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IST / DEEC / API

Industrial Industrial AutomationAutomation(Automa(Automaçção de Processos Industriais)ão de Processos Industriais)

http://users.isr.ist.utl.pt/~jag/courses/api1112/api1112.html

Slides 2010/2011 Prof. Paulo Jorge Oliveira

Rev. 2011/2012 Prof. José Gaspar

IST / DEEC / API

A steam engine built to James Watt's patent in 1848 at Freiberg in Germany [wikipedia]

IST / DEEC / API

Many options for controlling real world devices! Why PLCs?

Microcontrollers Computer + IO PLC

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IST / DEEC / API

IST / DEEC / API

Objectives:Objectives:

Industrial Automation

• Analysis of systems for industrial automation.

• Methodologies for the implementation of solutions in industrialautomation.

• Programming languages of PLCs (Programmable Logic Controllers).

• CAD/CAM and Computerized Numerical Controlled machines.

• Discrete Event Systems Modeling.

• Supervision of Processes in Industrial Automation.

IST / DEEC / API

1. Introduction to Automation [1 week]Introduction to components and methodologies.

2. Introduction to PLCs [2 weeks]Components of Programmable Logic Controllers(PLCs). Architecture, functional structure, IO.

3. PLCs Programming Languages [2w]Standard languages (IEC-1131-3): Ladder Diagram; Instruction List and Structured Text.

4. GRAFCET (Sequential Function Chart) [1 week]Norm, elements of the language, modelling.

ProgramProgram atat a a glanceglance::


5. CAD/CAM and CNC Machines [1 week]Types of Computerized Numerical Controlled machines. Interpolation of trajectories. Flexible fabrication cells.

6. Discrete Event Systems [1 week]Modeling of discrete event systems (DESs). Automata. Petri networks. State and dynamics of PNs.

7. Analysis of DESs [2 weeks]Properties of DESs. Methodologies for the analysis: reachability graph and matricial equation.

8. DESs and Industrial Automation [1week]Relations GRAFCET / Petri networks. Analysis ofindustrial automation solutions as DESs.

9. Supervision of Industrial Processes [2w]Methodologies for supervision. SCADA. Synthesis basedon invariants. Examples of application.

IST / DEEC / API

AssessmentAssessment andand gradinggrading::

• 2 Preliminary laboratory assignments - training purposes (0% of the final grade).

• 2 Laboratory assignments (20%+20% of the final grade). Groups of 3 students.

• 1 Seminar (20% of the final grade). Topics to be selected with each group.

• Exams (40% of the final grade). Two written.

Upon student choice, the second exam can be oral.

• Minimum grade: 9.0/20.0 val. in each component.


Extra 1 (one) valor for students attending more than 50% of recitations.

IST / DEEC / API

9Jan, 30Jan 20123hExams

One date >= week 90.5h seminar3rd lab. assignment

07/11-02/12/20114 weeks2nd lab. assignment

10/10-04/11/20114 weeks1st lab. assignment

03-07/10/20111 week2nd preliminary lab.

26-30/09/20111 week1st preliminary lab.

Fenix 14/09/2011First weekLab. registration

Schedule Schedule ((laboratorieslaboratories & & examexam))::

Important: define the students’ representative

IST / DEEC / API

Schedule Schedule ((accordingaccording to ISTto IST--GOP)GOP)::

• Recitation classes

Monday 11.00 h – 12.30h Ea5Friday 11.00 h – 12.30h Ea4

• Lab. Classes (once per week)

Monday 09.30h – 11.00h L1 LSDC4 (room 5.21)Friday 09.30h – 11.00h L2 LSDC4 (room 5.21)

• Groups registration for the LaboratoryBy September 25th 2009 with the students’ representatives.


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BibliographyBibliography::


• Automating Manufacturing Systems with PLCs, Hugh Jack (online version available).

• Peterson, James L., "Petri Net Theory and the Modeling of Systems", Prentice-Hall,1981.

•Modeling and Control of Discrete-event Dynamic Systems with Petri Nets and other Tools, Branislav Hruzand MengChu Zhou, 2007. New reference…

--- secondary---

• Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, 1996.

• Petri Nets and GRAFCET: Tools for Modeling Discrete Event Systems, R. DAVID, H. ALLA, New York : PRENTICE HALL Editions, 1992.

• Computer Control of Manufacturing Systems, Yoram Koren, McGraw Hill, 1986.

• Cassandras, Christos G., "Discrete Event Systems - Modeling and Performance Analysis", AksenAssociates, 1993.

• Moody, J. e Antsaklis, Supervisory Control of Discrete Event Systems, Kluwer Academic Publishers, 1998.

IST / DEEC / API

Slides 2010/2011, Prof. Paulo Jorge OliveiraRev. 2011/2012, Prof. José Gaspar

Industrial Industrial AutomationAutomation(Automa(Automaçção de Processos Industriais)ão de Processos Industriais)

IntroductionIntroduction to to AutomationAutomation

http://www.isr.ist.utl.pt/~jag/aulas/api1112/api1112.html

IST / DEEC / API

Ctrl Actuator

Sensor

Robot +Robot + ... + Global

Controller

= Automated

Industrial

Process

The subject of this course

IST / DEEC / API

Cap. 1 Cap. 1 –– IntroductionIntroduction to to AutomationAutomation [1 [1 weekweek]]

Introduction to components in industrial automation.

Cabled logic versus programmed logic versus networked logic.

Introduction to methodologies for problem modeling. Methodologies of work.


IST / DEEC / API Chap. 1 – Introduction to Automation

ComponentsComponents usedused inin industrial industrial automationautomationThe production of increasing amounts ofgoods requires the storage and handling oflarge quantities of resources.

The use of specialized, automatic toolsare mandatory.

Consistent trend in the last three centuries(since the Industrial Revolution).

Automation was also fostered by theinvention of computers,

IST / DEEC / API

RoboticRobotic ManipulatorsManipulators

Chap. 1 – Introduction to Automation

IST / DEEC / API

Riding an ABB IRB 6600 Robot 1 [Youtube]API Note: please understand the power, and do not do this; keep always the safety!

IST / DEEC / API

EndEnd EffectorsEffectors


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Major characteristics:

• Number of degrees of freedom• Types of joints (prismatic/revolution/...)• Programming tools and environments(high level languages, teach pendent, ...)

• Workspace• Accuracy, fiability• Payload and robustness



IST / DEEC / API

Workspace:

Examples



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Central problems to adress and solve:

• Direct / Inverse kinematics• Trajectory generation• Coordinate frames where tasks are specified• Level of abstraction of the programming languages



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Use in Flexible

Cells of Fabrication:

it is required that the manipulatorshave correct interfaces for thesynchonization and inputs for

external commands.



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ComputerizedComputerized NumericalNumerical ControlledControlled MachinesMachines

Examples:Milling, Lathes, ...


• Number of degrees of freedom• Interpolation methods• Load/unload automation, and also intool change• Programming (high level languages, teach pendent, ...)• Workspace• Accuracy, reliability• Payload and robustness• Interface • Synchronization with exterior


MITSUI SEIKI Machining Center


ComputerizedComputerized NumericalNumerical ControlledControlled MachinesMachines

Compact CNC plasma cutting machineEffective cutting :1.5 m X 3 mPlasma torch cutting capacity up to 5cm (mild steel), Gas torch as option up to 10cm.

IST / DEEC / API

For transport...

SolutionsSolutions for for HandlingHandling materialsmaterials



• Load/unload automation

• Accuracy, reliability

• Payload and robustness

• Interface

• Synchronization with exterior

IST / DEEC / API

AGVsAGVs ((AutomaticAutomatic GuidedGuided VehiclesVehicles))



• Load/unload automation



• Interface

• Synchronization with exterior

IST / DEEC / API

Example of fleet operating in industry

AGVsAGVs ((AutomaticAutomatic GuidedGuided VehiclesVehicles))


IST / DEEC / API

ActuationActuation

Major characterísticas:

• Type of start

• Type of control



• Interface with exterior

• Synchronization

Motors


IST / DEEC / API

Exemple of AC motor, with driver


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Factury example: production of aluminium packs

SpecificSpecific ComponentsComponents


IST / DEEC / API

CabledCabled LogicLogic versus ...versus ...


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... versus ... versus ProgrammedProgrammed LogicLogic ……


IST / DEEC / API

... versus ... versus NetworkedNetworked LogicLogic


IST / DEEC / API Analysis of the auto-evaluation test

IST / DEEC / API

IntroductionIntroduction to to methodologiesmethodologies

for for problemproblem modelingmodeling inin

Industrial Industrial AutomationAutomation


IST / DEEC / API

Refs: Programmable Logic Controllers, Frank D. Petruzella, McGraw-Hill, 1996.

ActuatorsSolenoide valveCommand relayPneumatic cylinderElectro pneumatic

SensorsPressure switchTemperature sensorsProximity sensors

Relay diagram / Ladder diagram

IST / DEEC / API

SolenoideSolenoide ValveValve


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CommandCommand RelayRelay


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PushPush buttonsbuttons


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Selector Selector withwith threethree positionspositions


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CylindersCylinders ((PneumaticsPneumatics))



ValvesValves ((ElectroElectro--pneumaticspneumatics))

IST / DEEC / API

IST / DEEC / API

SensorsSensors

PressurePressure SwitchSwitch


IST / DEEC / API

TemperatureTemperature

SensorsSensors


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ThermocoupleThermocouple ProximityProximity detectordetector


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MagneticMagnetic detectordetector MagneticMagnetic switchswitch


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SymbolsSymbols associatedassociated to to allall componentscomponents

Standards


IST / DEEC / API

ContactContact DiagramDiagram or LadderLadder DiagramDiagram


Methodologies for the implementation of solutions in industrial automation

DeviceDevice: : RelayRelay

IST / DEEC / API

LadderLadder DiagramDiagram

OrOr

ContactContact DiagramDiagram


IST / DEEC / API

Methodologies for the implementation of solutions in industrial automation

ContactsContacts diagramdiagram

ExampleExample


IST / DEEC / API

ExampleExample::


IST / DEEC / API

LogicLogicFunctionsFunctions


IST / DEEC / API

ExampleExample::


IST / DEEC / API

To To exploitexploit thethe advantagesadvantages ofof ProgrammedProgrammed LogicLogic


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