Factory Automation Course Code: 4354102

Practical No.1
Title: To study about fundamental of automations

A. Objective:

At the end of the practical, students will be able to understand and apply the
fundamentals of automation.

If you want to specify what kind of automation (e.g., industrial, home, software), or
include specific skills (e.g., working with sensors, using PLCs), I can refine it further.

B. Expected Program Outcomes (POs)

PO1: Apply the knowledge of mathematics, science, engineering fundamentals,
and an engineering specialization to the solution of complex engineering
problems.
PO4: use modern engineering tools and equipment understand automated
system.

C. Expected Skills to be developed based on competency:

•Understand the fundamentals of automation systems and their components.
Develop the ability to identify and connect automation hardware like sensors,
actuators, and controllers.
Gain hands-on experience in programming basic automation logic (e.g.,
using PLCs or microcontrollers).

D. Course Outcomes (Cos)

CO1. Understand the basic principles and components of automation
systems.

CO2. Identify and describe the functions of sensors, actuators, and

controllers used in automation.

CO3. Apply safety standards and best practices while working with
automation equipment.
 E. Practical Outcome (PRo)
• Apply safety procedures and standards during practical work
involving electrical and electronic devices.
• Demonstrate understanding of the fundamental components used in
automation systems (sensors, actuators, controllers).
• history and laws, various subsystem of robotics and basic parts of
robotics.

F. Expected Affective domain Outcome (ADos)

• Demonstrate a positive attitude toward learning and applying
automation concepts.
• Show responsibility and accountability in completing lab tasks and
assignments on time.

G. Prerequisite Theory:
History
Automation has been introduced very early in the history or human civilization. In
the form of mechanical tools like whe pulley, lever etc

Many electronic devices like triode, transistors, integrated circuits (invented in

1958), which combined tiny transistors

The IC laid a path for the introduction of the microprocessor (first- Intel 4004, in
1971) which integrates all the function of CPU of a computer.

1.1 Types of Automation:

1. Fixed automation
2. Programmable automation
3. Flexible automation
4. Integrated automation
 1. fixed automation:

Features
➢ High volume of production
➢ Fix operation
Factory types
➢ Continuous flow
➢ Discrete mass production
Examples
➢ Process automation
➢ Conveyors
➢ Paint shop

2 Programmable automation:

Features
➢ Changeable sequence of operation
➢ Electronic controls
Factory types
➢ Batch process
➢ Mass production
Examples
➢ Numerical control
➢ Assembly robot

3 Flexible Automation:

Features
➢ Computer controlled with graphically user interface, so that operator can
operate it.
 ➢ Changes should be preprogrammed, so that operator select certain
parameters and rest is done automatically.

Factory types
➢ Job shops
Examples
➢ CNC machining centers
➢ Automatic guided vehicles
4 Integrated Automation:

Features
➢ Advance optimizing algorithms
➢ There is lot of knowledge built in them and they do lot of mathematical
calculations based on sophisticated models.

Factory types
➢ To all types factories large

Examples
➢ Chemical process automation plant with automation computer
integrated manufacturing

D. Classify with Example:

➢ Industrial: Robots in manufacturing
➢ Office: Automated email systems
➢ Home: Smart lighting systems

1.2 Application:
➢ Industrial Automation: Involves automating manufacturing
processes, such as assembly, machining, and packaging.
➢ Agriculture Automation: Automates tasks like planting, harvesting,
and irrigation.
➢ Testing Automation: Automates the testing of software and
hardware, ensuring quality and efficiency.
1.3 Scope of industrial automation:
➢ Explosive growth with nanotechnology and Nano scale assembly system,
MEMS and nanotech sensors (tiny, low-power, low-cost sensors)
➢ Adaptive and multi- processing system interfaced with the real time
automatic system
➢ Remote controlled automation systems factory will be small, movable,
and flexible

1.4 Impacts of Automation:

➢ Social economic impacts of automation
➢ Automation and society
➢ Employment
➢ Automation and the individual

1.5 Advantages and disadvantages of automation Advantages

Advantages:
➢ Increased reliability and precision
➢ Improved worker environment
➢ High quality, high production rates and ultimately Economic Growth
Disadvantages:
➢ Security Threats/Vulnerability
➢ Unpredictable development costs
➢ High initial cost

1.6 Strategies for automation:

1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
1.7 Benefits of Low Cost automation:
➢ Low investment required, hence low risk
➢ Automation tailored around the existing machines with the people
involved; hence the changes are gradual, smooth and very cost
effective
➢ Technologies used are easy and simple to understand, maintain and
upgrade; losses will be minimal in case of breakdowns

1.8 AUTOMATION TOOLS:

➢ HMI-Human machine interface
➢ DSC-Distributed control system
➢ PLC - programmable logic controller
➢ PAC-Programmable automation controller
➢ SCADA - Supervisory control and data acquisition
➢ ANN- Artificial neural network Instrumentation Motion control Robotics

1.9 SOCIAL ISSUES OF AUTOMATION:

➢ Automation impact on employment.
➢ But automation need not bring unemployment for two reason
1.10 Automation Programming Language:
➢ Ladder Logic, Structured type, Python, C++, and Function Block Diagram
(FBD)

❖ Safety in Automation:
➢ Probably the topmost topic everybody’s talking about is the expansion of
IA into broader technologies like generative AI. But there isn’t just one
trend we’ll see emerging in the upcoming year for automation.
Organizations are expanding beyond repetitive tasks. We’re going to see
changes across ethics, strategy, governance, all-in-one solutions and how
business users interact with automation technology in real-time.
➢ features include emergency stops, guards, sensors, alarms, and interlocks
➢ Programmable automation is a type of automation where equipment can be
reprogrammed to perform different tasks or produce different products.
➢ It is ideal for batch production and offers moderate flexibility.

Examples: CNC machine

 Industrial robot

❖ levels of automation in industry

➢ Industrial automation generally progresses through several levels, ranging from
manual control to fully autonomous systems. A common framework identifies
five levels: Manual Control (Level 0), Basic Automation (Level 1), Advanced
Automation (Level 2), Integrated Automation (Level 3), and Intelligent
Automation (Level 4).

Conclusion:
as a fundamental concept, significantly enhances efficiency, productivity, and quality
across various industries.

MCQ:
1. What is the primary goal of industrial automation?

A) To increase production speed.

B) To minimize human intervention in processes.
C) To improve efficiency and reduce costs.
D) All of the above.
2. Which of the following is an example of an automation device?
A) Typewrie
B) Programmable Logic Controller (PLC)
C) Manual switch
D) Calendar

3. What is a disadvantage of automation?

A) Improved worker environment

B) High production rates

C) High initial cost

D) Use in hazardous environments

4. Which is NOT an automation tool?

A) HMI

B) SCADA

C) Spreadsheet

D) PLC

5. Which level comes after “System” in automation hierarchy?

A) Device

B) Machine

C) Plant

D) Enterprise

6. SCADA is used for:

A) Supervisory control and data acquisition

B) Simple control access

C) Short circuit analysis

D) Structured CAD automation

7. One benefit of low-cost automation is:

A) Low investment

B) Complex installation

C) Higher downtime
D) Costly maintenance

8. Automation helps in:

A) Increasing labor

B) Reducing technology use

C) Improving productivity

D) Avoiding machines

9. Which of the following correctly differentiates flexible automation from

programmable automation?

A) Flexible automation allows on-the-fly manual reprogramming, while programmable

automation does not.

B) Programmable automation supports graphical user interfaces; flexible automation

does not.

C) Flexible automation uses preprogrammed changes and GUIs, offering greater ease of
operation.

D) Programmable automation is used only in job shops; flexible automation is used in

batch processes.

10. What is the main drawback of integrated automation systems in terms of

system design?

A) Too simple for large systems

B) Lack of real-time processing

C) High complexity and development cost

D) Not scalable

Practical related question:

1. Write a short history of automation.
2. What are the strategies for automation?
3. What is flexible automation? How is it different from programmable
automation?
4. Name and describe commonly used automation tools.
YouTube link:
https://youtu.be/fIeoiLhe1XA?si=18ZOV_gKN9FZcODc

https://youtu.be/tw-79FiRYKA?si=ibJW2RfU7FYKDHIp

Assessment-rubrics: