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Control Systems and Automation Analysis

A) Represents a production system with high product quantity and low product variety, making it suitable for a fixed automation system. B) Reflects medium quantities and medium variety, making it a good fit for a programmable automation system which allows for some changes. C) Has low quantities but high variety, positioning it to benefit most from a flexible automation system that can easily adapt to different products.

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Siddheswar Biswal
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50 views12 pages

Control Systems and Automation Analysis

A) Represents a production system with high product quantity and low product variety, making it suitable for a fixed automation system. B) Reflects medium quantities and medium variety, making it a good fit for a programmable automation system which allows for some changes. C) Has low quantities but high variety, positioning it to benefit most from a flexible automation system that can easily adapt to different products.

Uploaded by

Siddheswar Biswal
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

1.

Match the types of Control Systems given in the left column with their
corresponding advantage/disadvantage given in the right column.

A. Advantage of closed loop control I. Easy to implement. Needs lesser


systems number of components. The overall
cost is lower.
B. Advantage of open loop control II. Easily affected by load
systems disturbances.
C. Disadvantage of Closed loop III. The control action is dependent on
control system the output.
D. Disadvantage of open loop control IV. Implementation is more complex
system and overall cost is higher.

a) A: III, B: IV, C: II, D: I


b) A: III, B: IV, C: I, D: II
c) A: II, B: III, C: IV, D: II
d) A: III, B: I, C: IV, D: II

Answer: (d)

Advantage of closed loop control system: Control action is dependent on output.

r + e u y
C(s) G(s)
-

u  C  s e

u  C  s  r  y

If there is any change in output (y) it will affect the control input (u) and
immediately takes the corrective action.
2. Suppose a company buys two types of band saw machines for cutting steel
ingots brought in by customers to dimension namely, Manual and Automatic, taking
loan from a bank to be paid back in 24 equal monthly instalments. From figures
given below for each machine, compute the amount of profit/machine the company
can earn from each type of machine in 2 years by cutting ingots for 200
hours/month assuming enough demand such that the machines cut every day
neglecting times for maintenance.
Manual Automatic
Cost ₹10,00,000 ₹20,00,000
Manpower 6 (@₹30000/month) 2(@₹40000/month)
Average energy 3 kW 4 kW
consumption
( Rs10/kWh)
Rate of annual simple 20% /yr 20%/yr
interest to be applied
on the borrowed
amount
Cost of saw/month ₹ 10,000 ₹ 30,000
Number of products 10
3
manufactured/hr
Cutting charge /ingot ₹ 1000 ₹1000

a) Manual: ₹4,82,96,000 , Automatic: ₹4,23,68,000


b) Manual: ₹ 42,96,000 , Automatic: ₹8,23,68,000
c) Manual: ₹ 82,96,000 , Automatic: ₹4,23,68,000
d) Manual: ₹ 82,96,0000 , Automatic: ₹4,23,68,00

Answer: (c)

Working hrs. : 200hr/month


Working month : 24 months

Manual Automatic
Cost of the Machine ₹ 10,00,000/- ₹ 20,00,000/-
Salary of employees (6 × 24 × 30,000) (2 × 24 × 40,000)
= ₹ 4,32,000/- = ₹ 19,20,000/-
Total cost of energy (200 × 24 × 3 × 10) (200 × 24 × 4 × 10)
= ₹ 1,44,000/- = ₹ 1,92,000/-
Total interest (10,00,000 × 0.2 × 2) (20,00,000 × 0.2 × 2)
= ₹ 4,00,000/- = ₹ 8,00,000/-
Total cost of saw (24 × 10,000) (24 × 30,000)
= ₹ 2,40,000/- = ₹ 7,20,000/-
Total cost price ₹ 61,04,000/- ₹ 56,32,000/-
Total selling price (200 × 24 × 3 × 1000) (200 × 24 × 10 × 1000)
= ₹ 1,44,00,000/- = ₹ 4,80,00,000/-
Total profit (₹ 1,44,00,000 - ₹ 61,04,000) (₹4,80,00,000 - ₹ 56,32,000)
= ₹ 82,96,000/- = ₹ 4,23,68,000/-
3. What type of automation system would you recommend for manufacturing
Fluorescent Tube Lights & Garments?

a) Fluorescent Tube Lights: Flexible & Garments: Fixed


b) Fluorescent Tube Lights: Programmable & Garments: Flexible
c) Fluorescent Tube Lights: Fixed & Garments: Programmable
d) Fluorescent Tube Lights: Fixed & Garments: Flexible
Answer: (d)

Fixed Automation: It is used in high volume production with dedicated equipment,


which has a fixed set of operation and designed to be efficient for this set.
Continuous flow and Discrete Mass Production systems use this automation. e.g.
Distillation Process, Conveyors, Paint Shops, Transfer lines etc.

A process using mechanized machinery to perform fixed and repetitive operations in


order to produce a high volume of similar parts.

Flexible Automation: It is used in Flexible Manufacturing Systems (FMS) which is


invariably computer controlled. Human operators give high-level commands in the
form of codes entered into computer identifying product and its location in the
sequence and the lower level changes are done automatically. Each production
machine receives settings/instructions from computer. These automatically
loads/unloads required tools and carries out their processing instructions. After
processing, products are automatically transferred to next machine. It is typically
used in job shops and batch processes where product varieties are high and job
volumes are medium to low. Such systems typically use Multi purpose CNC
machines, Automated Guided Vehicles (AGV) etc.
4. Match the types of Production Systems in factories given in the left column
with their corresponding products given in the right column

A) Continuous Flow Process I. Pharmaceuticals

B) Mass Manufacturing Of Discrete II. Garments


Products

C) Batch Production III. Steel

D) Job Shop IV. Cycles

a) A: III, B: IV, C: I, D: II
b) A: II, B: IV, C: III, D: II
c) A: III, B: I, C: IV, D: II
d) A: IV, B: II, C: I, D: III

Answer: (a)

A) Continuous flow process: Manufactured product is in continuous quantities i.e.,


the product is not a discrete object. Moreover, for such processes, the volume of
production is generally very high, while the product variation is relatively low.
Typical examples of such processes include Oil Refineries, Iron and Steel Plants,
Cement and Chemical Plants.

B) Mass Manufacturing of Discrete Products: Products are discrete objects and


manufactured in large volumes. Product variation is very limited. Typical
examples are Appliances, Automobiles etc.

C) Batch Production: In a batch production process the product is either discrete or


continuous. However, the variation in product types is larger than in continuous-
flow processes. The same set of equipment is used to manufacture all the product
types. However for each batch of a given product type a distinct set of operating
parameters must be established. This set is often referred to as the “recipe” for
the batch. Typical examples here would be Pharmaceuticals, Casting Foundries,
Plastic moulding, Printing etc.

D) Job shop Production: Typically designed for manufacturing small quantities of


discrete products, which are custom built, generally according to drawings
supplied by customers. Any variation in the product can be made. Examples
include Machine Shops, Prototyping facilities etc.
5. A,B and C are three different product manufacturing systems whose
characterisation in terms of product quantity vs product variety is shown below.
Choose the right option for automation system for A, B and C.

a) A: Fixed Automation System, B: Flexible Automation System, C:


Programmable Automation System.
b) A: Fixed Automation System, B: Programmable Automation System, C:
Flexible Automation System.
c) A: Fixed Automation System, B: Flexible Automation System, C:
Programmable Automation System.
d) A: Flexible Automation System, B: Fixed Automation System, C:
Programmable Automation System.

Answer: (b)

A) Fixed Automation: It is used in high volume production with dedicated equipment,


which has a fixed set of operation and designed to be efficient for this set.
Continuous flow and Discrete Mass Production systems use this automation. e.g.
Distillation Process, Conveyors, Paint Shops, Transfer lines etc.
A process using mechanized machinery to perform fixed and repetitive operations in
order to produce a high volume of similar parts.
B) Programmable Automation: It is used for a changeable sequence of operation and
configuration of the machines using electronic controls. However, non‐trivial
programming effort may be needed to reprogram the machine or sequence of
operations. Investment on programmable equipment is less, as production process
is not changed frequently. It is typically used in Batch process where job variety is
low and product volume is medium to high, and sometimes in mass production also.
e.g. in Steel Rolling Mills, Paper Mills etc.
C) Flexible Automation: It is used in Flexible Manufacturing Systems (FMS) which is
invariably computer controlled. Human operators give high‐level commands in the
form of codes entered into computer identifying product and its location in the
sequence and the lower level changes are done automatically. Each production
machine receives settings/instructions from computer. These automatically
loads/unloads required tools and carries out their processing instructions. After
processing, products are automatically transferred to next machine. It is typically
used in job shops and batch processes where product varieties are high and job
volumes are medium to low. Such systems typically use Multi purpose CNC
machines, Automated Guided Vehicles (AGV) etc.
6. Name the subsystems A, B and C of a typical sensor system shown below.

Physical
A B C
medium

Fig.Q6 Typical Sensor System

a) A: Sensing element, B: Signal Conditioning and Processing Element, C:


Target Signal Handling Element
b) A: Signal Conditioning and Processing Element, B: Sensing element, C:
Target Signal Handling Element
c) A: Signal Conditioning and Processing Element, B: Target Signal Handling
Element, C: Sensing element.

Answer: (a)

7. Name the levels A and B of a typical Automation Pyramid shown below.

Production
control

Automatic control

Sensors,actuators

Fig.Q7 Typical Automation Pyramid

a) A: Enterprise Management, B: Supervisory control


b) A: Supervisory control, B: Process Control
c) A: Supervisory Control, B: Enterprise Management

Answer: (c)
8. State three major functions of the Supervisory Control Level of an Automation
System

a) Process Scheduling, Maintenance Management, Inventory Management.


b) Set point generation, Process Monitoring, Operator Interface.
c) Set point generation, Inventory Management, Operator Interface.
d) Set point generation, Maintenance Management, Inventory Management.

Answer: (b)

9. State three major functions of a Production Control Level of an Automation


System

a) Process Scheduling, Maintenance Management, Inventory Management.


b) Set point generation, Process Monitoring, Operator Interface.
c) Set point generation, Inventory Management, Operator Interface.
d) Set point generation, Maintenance Management, Inventory Management.

Answer: (a)
10. What is the highest level of automation pyramid is present in the system shown
below

Fig. Q10: Automatic bottle filling system

a) Level 0
b) Level 3
c) Level 2
d) Level 1

Answer: (d)

Position of
valve at the tank Filled
Reference bottle
Controller
Weight +
-
signal Belt Driving
Mechanism

Weight sensor
11. What is the highest level of automation pyramid is present in the system shown
below

Fig Q11: Water level controller


a) Level 2
b) Level 3
c) Level 1
d) Level 0

Answer: (c)

Desired level Actual level


Pneumatic
Controller Tank
+ valve
-

Float
position

Common questions

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Choosing the right automation system directly impacts manufacturing efficiency and cost-effectiveness. Fixed automation is cost-efficient for large-volume production but inflexible, leading to high efficiency in specific scenarios only . Programmable automation balances flexibility and equipment cost for medium volumes, while flexible automation increases efficiency in varied production environments despite higher initial investments, saving costs through versatility in long run operations .

The profit from the manual band saw machine is ₹82,96,000 obtained by subtracting total costs (including machine cost, salary, energy, interest, and saw costs) from the selling price of the products manufactured [. The profit from the automatic band saw machine is ₹4,23,68,000, calculated similarly .

The Supervisory Control Level in an Automation System Pyramid plays a crucial role by generating set points for processes, monitoring the operations, and providing an interface for operators. This level ensures the proper execution of automation tasks and aligns them with enterprise management goals .

Fixed automation systems are suited for high volume production with limited product variety, such as in continuous flow or discrete mass production systems . Programmable automation is ideal for batch processing where product variety is low and volume is medium to high, often needing a significant programming effort for changes . Flexible automation is used in scenarios with high product variety and medium to low volume, leveraging computer-controlled systems for dynamic manufacturing operations .

Fixed automation is recommended for manufacturing fluorescent tube lights due to its efficiency in high-volume, low-variation production . Flexible automation is recommended for garments, as it accommodates high product variety and can adjust to different production runs efficiently .

Closed loop control systems have the advantage that the control action is dependent on the output, allowing for self-correction of any changes in the output . However, they are more complex to implement and are generally more expensive than open loop systems . In contrast, open loop control systems are easier to implement and require fewer components, resulting in lower overall costs, but their control action is not dependent on the output, making them sensitive to load disturbances and variations .

Automation type significantly affects the product lifecycle by determining production scalability, adaptability to consumer demands, and costs. For example, fixed automation optimizes the lifecycle for high-volume, uniform products by lowering per-unit costs but limits innovation. Flexible automation supports frequent changes in product design, enhancing lifecycle management for diverse products but at a higher initial system setup cost. Programmable automation offers a middle ground, allowing moderate flexibility with manageable cost adjustments .

A typical sensor system consists of the Sensing Element, which detects physical quantities and converts them into signals; Signal Conditioning and Processing Element, which amplifies and filters the signal; and the Target Signal Handling Element, which prepares the signal for output or further interpretation .

Batch production uses the same equipment for various product types but requires distinct setups or 'recipes' for different batches, offering moderate flexibility compared to continuous flow production which focuses on a single product type in mass quantities with little variation or flexibility . Job shop production offers the highest flexibility, designed for custom, small-scale production, varying based on customer specifications .

The Production Control Level manages process scheduling, maintenance management, and inventory management. It ensures that production is efficient and inventory is in sync with production demands, while also organizing maintenance activities to minimize downtime .

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