Automated process control and CAM

Presented By- Anoop Singh
Guidance of- Sir Dr. Jaybir Singh

INTRODUCTION
AUTOMATION:-
Means the use of machines and equipments for performing physical and
mental operations in a production process in place of human being.
Is a system of doing work where material handling , production process and
product designs are integrated through mechanism of thoughts and efforts
to achieve a set regulating & controlling system.
Is the result of Industrialization , driven by the need to increase
productivity & to achieve consistent quality products
It can be done at various levels of manufacturing system-
 Handling of raw materials, semi-finished goods or finished goods
 During production process (efficient machines are used )
 In Inspection and Quality control operations.

AUTOMATION IN PHARMACEUTICAL INDUSTRY
Basic purpose of AUTOMATION in Manufacturing industry is:-
 To increase Productivity.
Improve quality of products & to reduce waste.
To reduce the costs.
For safe handling of Hazardous substances.
 To take heavy work from workers.
Regulation is a major consideration for Automation as it ensures
compliance
with safety considerations and guidelines.

ADVANTAGES:-
 It provides better quality of goods and service.
 It causes reduction in direct labor costs.
There is effective control on operation.
 There is greater accuracy, more output and greater speed.
 The production planning and control is to be done in the beginning only
The working conditions can be improved
 Safety of workers is improved.
 Minimization of wastage
 The service to the consumer is enhanced.
The quality of product improves as human input is minimized.

DISADVANTAGES:-
 Huge capital investment is required.
 The maintenance cost is very high because maintenance labor of high caliber
is required.
 It can create unemployment.
 Continuous power supply is required.
 Large inventories are required.
 Any breakdown , anywhere would lead to complete shut down.
 Requires highly skilled manpower.
There are restrictions in designing and construction of the building.

AUTOMATIC CONTROLLERS
Industrial automatic process controller varies from simple on off device to
special purpose computing instruments.
Three general type of controllers-
1)Self operated controller-
 On off controllers
 Proportional controller
2) Electronic controller
3) Pneumatic controller
4) Miscellaneous controller – Hydraulic, fluidic and special response
controller.

1)Self operated controllers- Some control systems obtain
the power require to operate the error detector and final control element
from the controller medium of the process by way of the sensing element
such controller are self operated controller , used for temperature , liquid
and pressure controller .
There are two type of self operated controller –
a) On off controller – in this controller, the amount of control action applied
at the process input is either zero or the maximum available.
b) Proportional controllers- The action of a proportional controller is
smooth and continuous over the operating range.
For example In a steam-heated process vessel, if the temperature to be
controlled increase above the set point, the controller output well
increase a proportional amount. This output may reduce the amount of
heat being added.

2) Electronic controllers- Are extensively used for process
control .
The reason for their increase usage are-
solid state circuit
Easier servicing
 Smaller particle size
can easily be linked with process control computer
cost completive compare to pneumatic controller
 may be more accurately tuned.
3) Pneumatic controllers- Its basic purpose is to supply
compressed air to a pneumatic valve actuator in response to an error
signal, based on the deviation of measured variable from the set point.

Computer process control
In the hierarchy of computer control of a process. Five levels can be
identified-
 Unit operation control
 Unit process control
 Plant control
 Departmental and corporate control level of a company.
Without computer control at the plant or unit process level, the study state
plant operating period tend to become, several days.

Process control computer
1. Analog computer
2. Digital computer
Analog computers- represents the numbers being manipulated by the
magnitude of a physical quantity, such as volts or pressure.
Mathematically operations are carried out in a continuous manner.
Digital computers- are counting device that operates directly on
numbers to perform the four fundamental mathematical operation
addition, subtraction, multiplication, and division

Elements of Process Control
1. Controlled variable
What you want to control (temperature , pressure,flow rate, dimensions,
position, etc.)
2. Measured variable
What you observe in order to determine the actual condition of the
controlled variable
In most cases, you measure the controlled variable itself. For instance, if
you want to know how fast a car is going, you measure its speed. In other
cases, you measure a different variable to determine the condition of the
controlled variable. For instance, you can determine the level (controlled
variable) of liquid in an open or vented tank by measuring the pressure
(measured variable) at the bottom of the tank.
3. Set Point
The desired value of the controlled variable; for example, 70 room
temperature.

4. Deviation
The difference between the set point and the actual value of the
controlled variable (which is the measured variable). For example, if
your indoor thermometer reads 65 and you would like a room
temperature of 70, the deviation is 5
Note: Deviation is also referred to as difference or error.
5. Manipulated variable
The variable that is adjusted to close the gap (deviation, difference, or
error) between the set point and the controlled variable; for example,
the amount of electricity or gas to the heater.
6. Disturbances
Anything that affects the process and could cause deviation from the
set point; for example, a window left open, poor insulation, a
damaged thermostat.

Process Variables
The process variable is a dynamic feature of the process which may
change rapidly. Accurate measurement of process variables is
important for the maintenance of accuracy in a process. There are four
commonly measured variables which affect chemical and physical
process: pressure, temperature, flow.

TEMPERATURE MEASUREMENT
 THERMOCOUPLES
 Resistance thermometers
 Filled in thermometers
 Bimetal thermometer
 Liquid in glass thermometers
 Pyrometers

THERMOCOUPLES-
Principle – An electric current flows in a continuous circuit of two different
metallic wires, if the two junctions are at different temperature. A& B are the two
metals &T1&T2 are the temperature of the junction. If t1is the colder junction &
thermoelectric current I flows in the direction indicated, metal A is referred to as
thermoelectrically positive to metal B. The thermal emf is a measure of the
differences in temperature between T2&T1.

RESISTANCE THERMOMETERS-
Based on the inherent characteristics of metals to change in electrical resistance
when they undergo a change in temperature.
Change in resistance is recorded and electrical resistance is calibrated in units of
temperature.

Filled in thermometers-
The filled in system thermometer has a sensitive measuring element (bulb)
containing a gas or a liquid which changes in vapour pressure or volume with
temperature .
This change is communicated through a capillary tube to the bourdon tube or
other pressure or volume sensitive device .
The bourdon tube responds so as to provide a motion related in a definite way
to the bulb temperature .
System which respond to volume changes are completely filled with a gas or
are partially filled with a volatile liquid.

BIMETAL THERMOMETERS-
The working principle of bimetal thermometer is to utilize two different metals
with different thermal linear expansion coefficient.
One end is welded on a fixed point; the other end will bend when the
temperature changes. This torsion will rotate the pointer to indicate the
temperature.

PRESSURE MEASUREMENT DEVICES-: 3 types -
Based on measurement of height of liquid column.
Based on measurement of the distortion of an elastic pressure chamber.
 Electrical sensing devices.
1-) Liquid column pressure measuring device.
Manometer- in this the pressure being measured is balanced against the
pressure exerted by a column of liquid. If the density of liquid is known the
height of the liquid columns is a measure of the pressure. These types of
device are commonly called manometer.

2- Elastic element pressure measuring devices-
These are those in which the measured pressure deforms some elastic
material (usually elastic) within its elastic limit, the magnitude of the
deformation being approximately proportional to the applied pressure.
These devices may be broadly classified into 3 types-
 Bourdon type e.g. C- spring bourdon
 Bellows type
 Diaphragm type.
3- Electric sensing devices-: • e.g.- Strain gauge -: when a wire
or other electrical conductor is stretched elastically , its length is increased
& its diameter is decreased Both these dimensional changes result in an
increases in electrical resistance of the conductor.

AUTOMATION IN TABLET MANUFACTURING
Benefits of automation in tablet production-
Improve material handling.
Improve specific unit operation- Unit operations in tablet manufacturing-
 Particle size reduction
 Sieving
 Mixing.
 Particle size enlargement.
 Drying.
 Compression.
 Sorting.
 Coating.
 Packaging.
Eliminate or combine processing steps.
Incorporate automated process control of unit operation and processes.

Examples of material handling improvement
Granulation and tableting sections of the computer controlled tablet
manufacturing process by Merck Sharp & Dohme (MSD) and Eli lily
and company.
Advantages-
 No human handling of material.
 The system is built in 3 story building which incorporate
vertical drops to utilize gravity whenever possible and uses
pumps, vacuum, bucket conveyors to move material upward
whenever necessary.
Processing step combination or elimination in Direct compression -
 Raw materials.
 Weighing and measuring (automatic weigher and recording
system.)
 Gravity feeding
 Compression (high speed rotary press)
 Aqueous coating (Hi coater).

Wet granulation -:
Standard processing steps -Load processer Weigh ingredients Mix,
mass, agglomerate, dry lubricate Transfer (store),Continuous batch
powder mixing and massing equipment.
E.g. Dionsa mixer & granulator is a high – shear powder mixer and
processor

Coating process improvement-:
Coating of tablets and pills using coating pan is entirely operator
dependent.
Typical Accela cota- : for aqueous or solvent film coating. This is a side
vented or perforated coating pan.
Advantages:
One way flow of air through the tablet bed and out the perforation of the
pans. These greatly reduces or eliminate the bounce back of atomized
spray and particle spray drying of the spray droplets that occurs
especially with solvent based coating with conventional pans.
 It benefits coating because the greater air flow through the bed
facilitates drying.
 Used for continuous coating of film and sugar systems.

Automated process control and CAM

Computer aided manufacturing
•Computer-aided manufacturing (CAM) is the use of software to
control machine tools and related ones in the manufacturing of
workpieces.
•This is not the only definition for CAM, but it is the most common; CAM
may also refer to the use of a computer to assist in all operations of a
manufacturing plant, including planning, management, transportation and
storage.
•Its primary purpose is to create a faster production process and
components and tooling with more precise dimensions and material
consistency, which in some cases, uses only the required amount of raw
material (thus minimizing waste), while simultaneously reducing energy
consumption.
•CAM is now a system used in schools and lower educational purposes.
•Computer-aided manufacturing (CAM) is the use of computer systems to
plan, manage, and control the operations of a manufacturing plant
through direct or indirect computer interface with plant’s resources.

NEED FOR CAD/CAM
• To increase productivity of the designer
•To improve quality of the design
•To improve communications
•To create a manufacturing database
•To create and test toolpaths and optimize them
•To help in production scheduling and MRP models
•To have effective shop floor control

Automated process control and CAM

More Related Content

What's hot (20)

Similar to Automated process control and CAM (20)

More from Anoop Singh (14)

Recently uploaded (20)

Automated process control and CAM