INTEGRATED AUTOMATION TECHNOLOGIES

A Short Term Course (STC) on Integrated Automation Technologies was organized by Indian Institute of Technology, Delhi during 1st -6th June 2015. The objective of the course was to impart knowledge on automation and also to provide hands-on training on contemporary automation technologies, their integration and application related concepts.

Prof. D. V. Bhise from Department of Mechanical Engineering, Dronacharya Group of Institutions, Greater Noida participated in the short term course.

01/06/2015

Inaugural session:

STC was inaugurated on 1st June 2015 by Prof.(Dr.) Sunil Kale, Head of the Department, Mechanical Engineering, IIT Delhi. During the inaugural session Prof. (Dr). Sunil Kale highlighted the importance of Automation in day to day life. Prof. Kale discussed the example of Airbus and number of controls required to operate it. He said that 2,50,000 sensors are required to control the airbus and the biggest challenge is to how one controls these sensors.

Mr. Anup Wadhwa, Director, Automation Industry Association (AIA) and Ex alumni of IIT Delhi, highlighted role and activities undertaken by AIA. Mr. Wadhwa was official observer for the STC. He explained the requirement of industries from Automation perspective and said that System Integration is need of the hour. He highlighted the efforts made by AIA to educate students and faculty members about role and importance of Automation in industries.

Mr. Rajiv Sachdeva, Ex alumni of IIT Delhi and the second observer of the STC, discussed Fuel Cell Technology and its Automation. Mr. Sachdeva requested the participants to take a feel of sense of the industry and asked them to act accordingly.

Dr. Sunil Jha, Course Coordinator, explained the need of the STC on Integrated Automation Technologies. Dr. Jha elucidated the course objectives and outcomes.

Session I: Introduction to Industrial Automation, Technologies Involved and Relevance of the course.

The session was conducted by Dr. Sunil Jha who gave an Introduction to available Automation Technologies. Dr. Jha explained the process of learning Automation as:

1. Awarenes

2. Acquiring Knowledge

3. Gaining expertise, hands-on Implementation

Dr. Jha discussed the concept of Integrated Automation Technologies as interaction of:

1. Hardware Components

2. Software

3. Services

Session II: Fluid power Control in Industrial Automation

Dr. Jha continued the session and discussed common Automation tasks required in manufacturing industries. Dr. Jha discussed Automation with following simple example:

An object having 20 kg weight has to be moved by 150 mm in linear direction with repeatability of 100 micron.

Following solutions to the above mentioned problem were discussed in depth:

1. Ball Screw arrangement

2. Hydraulic Systems

3. By using Conveyors

4. By using Linear motors

Dr. Jha also discussed types of Automation as:

1. Fixed (Pick-n- Place type)

2. Programmable (Robots)

3. Flexible (More number of machines are involved)

Session III: Electro-Pneumatics and Electro-Hydraulics System Design

During the session Dr. Jha explained the fundamental concepts of Electro-Pneumatics and Electro-Hydraulics Systems in detail and discussed the following:

1. Control and transmission in hydraulic system

2. Directional control valves

3. Actuators

4. Flow control valves

Session IV: Lab session on Pneumatics & Electro-pneumatics

During the session Mr. Faiz Iqbal, PhD Scholar, IIT Delhi, demonstrated working of following components used in Pneumatics & Electro-pneumatics:

1. Displacement & pressure sensor

2. Limit switches

3. Read Switches

4. Proximity sensors

5. Relays

6. Actuators

02/06/2015

Session I: Programmable Logic Controllers- Basics & Programming

During the session Dr. Sunil Jha explained the basics of PLCs and how PLCs can be used for solving the Automation problems. The basic components of PLCs were explained as follows:

1. PLC Processor

2. Input Output module

3. Chassis

4. Power supply

5. Software

6. Network Interface

A Case of automated water sprinkling system was discussed during the session

Session II: PLC Programming Hands-on

PLC Programming on Rockwell RS Logics 500 was done for Automated Water Sprinkling System Problem

Session III: Sensor Lab demonstration and Hands-on

During the session various sensors were demonstrated with their applications.

Session IV: Automation Studio software demonstration

During the session Mr. Naganarayanan Meyyappan from Famic Technologies, discussed the working and applications of software through online demo.

03/06/2015

Session I: Basics of Motion Control, Visualization in Automation

During the session Dr. Jha discussed the following:

1. Motion Control

2. Visualization

3. Operator Interface

4. HMI features

A Case for development for HMI for controlling the speed of a servo motor using factory talk view studio was discussed

Session II: Industrial Sensors and their role in Automation

During the session Mr. Sudhanshu Kantoor from Pepperl & Fuchs discussed various types of sensors used in industrial automation. Following sensors were discussed in depth:

1. Inductive

2. Capacitive

3. Photo

4. Ultrasonic

5. Magnetic

Mr. Sudhanshu also explained the process of choosing right sensors for industrial automation as:

1. Housing Design

2. Range selection

3. Data Connection

4. Switching frequency

5. Load requirement

Session III: Automation Tools for Machine Designers

During the session Ms. Coneenika Choudhuri from Titan Machines, discussed about Automation in every day life quoting examples of ATM, Coffee Machine & Building Automation. Ms Choudhuri discussed the concept of high speed automation where response time is of the order of one second. Ms. Choudhuri also discussed Walking Beam Chassis designed and developed by Titan Machines.

Session IV: Applying Motion Control Systems

During the session Mr. Praveen Vaidya from B&R Automation discussed about motion control and applications in automation. Mr. Vaidya discussed the following:

1. Types of motion controllers

2. Servo Drive

3. Actuators

4. Cam Switch

A case of shop floor automation in manufacturing was discussed during the session.

04/06/2015

Session I: Blended Learning as a cost effective tool for skilling in Automation

During the session Mr. S Sendil Kumar, Manager, Didactic, FESTO Controls Pvt. Ltd, discussed about the concept of blended learning and application in automation. Mr. Sendil Kumar discussed the following with respect to blended learning:

1. Skilling necessity

2. Need for incremental knowledge

3. Multi-skilling

4. Technological Changes

5. E-Learning

6. Web based trainings

7. Knowledge portals

8. Tec-2 screen

Session II: Integrated Automation Platform-a Teaching Tool

During the session Mr. Milind Kulkarni, Chief Manager, factory Automation, SIEMENS, discussed about integrated automation developed by SIEMENS for Industrial Automation. Mr. Kulkarni also discussed customer requirement regarding plants automations:

1. Openness and standards

2. Scalability

3. High plant availability

4. Integration

5. Compatibility

6. Innovative products

7. Manufacturing execution system (MES)

Session III: Integrated Automation Exercises

During the session A pick and place work station was designed and tested successfully problem was solved.

Session IV: Integrated Automation Exercises-Automation Modules Control

During the session demonstration on integrated automation by using integration modules were given. Following components were used in the integration modules:

1. PLC

2. PID

3. HMI

4. Power supply

5. Variable frequency Drive (VFD)

6. Solid State Relay (SSR)

7. Relays

8. Energy Meter

05/06/2015

Session I: Industrial Visit

Industrial visit to BSES Yamuna Power Limited: SCADA (Supervisory Control and Data Acquisition) Centre was organized. The visit was aimed at SCADA Centre developed by BSES to reduce power fault restoration time. The SCADA System Centre monitors the power distribution system and supply on a real time basis and abnormalities in the system are immediately flagged and corrective action is taken. Stating that "the communication between the Grid Station and Control Centre is being established and optic fibre network with ring loop formation ensures online connectivity at all times,'' a BSES official said SCADA leads to faster identification-isolation-and restoration of faults, loss minimisation, forecasting of load, intelligent alarms, better resource handling, reactive power management, Distribution Management System (DMS), more efficient outage management, switching optimisation and network study and planning.

Session III: Integrated Process automation and Analytics

During the session Ms. Jaya Nangia, AVP Cell, CHEMTROLS, discussed about problem of air pollution and solutions for monitoring the same. Ms Nangia discussed the following:

1. Pollution due to process plan

2. Measurement of ammonia, NO, SO2 & CO2

3. Outlet Desox acid gas control

4. Measuring techniques for gas emissions

5. Dilution techniques

6. Hot wet extractive system

7. Cold dry extractive system

8. In-situ analysis techniques

9. Particulate monitoring system

10. Ambient air quality management system

Session IV: Advances in Sensor, Control and information Networks

During the session Mr. Ravi Agrawal, Director, Pepperl & Fuchs, discussed classification of industrial vision systems. Mr. Agrawal also discussed that need of the hour is to design and develop the automation systems having:

1. Interoperability

2. Flexibility

3. Diagnostics

4. Network capability

5. Energy optimization

6. Wireless Capability

7. Remote Configuration

8. Adaptability

9. Collaborative

06/06/2015

Session I: Building Automation

During the session Mr. Vikram Sinha Patil, Business development Manager, Beckhoff Automation, discussed about building automation technologies. Mr. Patil also discussed the following:

1. Energy consumption in high rise buildings

2. Energy efficient buildings

3. Intelligent building management systems

An intelligent building management system includes fire alarm, energy management, security management, communication system, HVAC, Fluid Management System.

Session II: Implementing Systems Engineering Projects

During the session Mr. Dayanand Arya, CEO, ADROIT Controls India Pvt. Limited, explained in detail how automation projects are planned and implemented. Mr. Arya also discussed the following with respect to planning of automation projects: 1. Concept of operations

2. Requirement and architecture

3. Detailed design

4. Operation and maintenance

5. System verification

6. Integration and testing

Mr. Arya also discussed a case of automated extrusion machine developed by Adroit Technologies.

Session III: Design and Development of CNC MRF Machine

During the session Dr. Sunil Jha discussed the research carried out by him and his students at IIT Delhi. Dr. Jha show cased CNC MRF machine fully designed and developed by IIT Delhi. This machine is used for Nano-finishing of Ferrous and Non-ferrous materials and can be used in defense applications.

Valedictory session:

During the valedictory session Prof. (Dr). Sunil Kale, Head of the Department, Mechanical Engineering, IIT Delhi, highlighted the importance of hands on in teaching automation. Prof. Kale also discussed the role of a teacher in today’s environment and said that teachers must work in industry during their teaching career. Prof Kale awarded participation certificates to all the participants. The STC ended on a note that Institutes should spend more efforts in training the students and develop relevant curricula, while the industry should spend more efforts in training the teachers.