INDUSTRIAL AUTOMATION

BMFA 3443

SEMESTER 2

SESI 2011/2012

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Learning Outcomes Upon completion of this Assignment 2, students should be able to: a) Apply knowledge in industrial automation system for control of automation processes and the machineries involved. b) Design and analysis PLC programme to solve problems in automation using logic control and logic diagram. c) Design an integrated automation system based on fluid power equipment, robot work cell, PLC, vision system and other types of automation tools.

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Assignment Implementations Date Receiving Date (Week 9): 23 April 2012 Submission/Deadline Date (Week 13): 21 May 2012 Note: Each group of 5 students has to complete the assignment. Softcopy Hardcopy Late Submission

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Assignments Evaluations No. 1 Assignment 2 Course work 1 x 10% Percentage, % 10

Students will receive Project Report later on.

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Detail Assignments Structure QUESTION 1 a) Search from the internet for the information about components pick and place system (mounting machine) of Surface Mount Technology (SMT) line in PCB assembly production. Investigate the application of robot in the system (machine). Answer: SMT (surface mount technology) component placement systems, commonly called pick-and-place machines or P&Ps, are robotic machines which are used to place surface-mount devices (SMDs) onto a printed circuit board (PCB). They are used for high speed, high precision placing of broad range of electronic components, like capacitors, 1

resistors, integrated circuits onto the PCBs which are in turn used in computers, telecommunications equipment, consumer electronic goods, industrial equipment, medical instruments, automotive systems, military systems and aerospace engineering. The robot system used in the pick-and-place machine is a cartesian coordinate robot. Cartesian coordinate robot (also called linear robot) is an industrial robot whose three principal axes of control are linear (i.e. they move in a straight line rather than rotate) and are at right angles to each other. Among other advantages, this mechanical arrangement simplifies the robot control arm solution. b) Explain homing process in robot application. Answer: Homing procedure represents set of actions automatically leading the all robot elements from initial generally unknown position (i.e. arbitrary position from a robot workspace) to predefined known deterministic position, so-called home position. This position may be an initial position for a sensor calibration, for real work operations or for a work-tool replacement etc. The real homing procedure is determined by used robot drives: linear drives rotational drives more precisely, by character of the drive sensors (possible other additional sensors): positional (absolute) sensors incremental sensors denoting the pieces of information on the robot position, generally on the robot state. Furthermore, the procedure depends on type of the robot structure and configuration, i.e. if the structure has serial, parallel or hybrid character. Homing is a term that robotics has borrowed from biology, where it is usually used to describe the ability of various living organisms to return to their nest after having distanced themselves to forage. To start the procedure, it is necessary to know rough robot position, appropriate drive positions, respectively, e.g. known quadrant in the case of rotational drives or interval in the case of linear drives in relation home position. For this purpose, specific mechanical or electromechanical elements (marks) are suitable to be considered. These elements stand for positional (absolute) homing marks, one part of which representing reference (e.g. robot frame, previous link) is fixed, and the second part is mounted on appropriate place moving relative to part one (e.g. slide rest, drive spindle). In case of positional (absolute) sensors, mainly at linear drives, such orientation element may be directly sensor itself, but it need not be a rule. The real homing procedure can be generally done as follows: (1) The robot is switched on and the control unit tests the values of the marks. (2) In a correspondence to these values, the control unit set the input value and its sign for each drive. The robot starts to move slightly towards home position. (3) During the process, the positional drive sensors should register their values, although the values are not directly connected to physical meaning. (4) Once some of drivers achieves the change of marks (change 0 -> 1 or 1 -> 0), the value of position from drive sensor is stored in memory and the appropriate drive is stabilized in this position. The stabilization can be provided by a simple PI controller. (5) When all drives achieve the mark change, the robot reaches the home position and it is stabilized in this position.

QUESTION 2 a) Search from the internet for the information about magazine (rack) loader and un-loader machine of Surface Mount Technology (SMT) line in PCB assembly production. Investigate the application of fluid power devices in the machines. 2

Answer: Connect with SMT and AI productions line, safety design ensure not to break any PCB when it is pushed and thus reduce defect rate. Agility operation. With high accuracy, automatic counting, fault alarm functions, it is required for a full range of automation equipment. The PCB Magazine Loader is designed for loading of PCBs. The unit loads the production line automatically by pushing PCBs out of a magazine onto the conveyor of the downstream machine. The PCB Magazine Unloader is designed for unloading of PCBs; an arriving PCB is taken up by the attached conveyor and then pushed into the magazine by a specially designed pusher. The magazine indexes to the next position and is ready for the following unloading cycle. PLC is used to control the magazine loaders/unloaders, and is capable of automatic board width adjustment and barcode reading based on the magazine rack size. Meanwhile, both loader and unloader is designed with a lifter which is used to lift up and down in order to transfer the magazine (with PCBs)into the SMT line or transfer out the magazine. Pneumatic cylinder is used to lift up and lift down the lifter. b) Draw pneumatic circuit of a single acting spring return cylinder which is controlled by two 3/2-way push buttons under the condition of; c) OR application. d) AND application Answer: i.

ii.

QUESTION 3 a) Describe PID controller in your own word. Answer: A proportionalintegralderivative controller (PID controller) is a generic control loop feedback mechanism (controller) widely used in industrial control systems a PID is the most commonly used feedback controller. A PID controller calculates an "error" value as the difference between a measured process variable and a desired setpoint. The controller attempts to minimize the error by adjusting the process control inputs. The controller regulates the feedback loop. The PID controller calculation (algorithm) involves three separate constant parameters, and is accordingly sometimes called three-term control: the proportional, the integral and derivative values, denoted P, I, and D. Heuristically, these values can be interpreted in terms of time: P depends on the present error, I on the accumulation of past errors, and D is a prediction of future errors, based on current rate of change. The weighted sum of these three actions is used to adjust the process via a control element such as the position of a control valve, or the power supplied to a heating element. In the absence of knowledge of the underlying process, a PID controller has historically been considered to be the best controller. By tuning the three parameters in the PID controller algorithm, the controller can provide control action designed for specific process requirements. The response of the controller can be described in terms of the responsiveness of the controller to an error, the degree to which the controller overshoots the setpoint and the degree of system oscillation. Note that the use of the PID algorithm for control does not guarantee optimal control of the system or system stability. PID is proportionalintegralderivative controller and you will find one inside the other 3 acronyms you mention. Some applications may require using only one or two actions to provide the appropriate system control. This is achieved by setting the other parameters to zero. A PID controller will be called a PI, PD, P or I controller in the absence of the respective control actions. PI controllers are fairly common, since derivative action is sensitive to measurement noise, whereas the absence of an integral term may prevent the system from reaching its target value due to the control action.

b) Explain the principle of the measurement of flow rate by measuring differences in pressure. Answer: Differential pressure measurement is a universal flow measurement for liquids, gases and vapors. Differential pressure flow meter always provides accurate results even with large bores, high temperature and extreme pressure. Differential pressure flowmeters use Bernoulli's equation to measure the flow of fluid in a pipe. Differential pressure flowmeters introduce a constriction in the pipe that creates a pressure drop across the flowmeter. When the flow increases, more pressure drop is created. Impulse piping route the upstream and downstream pressures of the flowmeter to the transmitter that measures the differential pressure to determine the fluid flow. Bernoullis equation states that the pressure drop across the constriction is proportional to the square of the flow rate. Using this relationship, 10 percent of full scale flow produces only 1 percent of the full scale differential pressure. At 10 percent of full scale flow, the differential pressure flowmeter accuracy is dependent upon the transmitter being accurate over a 100:1 range of differential pressure. Differential pressure transmitter accuracy is typically degraded at low differential pressures in its range, so flowmeter accuracy can be similarly degraded. Therefore, this non-linear relationship can have a detrimental effect on the accuracy and turndown of differential pressure flowmeters. Remember that of interest is the accuracy of the flow measurement system --- not the accuracy of the differential pressure transmitter. There are several types of flow meter that rely on Bernoulli's principle, either by measuring the differential pressure within a constriction, or by measuring static and stagnation pressures to derive the dynamic pressure.

QUESTION 4 Engr. Dr. M Minhat

a) Describe the term serial communication. Answer: In telecommunication and computer science, serial communication is the process of sending data one bit at a time, sequentially, over a communication channel or computer bus. This is in contrast to parallel communication, where several bits are sent as a whole, on a link with several parallel channels. Serial communication is used for all long-haul communication and most computer networks, where the cost of cable and synchronization difficulties make parallel communication impractical. Serial computer buses are becoming more common even at shorter distances, as improved signal integrity and transmission speeds in newer serial technologies have begun to outweigh the parallel bus's advantage of simplicity (no need for serializer and deserializer, or SerDes) and to outstrip its disadvantages (clock skew, interconnect density). The migration from PCI to PCI Express is an example.

b) Explain the term SCADA. Answer SCADA (supervisory control and data acquisition) generally refers to industrial control systems (ICS): computer systems that monitor and control industrial, infrastructure, or facility-based processes, as described below:

Industrial processes include those of manufacturing, production, power generation, fabrication, and refining, and may run in continuous, batch, repetitive, or discrete modes. Infrastructure processes may be public or private, and include water treatment and distribution, wastewater collection and treatment, oil and gas pipelines, electrical power transmission and distribution, wind farms, civil defense siren systems, and large communication systems. Facility processes occur both in public facilities and private ones, including buildings, airports, ships, and space stations. They monitor and control HVAC, access, and energy consumption.

c) Thoroughly discuss why the CAN system is so important. (Long answer is expected) Answer Controller Area Network (CAN) is a network protocol that allows multiple processors in a system to communicate efficiently with each other. In the early 1980s microprocessors became small enough and powerful enough to start appearing everywhere, not just inside personal computers. The typical automobile built since 1985 has dozens of embedded processors. Electronic fuel injection systems have replaced carburetors. Anti-lock braking systems use fast microprocessors to make split second decisions, as do safety systems like air bags and seat belts. Other systems have built-in processors to work as sensors, keeping track of and reporting on temperature and pressure changes for the coolant system, transmission, and oil. Still others monitor emissions, steering performance, and brake fluid levels. As more and more electronic systems were added to automobiles and other machines to make them safer, more efficient, more reliable, and easier to maintain, it became increasingly important for these systems to communicate with each other. To this end the Controller Area Network protocol was introduced in 1983. Today Controller Area Network is the standard for high-speed, mission critical, real-time control networks in many machines. CAN chips are reliable, simple, and cheap. They last a long time and are able to endure temperature and pressure extremes. CAN makes it possible for all of the separate microprocessors in a system to send and receive messages without relying on some form of central control. This makes for much more efficient control of message traffic, and it reduces the need for internal computer wiring by as much as 90 percent in some cases. Also, CAN systems are flexible and easy to maintain. Mechanics or technicians can repair or replace computer hardware in the system without affecting the rest of the network. Design engineers can rework CAN systems and add or remove network nodes easily. Finally, this leads to a system that lends itself well to project management. Because of the industrywide CAN standard, each functional unit in a CAN system can be developed and tested separately. When every individual part is shown to work independently, there is a high probability that when all of the components are assembled they will work as a system. A CAN system sends messages using a serial bus network, with the individual nodes (processors) in the network linked together in a daisy chain. Every node in the system is equal to every other node. Any processor can send a message to any other processor, and if any processor fails, the other systems in the machine will continue to work properly and communicate with each other. Any node on the network that wants to transmit a message waits until the bus is free. Every message has an identifier, and every message is available to every other node in the network. The nodes select those messages that are relevant and ignore the rest.

The CAN protocol was designed for short messages, no more than eight bytes long. It is generally used for sending signals to trigger events, such as to lock seat belts during heavy braking, and measurement values, such as temperature and pressure readings. The protocol never interrupts an ongoing transmission, but it assigns priorities to messages to prevent conflicts and to make sure that urgent messages are delivered first, and includes error checking to make the traffic highly reliable. Even so CAN systems are fast. A CAN system is able to transmit up to 7600 8- byte messages or 18,000 trigger signals per second.

d) Describe the purpose of ControlNet. ControlNet is a real time control network which has robust, deterministic and secure features for challenging industrial automation applications. Popularly known as fieldbus, this open network protocol, originally developed by Rockwell Automation is a member of the CIP (Common Industrial Protocol) network family. Earlier it was carried by ControlNet International, but now the whole supervision and organization of ControlNet has been transferred to ODVA, (an association responsible for management of all protocols in the Common Industrial Protocol family). For configuration purpose each ControlNet device requires electronic device data sheets (i.e. EDS-Files containing electronic descriptions, all relevant communication parameter and objects of the ControlNet device) which are provided by the device manufacturers. Also an exclusively available configuration tool e.g. Rockwells RSNetWorx need to be employed during the initial setting phase of the ControlNet network for configuring ControlNet Master Scanner. QUESTION 5 Engr. Dr. M Minhat

a) Thoroughly describes how a servo is homed. Answer: The procedure is very simple. The operator moves each axis to a safe location and then sets a home key for each axis. A safe location has no fixtures, parts, or other tooling that the machine will run into as it homes. Lets examine what happens when one axis is homed. Study the position loop and the table switches. The machine table can contact three switches: a X limit switch, a +X limit switch, and a home switch. The limit switches are for overtravel protection to disable the motor drive if the table ever moves far enough to contact them. If the table contacts the X limit switch, for example, the motor drive is disabled, preventing any further movement in the X direction. The con- trol goes into an error condition, and the operator must reset the error and move the axis in the +X direction until the table is off the X limit switch. The same is true if the table contacts the +X switch. The home switch roughly positions the table during the homing routine. The operator moves the table to a safe position and touches the home key for the X axis. The table begins to slowly move toward the home switch. When the table contacts the switch, a signal is sent to the CNC control. It senses that the switch has closed and then reverses the motor and very slowly turns it. The CNC control monitors the encoder pulses now until it sees the home pulse. When the CNC control sees the home pulse from the encoder, it initializes its position. It now knows exactly where this axis is. So the home switch ensures that the table is close to position and in the right revolution of the encoder. The encoder pulse then ensures that the machine is exactly in position. Each axis homes in the same manner. b) The following section of CNC program using the G/M-codes is given. The absolute method of circular interpolation only is used or else incremental method is used. N005 G71 7

N010 G90 N015 G00 X15000 Y10000 Z-10000 S500 M03 N020 G91 N025 G01 X35000 Y0000 Z0000 F100 N030 G00 X-30000 Y0000 Z0000 N035 G01 X0000 Y2000 Z0000 N040 G01 X30000 Y0000 Z0000 N045 G00 X-30000 Y0000 Z0000 N050 01 X0000 Y2000 Z0000 N055 G01 X30000 Y0000 Z0000 N060 G00 X-30000 Y0000 Z0000 N065 G01 X0000 Y2000 Z0000 N070 G01 X30000 Y0000 Z0000 N075 G90 N080 G03 X80000 Y46000 Z-10000 I50000 J46000 N085 G02 X40000 Y86000 Z-10000 I80000 J86000 N090 G01 X20000 Y86000 Z-10000 N095 G01 X20000 Y16000 Z-1000 N100 G00 X0000 Y0000 Z0000 N105 M00 On the graph paper, plot the tool path given by the section of CNC program above. Answer:

c) For what are G/M- codes used and what does modal mean?? Answer M-Codes are mostly used to operate external devices within the program, turning coolant on and off, or spindle on off, they are also used to end the program. A program code used to signal an action from a miscellaneous group of commands. M codes change cutting tools, turn on or turn off the coolant, spindle, or workpiece clamps, etc. G-codes are also called preparatory codes, and are any word in a CNC program that begins with the letter "G". Generally it is a code telling the machine tool what type of action to perform, such as:

Rapid move (transport the tool through space to the place where it is needed for cutting; do this as quickly as possible) Controlled feed move in a straight line or arc Series of controlled feed moves that would result in a hole being bored, a workpiece cut (routed) to a specific dimension, or a profile (contour) shape added to the edge of a workpiece Set tool information such as offset Switch coordinate systems

Many codes are "modal", meaning that they stay in effect until they are cancelled or replaced by a contradictory code. For example, once variable speed cutting (CSS) had been selected (G96), it stayed in effect until the end of the program. In operation, the spindle speed would increase as the tool neared the center of the work in order to maintain a constant surface speed. Similarly, once rapid feed was selected (G00), all tool movements would be rapid until a feed rate code (G01, G02, G03) was selected.

QUESTION 6 Engr. Dr. M Minhat a) Describe thoroughly by your own words what is a NEMA enclosure? Ans: NEMA defines standards for various grades of electrical enclosures typically used in industrial applications. Each is rated to protect against designated environmental conditions. A typical NEMA enclosure might be rated to provide protection against environmental hazards such as water, dust, oil or coolant or atmospheres containing corrosive agents such as acetylene or gasoline What is a Nema Enclosure? It is a type of electrical enclosure used inside or outside for your home or business. NEMA is trade association for the electrical and manufacturing industry. They are used for different needs but it is crucial to determine the National Electrical Manufactures Association (aka NEMA) rating you will need for the enclosures. There are different varieties of NEMA enclosures available in the market today, ranging in a variety of sizes and shapes as well. When purchasing NEMA enclosures one will have to make many decisions, as they will be having many options to choose from, from finding the right outdoor and/or indoor enclosures that fit your specific needs. Here are some of the different types of enclosures: Type 1: General Purpose Indoor Type 2: Drip-Proof Indoor Type 3: Dust tight, Rain tight, Sleet tight Outdoor Type 3R : Rain tight, Sleet Resistant Outdoor Type 3S : Dust tight, Rain tight, Sleet tight Outdoor Type 4 : Water tight, Dust tight, Sleet Resistant - Indoor & Outdoor Type 5 : Dust tight, Drip-Proof - Indoor NEMA enclosures are some of the most highly recommended electrical enclosures that are available on the market today. One reason is because NEMA goes by a firm rating system when it comes to the dependability and long lasting quality of all of their enclosures so that they will be able to provide you with the kind of protection for your specific need to keep you and your environments safe from any type of electrical damages.

b) Why should enclosures be used? Enclosures are used to protect the control devices from the environment of the application. A cabinet type is chosen based on the characteristics of the environment. Cabinets typically protect the PLC from airborne contamination and metal cabinets protect from electrical noise. c) What is the major cause of failure in systems? P o o r d e v e l o p m e nt pr a c t i c e s. I n c o r r e c t a s s um p t i on s w i t h r e g a r d t o s ys t e m r e q u i r e m e nt s P o o r u s er i n t er f a c e. F a u l t y h a r dw ar e . 9

I n a d e q u a t e u s e r t r a in i n g / u s e r e r r o r . P o o r f it b et w e en s ys t e m s a n d o r g a n i s a t i o n .

d) Describe at least three precautions that should be taken to help reduce the problem of noise in a control system. To reduce the effects of noise, follow these steps. Properly mount the PLC within a suitable enclosure. Properly route all wiring. Properly ground all equipment. Install suppression to noise-generating devices. Noise Isolation - The other way to deal with noise is isolation, which physically separates the device or devices that cause trouble from the control system. The enclosure can help to do this. In many cases field wiring must be placed in very noisy environments to allow sensors to monitor the process. This presents a problem especially with low voltages. Shielded twisted-pair wiring should be used for the control wiring in these cases. The shielding should be grounded at only one end. The shield should be grounded at the single-point ground.

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