Lecture - 2 Architecture of Industrial Automation Systems

Instructional Objectives

After learning the lesson a student should be able to:

• Name the Levels of Industrial Automation

• Describe the hierarchical structure of Industrial Automation System

• Describe essential functions of each level

• Mention three differences between Automatic Control and Supervisory Control

Table of contents

1. The Structural Elements of Industrial Control Sensor System

2. Sensing and Actuation.Industrial Sensor Systems

•  Sensing Element

3. Signal Conditioning and Processing:

•   Analog Electronic Signal Conditioning

•   Digital Processing

•   Signal Processing

•   Diagnostics/Calibration/Configuration

•   Communication

•   Signal Protection and Transmission

4. Actuator System

5. Industrial Actuator System

• Electronic Signal Processing

• Electrical Power Amplification

• Electro-Hydraulic/Pneumatic/Mechanical

• Feedback Control for Precision

• Auxiliaries for Lubrication/Cooling/Filtering

• Remote Operation and Safety

• Energy Optimisation

6. Automatic Control Loop

7. Automatic Control.Continous Variable Control

•  Controls Analog Continous Process Variables

• Cloused Loop Control

• Track/ Hold Set Point

• Reject Disturbance

• Generic P-I-D /Special purpose

• Tunable

8. Automatic Control.Sequence/Discrete Event Control

• Control of Discrete Valued Process Variables

  - On/ Off

  - High/ Medium/ Low

• Discrete Sensing: Limit Switch/ Pressure Switch/ Photo Switch

• Interlock, Alarm

• PLC/ Industrial PC/ Dedicated Processor based

• No tuning needed

• Status/Sequencing/ Timing control

9. Supervisory Control

• Set point computation

  - Impact on energy, quality, production volume

• Start up/ Shut down/ Emergency Operations

• Control Reconfiguration/ Tuning

• Performance Monitoring/ Diagnostics

• Operator Interface

• Domain dependent: Physical model based

• Hard/Soft real time

• Expensive

10. Production Control

• Process Scheduling

• Material Handling

• Maintenance Management

• Inventory Management

• Quality Management

• Resource Optimistaion Technology

• On-line Non-real time

11. Lesson Review

• Hierarchical Structure of IA

• Level 0: Sensors and Actuators

• Level 1: Automatic Control

• Level 1: CV and DE Control

• Level 2: Supervisory Control

• Level 3: Production Control

• Level 4: Enterprise Control

12. Points to Ponder

• Explain the difference between Continuous Variable and Discrete Event Control

• Draw the block diagrammatic structure of

  - An Industrial Sensor

  - An Industrial Actuator

• Explain the function of each block

• Define Automatic Control. Distinguish it from Supervisory Control. Give an example

• State three major functions for each level of the Automation Pyramid