INDUSTRIAL ELECTRONICS

Introduction to Industrial
Electronics
Presented by:
Aaron Charles R. Alday, ECT
SIGNIFICANT EVENTS

**Major events and inventions that permitted

industry to move from the craftsperson and
manually operated machines to the fully
automated production systems used nowadays
1801
• Joseph Jacquard invents a textile
machine that is operated by punch
cards
1834
• Charles Babbage invents a
numerical engine that would later
become the computer
1890
• Nicola Tesla demonstrates remote
control of a boat using an
electronic control
1930
• A. O. Smith Company puts the first
fully automatic factory into operation
making card frames. The new facility
makes one frame every six (6)
seconds.
1938
• Walter Schottky, a native of Germany,
invents the semiconductor diode.
1941
• The first variable-speed AC motor
control system is offered to industry
1945
• The first computer, called ENIAC, is
built.
1947
• American scientists, William
Shockley, Walter Brattain and John
Bardeen, invent the transistor.
1948
• Norbert Wiener, a professor at
Massachusetts Institute of
Technology (MIT), publishes
Cybernetics.
1954
• George C. Devol develops the first
programmable robot and coins the term
universal automation; Chappman, Fuiler
and Pearson of Bell Labs develop silicon
photovoltaic cell.
1956
• George C. Devol and Joseph F. Engelberger
form the first successful robot-manufacturing
company under the name Unimation
1957
• The first solid-state variable-speed motor
controller is offered to industry.
1958
• Kearney and Trecker introduce a
computer-controlled, all-in-one
machine tool.
1960
• Lasers for material processing
and communications are
developed
1961
• The first Unimate robot is
installed to unload a die-casting
machine.
1968
• The programmable logic controller was
developed with support from General
Motor’s Oldsmobile Division.
1969
• Molins Machine in Britain uses
computers to control industrial
processes.
1970
• Franz Morat develops the first
computer-controlled, totally automatic,
industrial knitting machine.
1971
• Ted Hoff at Intel Corporation invents the first
microprocessor.

1973
• Richard Hohn from Cincinnati Milacron
Corporation invents the first commercially
available, minicomputer-controlled industrial
robot called The Tomorrow Tool (T3).
1977
• ASEA Brown Boveri Robotics (ABB) Inc., a
European robot company, offers two sizes of
electric-powered industrial robots with a
microcomputer controller.
1978
• Apple Computer Company introduces
the Apple II, the first widely used home
microcomputer.
1980
• The concept of computer-integrated
manufacturing (CIM) is introduced in
Japan, the United States, and Great
Britain.
1984
• Adept Corporation introduces a direct-
drive robot arm.
1994
• Intel introduces the 64-bit
microprocessor
1998
• Tag-based programmable logic
controllers start to be adapted by
the industry.
2000
• Device networks like DevicNet,
ControlNet, Foundation Field bus,
Profibus and Ethernet/IP are adopted
frequently by industry.
2001
• Wireless networks find
broader application in
automation.
A review of the nearly 200 years of
inventions, discoveries and
developments indicates several
important concepts:
• Industrial control has been evolving
for many years.
• The evolution in industrial control
and automation was preceded by
the developments in electronics and
computers.
• The need for engineers and
technicians trained in industrial
electronics concepts has existed for
over fifty years and will continue in
the future.
 CLASSIFICATION OF
INDUSTRIAL CONTROL
ELECTRONICS
MANUAL MACHINES
• A large group of machines operated
in the manual mode to support
every operation in the production of
PROGRAMMABLE
goods.
MACHINES
• A large group of computer
numerically controlled (CNC)
machines that perform a variety of
materials processing tasks like
machining metal parts or forming
plastic parts in an automatic mode
under program control.
ROBOTS
• Industrial machines capable of being
programmed and tooled to perform many
different manufacturing tasks, including
welding, material handling, painting and
MATERIAL MOVING
assembly.

SYSTEMS
• A broad range of systems that move raw
materials and finished goods through
manufacturing using a variety of
automation technologies, including belt
and chain conveyors and automatic
guided vehicles.
MATERIAL TRACKING
SYSTEMS
• Identification technology represented by a broad range of systems
that identify raw materials and finished goods during manufacturing
using bar codes and other object identification and recognition
technologies.

MATERIAL STORAGE AND

RETRIEVAL SYSTEMS
• An automated system, called Automatic Storage and Retrieval
System (ASRS), stores and retrieves raw materials, finished parts
and completed products. The system’s range in size from bench top
models with less than 100 storage locations to systems that fill
entire warehouses and have thousands of pallet-size storage
locations.
FLEXIBLE MANUFACTURING
CELLS (FMC)
• A group of related machines that perform a
particular process or step in a larger
manufacturing process. A typical FMC
consists of a CNC process machine, some
type of material handling and possibly a
FIXED AUTOMATION
robot.
MACHINES
• A large class of dedicated automation
machines designed to manufacture and
assemble parts into finished products with a
minimum of human intervention.
FLEXIBLE MANUFACTURING
SYSTEMS
• One or more manufacturing machines
integrated by an automatic material
handling system. Its operation is
controlled by a computer and it could
be a combination of FMCs linked by a
CONTINUOUS
material handling PROCESS
system.
SYSTEMS
• Computer-controlled production
systems used in the preparation of
food in the production of chemicals,
pharmaceuticals, and paper products.
MANUFACTURING
CLASSIFICATIONS
 PROJECT
JOB SHOP
REPETITIVE
LINE
CONTINUOUS
P Products in this category are
complex, have many parts and
R are most often, one of a kind.
O
The production and assembly
J labor is mostly manual, with
machines used to make some of
E the component parts
C eg: (would be used to build) oil
refineries, large office buildings,
T cruise ships and large aircraft
J Non-complex products with few
parts and small production
O volume; the size and weight of
B parts are very small (as
compared to the project
category)
Combinations of manual and
S automated machines are used to
produce the parts.
H
O eg: machining a
P nonstandard-size bearing
for a pump
R Orders for repeat business
E approach 100%; multiple-year
contracts on products is
P common and production
E quantity varies widely but is
T generally high
Automated processes and
I special-purpose automation is
often used because the product
T orders are predictable and
I spread over long period
eg: components for the
V automotive industry like water
E pumps, alternators and
transmissions
L (1) The delivery time required by
the customer is often shorter
than the total time it takes to
build the product; (2) The
I product has many
options/models
(3) An inventory of

N subassemblies is normally
present

E eg: automotive production

C Describes a flow of products
O from a manufacturing system
that is never interrupted;
N systems producing this type of
T product are highly automated
I with little manual labor.
The products produces in this
N kind of method are frequently
U products that customers must be
able to buy whenever they
O desire.
U
eg: breakfast cereal,
softdrinks, mouthwash and
S
toothpaste
Manufacturing Systems and Industrial Control
Electronics
TECHNOLOGY PYRAMID
AND TREE
 TECHNOLOGY PYRAMID
O Illustrates a set of necessary competencies for
the engineers and technicians who design,
build, test, program and maintain automated
production systems.
O Gives a snapshot of technologies associated
with industrial control, starting with single
components like switches and building to fully
functional automation systems.
O Indicates the order in which the technologies
should be studied, starting from the bottom
level.
 9
Data
Networking
(16)
8
Open- and closed-loop
process control and
industrial robots
(14,15)
7
Programmable logic controllers
and embedded
microcontrollers (12, 13)

6
DC, AC and special purposes
motors and controls (9, 10, 11)

5
Safety (8)
4
Discrete and Analog Sensors (6,7)
3
Solid-state AC switching devices (5)
2
Solid-state devices and operational amplifiers (3,4)
1
Mechanical and Electromechanical Devices (2)
TECHNOLOGY PYRAMID
O Bottom three levels
- Focus on learning the devices that are the
building blocks for industrial automation.
- Covers devices as simple as push-button
switch and as complex as an operational
amplifier.
- Switches, transistors, operational
amplifiers and AC switching devices
identified are used to build the discrete
and analog sensors at the next highest
level.
TECHNOLOGY PYRAMID
O Safety (Level 5)
- A high priority in industry and
understanding of it is needed before
proceeding to the higher levels

O Sensors, Motors and Solid-State

Principles (in Level 4 and 6)
- Components for the controllers in
Level 7
 TECHNOLOGY PYRAMID
O Level 8
- Covers open- and closed-loop process control and
robots used in industrial automation such as
computer numerical controlled mills and latches
and systems to move, store and track material and
assembled products.
- Systems identified in this level are built using the
devices and concepts in the first seven levels.

O Data Networking (Top Level)

- Describes how the information from all of the
different industrial automation system is transferred
between the automated machines and systems.
 TECHNOLOGY TREE
OProvides a hierarchical list of the
software and devices that are used
in automation systems in industries.
OProvides an excellent overview of
the topics that should be mastered
by engineers and technicians
working with these industrial
electronic systems.
Anouncement:

Quiz 1 (Written Quiz):

Coverage: Introduction to Industrial Electronics
No. of items: 1 - 20
THANK YOU 