Automation system
The Automation system is the experience of using modern technology tasks instead of human beings to maximize productivity, performance, and accuracy. at the same time, it minimizes the human errors.
What is the definition of an Automation system?
Automation is defined as when technology is utilized to
integrate processes in general and industrial processes as a specified branch
which is executed by human beings to a minimum as much as possible by using modern
and up to date like robots, computers as well and artificial intelligence (AI). The
automation assignments vary from easy, and repetitive, to complex ones like
problem-solving and even decision-making.
What is the history of automation systems?
Water frame is the first automated spinning machine invented
in 1771 by Richard Arkwright. It used the water power to spin disks to produce
cotton yarn. The spin force by water had more power than the rotation power by
humans. In 1785 a fully automated flour mill was developed by Olive Evans where
the water power drove and made the mill continuously operate to produce flour.
That machine reduces the number of workers from four to one. And also increase
the produced flour from the given grain amount.
Devolving automation over time was done till
reached 1920 when electricity was invented and as a result, the production
process became faster. From 1930 to 1940 a significant improvement was achieved when
feedback control was used.
Advantages of the automation system.
- Increase productivity by replacing humans with robots and machines to make the processes faster and more efficient when used by humans.
- Increase and improve the product quality.
- Increase the accuracy of the processes and keep the precision at its highest value.
- Increase the safety factor by replacing humans with a machine in areas that have high risk levels minimizing the chance of injuries and accidents occurrence.
- Utilizing the cost saving by reducing labor costs as well as minimizing the expenses and efficiency improving.
Disadvantages of the automation system.
- Replacing human beings with machines and robots cause the human to lose their jobs.
- High initial cost spent in equipment purchasing, training, and software though it has a long-term cost saving.
- Complications with the automation system made some side effects that led to the interference of humans again in the presence of system usability in start-up and stop-down the system and also in emergency cases.
- Decreases the experience skills of the working employees over time.
What are the a pplications where the automation system is used?
- heavy industries manufacturing which have very high numbers and large-scale processes are used.
- Feed rate control in many industrial processes.
- Robotic manufacture.
- Smart home applications
- Smart autos and automotive manufacture.
- Physical and chemical labs.
- Transportation and aircraft (auto-pilot technology).
- Space-ships, and space rockets manufacturing and operation.
What is the Automation pyramid?
The automation pyramid represents the standard 5 layers or levels of the automation system. These levels or layers describe the hauling process from raw material to the final product in all factories.
What are the levels used in industrial automation levels?
Field level.
where the devices such as sensors, motors, and
actuators have existed. At this level, these devices are in connection with
the process itself. At this level, there are 2 types of devices. The first device converts the electrical control signal from the control
level to physical quantities.
Examples of these devices are the motors which control fan speed to increase and decrease air flow, control conveyors' speed, and increase
or decrease the feed rate by increasing the belt feeder’s speed. Actuators
and regulators are devices used to control the output of a process it
could be used to open and close gates, and increase or decrease fuel fired in boilers
burners, or heat generation processes by controlling fuel nozzles.
The field level also includes the instrumentation devices
which measure the actual value of the process output represented as feedback
and drive it back to the control level. These transducers, sensors, and
transmitters could be temperature, pressure, flow, level, motion, vibration,
speed, and light sensors, pressure sensors.
Control level.
Where special controllers like Programmable
Logic Control (PLCs) and Proportional, integration, and differential (PIDs) have existed. At that level, the software and hardware control is done for the
processes. PLCs are considered the most widely use for controllers as it has
some advantages like ease, low cost, and low size although they can include a large
number of controllers.
The controllers in
the control level collect and read the input signals driven from the
field level. Based on the controller program and its predefined parameters it processes
the input and drives the output control signals back to the field level to get
the output of the process and at the same time, it sends these data to the upper supervision
level.
Supervision level.
where the SCADA and HMI systems have existed.
At that level, the mentioned tools enable the operators to monitor and make
analyses and reports to utilize the system and increase the system's performance.
In this level, the data is collected from the controller level and monitored at the central control room CCR where one or more operator monitors the data. Operators
can do some control actions manually in some special cases. At this
level, the operator has many supporting tools like trends and reports to help him analyze the performance
of the processes.
Planning level.
where the Manufacture Execution System has existed.
The (MES) is a digital computerized solution used to monitor track and document
the plant key performance indicators (KPIs). The data monitored at that level
could be used to optimize and control the overhaul performance of the system. Mobile applications could be an example of the solutions used through that level where
you can monitor the plant data easily on your mobile anytime and anywhere. All
you need is a mobile set and internet access.
Management level.
In this level where enterprise resource planning has existed, some modules were added to the previous level like HR, spare parts store, supply chain, finance, and procurement department to enable all these modules to communicate together to achieve the plant targets and KPIs.
The importance of that level is that it is the top of the automation pyramid which takes all the results and reports from the pyramid's low levels and prepares your plan in which the top managers are involved. The best example for that level is SAP application where the SAP stands for (System application and product. It could be discussed in detail in a separate article
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