Industrial Automation System Design: Introduction (Assignment Questions) Solution

ASSIGNMENT-1

QUESTION 1.1 What is industrial automation (IA)?

ANS.

Rahul Shandilya:  Automation = self dictated (ancient Greek)
Industrial automation is the use of control devices such as PC/PLC/PAC/DCS etc to control industrial processes & machinery replacing human operator

 Pawan Rana:  Automation is the use of machines, control systems and information technologies to optimize productivity in the production of goods and delivery of services. The correct incentive for applying automation is to increase productivity, and/or quality beyond that possible with current human labor levels so as to realize economies of scale, and/or realize predictable quality levels. The incorrect application of automation, which occurs most often, is an effort to eliminate or replace human labor. Simply put, whereas correct application of automation can net as much as 3 to 4 times original output with no increase in current human labor costs, incorrect application of automation can only save a fraction of current labor level costs. In the scope of industrialisation, automation is a step beyond mechanisation

Vikas Malviya:  the use of robotic, machines & PC,PLC,PAC etc devices to complete the manufacturing task in industries

Question 1.2 Differentiate between IA & mechanization?

Rahul Shandilya:  Mechanization provided human operators with machinery to assist them with the physical requirements of work
Automation is a step beyond mechanization
Automation greatly reduces the need for human sensory and mental requirements as well

Vikas Malviya : MECHANIZATION is the process of replacing human or animal labor by machines. mechanization needs human operators to machineries.  AUTOMATION is a step beyond mechanization in which human operators are replaced by automatic industrial processors such as PLC etc

Question 1.3 Why manufacturing/industrial process to be automated?

Rahul Shandilya 1. To increase productivity
2. Reduce production cost
3. To improve product quality
4. To increase the flexibility and convertibility in the manufacturing process
5. Environmental friendly
6. Operator friendly

Question 1.4 Make a list of IA system tasks?

ANS: IA System Task are following
1. Logic control
2. PID control
3. Advanced control
4. Data acquisition, analysis & presentation
5. Data logging
6. Process visualization
7. HMI design
8. Integration with the enterprise net work
9. Motion control
10. Vision systems
11. Enterprise Resource Planning (ERP) systems
12. Maintenance etc

‎1.5 Draw process automation system hierarchy flow chart?

 1.6 What are the different process automation functions in each functional level

 ANS:       Functions: Dîrect Process Control
> Data acquisition
> Data check
> Plant monitoring
> Open & closed loop control
> Reporting
Functions: Plant Supervisory Control
>Plant performance monitoring
> Plant co-ordination
> Optimal process control
> Adaptive control
> Failure detections

‎1.7 Draw manufacturing automation system hierarchy structure