturing process.
• Some of the key benefits of using PLCs in industrial
automation include increased efficiency and
productivity, reduced downtime and maintenance
costs, and improved product quality and consistency.
PLC Programming and its elements
Functions of PLC
ADVANTAGES OF PLC
Disadvantages of PLC
 Human Machine Interface (HMI)
• Human Machine Interface (HMI) is a type of user interface that
allows interaction between humans and machines or devices. In
an industrial context, an HMI is a device or software application
that enables operators to control and monitor the status of
industrial automation equipment, such as programmable logic
controllers (PLCs), sensors, motors, and other devices.
• An HMI typically includes a display screen, input devices such as
buttons or touchscreens, and software that runs on a computer
or microprocessor. It is designed to be user-friendly, intuitive,
and provide real-time feedback to operators about the status of
the machines or processes being monitored.
 Key functions of an HMI
• Data visualization: An HMI provides visual representations of
data, such as graphs, charts, and gauges, to help operators
understand the current status of the system.
• Data entry: An HMI allows operators to enter data into the
system, such as set points, commands, or feedback.
• Alarm management: An HMI can alert operators to issues or
problems in the system through visual and audible alarms,
allowing for quick response and resolution.
• Control: An HMI allows operators to control the operation of
equipment, such as starting and stopping machines, adjusting set
points, and changing parameters.
• Historical data logging and analysis: An HMI can store data over
time, allowing for analysis of historical trends and patterns in the
system's performance.
 Communication Systems in Industrial
Automation Systems
Communication systems are a critical component of industrial automation systems. They
enable the exchange of data and commands between different components of the system,
including sensors, controllers, actuators, and human machine interfaces.
There are several communication protocols and technologies used in industrial automation
systems, including:
• Ethernet: Ethernet is a widely used protocol for industrial communication, providing high-
speed, reliable communication between devices. It is used for both local and wide area
networks and can support a range of applications.
• Modbus: Modbus is a serial communication protocol that is commonly used in industrial
applications. It is a simple, open protocol that can be used with a variety of devices and
supports communication over a wide range of distances.
• Profibus: Profibus is a widely used industrial communication protocol that is used in a variety of
applications, including factory automation, process automation, and building automation. It
supports both digital and analog signals and can operate over long distances.
• DeviceNet: DeviceNet is a communication protocol that is used to connect industrial devices,
such as sensors, actuators, and controllers, in a network. It provides a simple and cost-effective
solution for connecting devices, reducing wiring and installation costs.
• Industrial Wireless: Industrial wireless technologies, such as Wi-Fi, Zigbee, and Bluetooth, are
increasingly being used in industrial automation systems. They provide a flexible and scalable
solution for connecting devices and can be used in a wide range of applications.
 Applications of Industrial Automation
Systems
• Manufacturing
• Food
• Metals
• Power
• Mining
• Petrochemical/ Chemical
Advantages of Industrial Automation
Systems
Disdvantages of Industrial Automation
Systems
Disadvantages of Automation