Introduction to Mechanical Engineering (BENSC104D/204D) Autonomous Module 5

Introduction to Mechanical Engineering

(BENSC104D/204D)
Autonomous

Module 5:
Introduction to Mechatronics and Robotics: Mechatronics systems – Definition of
mechatronics, elements of mechatronics systems, examples. Classification based on robot
configuration: Polar, Cylindrical, Cartesian coordinate and Jointed arm. Robot application,
advantages and disadvantages.
Elementary sensors: Working principle and applications of Potentiometer, Capacitive sensor and
Optical encoders.
Automation in Industry and Introduction to IIoT: Definition, types – Fixed, programmable
and flexible automation, basic elements with block diagrams, advantages. Definition and
characteristics of IIoT, Industry 4.0

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Contents
1. Introduction to Mechatronics and Robotics: ........................................................................... 3
1.1 Introduction to Mechatronics .......................................................................................... 3
1.1.1 What is mechatronics? ............................................................................................ 3
1.2 Basic Elements of Mechatronics System ........................................................................ 4
1.2.1 Definition of Control system: ................................................................................. 5
1.2.2 Classification of control system: ............................................................................. 5
1.2.3 Open loop control system (NO FEEDBACK control system): .............................. 5
1.2.4 Closed loop control system (WITH FEEDBACK control system): ....................... 6
1.2.5 Difference between Open and Closed loop control system .................................... 8
1.3 Basic Configurations of ROBOT .................................................................................... 9
1.3.1 Cartesian Configuration Robots: (LOO) ................................................................. 9
1.3.2 Cylindrical Configuration Robots: (TLO) ............................................................ 10
1.3.3 Polar (Spherical) Configuration Robots: (TRL) ................................................... 11
1.3.4 Jointed Arm Configuration / Revolute Robots: (TRR) ......................................... 11
1.3.5 Robot Applications................................................................................................ 12
1.4 Elementary Sensors ....................................................................................................... 13
1.4.1 Potentiometer ........................................................................................................ 13
1.4.2 Capacitive sensor .................................................................................................. 14
1.4.3 Optical encoders.................................................................................................... 15
2. Automation in Industry and Introduction to IIoT ................................................................. 17
2.1 Automation in Industry ................................................................................................. 17
2.1.1 Definition of Automation ...................................................................................... 17
2.1.2 Types of Automation ............................................................................................. 17
2.1.3 Fixed automation: ................................................................................................. 17
2.1.4 Programmable automation: ................................................................................... 17
2.1.5 Flexible automation: ............................................................................................. 18
2.1.6 Basic Elements of an Automated System ............................................................. 18
2.2 Industrial Internet of Things (IIoT) ............................................................................... 20
2.2.1 Characteristics of IIoT: ......................................................................................... 21
2.2.2 Difference between IoT and IIoT.......................................................................... 21
2.2.3 Benefits of IIoT ..................................................................................................... 22
2.2.4 Risks and challenges of IIoT................................................................................. 22
2.3 Industry 4.0 ................................................................................................................... 23
2.3.1 Characteristics of Industry 4.0: ............................................................................. 23
2.3.2 Relation Between IIoT and Industry 4.0: .............................................................. 23

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1. Introduction to Mechatronics and Robotics:

1.1 Introduction to Mechatronics
1.1.1 What is mechatronics?
Mechatronics is defined as the complete integration of mechanical system with electrical,
electronic and computer system into single system.

Mechatronics comprises of
• Motion control
• Actuators and Sensors
• Micro devices and optoelectronics
• Robotics
• Automotive systems
• Modelling and Design
• Mechatronics
• Mechanical
• Systems
• Electrical Systems
• System Integration
• Manufacturing
• Vibration and noise control
Advantages of Mechatronics:
1. The products produced are cost effective and very good quality.
2. High degree of flexibility
3. Greater extent of machine utilization
4. Greater productivity
5. High life expected by proper maintenance.
6. The integration of sensor and control system in a complex system reduces capital expenses.
Disadvantages of Mechatronics:

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1. Higher initial cost of the system.

2. Important to have Knowledge of different engineering fields for design and
implementation.
3. Is expenses to incorporate Mechatronics approaches to existing/old systems.
4. Specific problem of various systems will have to be addressed separately and properly.
Characteristics of Mechatronic system:
1. High quality product.
2. Safe.
3. Low cost.
4. Portable produced quickly
5. Serviceability, maintainability and upgradeability.
Applications of Mechatronic systems:
1. Automotive machines.
2. Fax and photocopier mechanics
3. Dishwashers.
4. Automatic washing machine
5. Air conditioners, elevator controls.
6. Documents scanners
7. IC manufacturing systems.
8. Robotics employed in welding, nuclear inspection, painting etc.,
9. VCRS (Videocassette recorder) and CD Players.

1.2 Basic Elements of Mechatronics System

Mechatronics is the synergistic integration of mechanical engineering, electronics, and intelligent
computer control in the design and manufacture of products and processes

Sensors and Actuators

Signals and Signal

Conditioning

Digital Logic Systems

Software and Data

Acquisition Systems

Computers and Display

Devices

Sensors and Actuators: Sensors and actuators form the physical interface of a mechatronics
system. Sensors are used to detect the condition of mechanical variables such as displacement,
velocity, acceleration, pressure, temperature, flow and many other physical quantities. They

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convert these physical parameters into electrical signals which can be processed by the electronic
controller. Actuators perform the opposite action. They convert electrical signals from the
controller into mechanical motion or force. Typical actuators used in mechatronics include electric
motors such as DC motors, AC motors, stepper and servo motors, as well as pneumatic, hydraulic
and piezoelectric actuators.
Signals and Signal Conditioning: Signals in a mechatronics system may exist in analog or digital
form and require conditioning before being used by the controller. Input signals from sensors must
be processed, amplified, filtered or converted into a form suitable for the controller, usually
through analog to digital conversion. Similarly, output signals from the controller may be too weak
or not in the correct form, so they are conditioned using digital to analog converters, amplifiers,
power electronics or display drivers before being sent to actuators or display devices. Therefore,
signal conditioning ensures correct communication between the physical system and electronic
control unit.
Digital Logic Systems: Digital logic systems are responsible for decision-making and control
within mechatronic products. These systems use logical operations, timing sequences,
microcontrollers, programmable logic controllers and embedded control algorithms to manage the
behaviour of the entire system. They receive conditioned input signals, compare them with desired
conditions and generate output decisions based on programmed control logic. These systems form
the “intelligence” of the mechatronic system and allow automatic operation instead of manual
control.
Software and Data Acquisition Systems: Software is used to collect, analyse and control data
inside the mechatronics system. Data acquisition systems collect output signals from sensors in
the form of electrical values such as voltage, resistance or frequency and convert them into digital
data that can be processed by computers or microprocessors. A typical data acquisition unit
consists of multiplexers, amplifiers, registers and control circuits. Software programs supervise
data collection, store real-time values, apply control algorithms and generate necessary output
signals. Examples include data loggers and computers with plug-in acquisition cards.
Computers and Display Devices: Computers act as the main processing and storage units in a
mechatronics system. They store a large quantity of data, execute control programs and provide
platforms for simulation, modelling and monitoring. Display devices are used to present system
information to the operator in visual form. They provide feedback on operating status,
measurements and system performance. Common display devices include LED indicators, LCD
screens, CRT monitors and digital numeric displays. These devices improve human-machine
interaction and make the operation of the mechatronic system easier and more understandable.
1.2.1 Definition of Control system:
A group of devices/elements which maintains the required output based on the predefined value
by controlling the parameter responsible for output.
1.2.2 Classification of control system:
1. Open loop control system (NO FEEDBACK control system).
2. Closed loop control system (WITH FEEDBACK control system).
1.2.3 Open loop control system (NO FEEDBACK control system):
In which the output is dependent on the input, but input is independent of output is called open
loop control system.

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Example 1: ON/OFF of an electric lamp: electric lamps are used for lighting the lamp. ON/OFF
control is carried out with the help of a switch and the switch is generally operated by an operator
depending on the amount of light that exist in that area. If the switch is ON, the lamp is glow. If
the person operating the switch does not put OFF of then switch, the lamp remains ON until he
switched OFF. So, it is called open loop control system.
Example 2: Control the temperature of the room with room heater: the amount of heat generated
by a room heater depends on the amount of input power controlled by a regulator. If the power is
switch ON, the power supplied to the heater continues and temperature of the room goes on
increasing immaterial of whether heat is required in the room or not. Here person is to go and OFF
the power supply switch and there by cooling the temperature of the room is decreasing.
Advantages of open loop control system
1. Less costly.
2. Relatively simple.
3. Good reliability.
4. Easy maintenance.
5. Inherently stable.
Disadvantages of open loop control system:
1. Inaccurate since there is no correction of error.
2. Relatively slow in response to change in demand.
3. The control depends on the human judgment.
4. Often leads to waste.
5. Any change in system component not to be taken care automatically.
1.2.4 Closed loop control system (WITH FEEDBACK control system):
In which input is depend on the output. i.e., variation in the output influences the input by some
means of controlling on the input is called a closed loop system.

Elements of closed loop control system:

The basic elements of a closed loop control system are:

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1. Comparison element.
2. Control unit.
3. Correction unit.
4. Process unit.
5. Feedback unit.
Functions of each element of a closed loop system:
Comparison element: this unit compares the reference value with feedback value and produces
an error signal.
Error = reference value - feedback value
Control unit: Control unit analyses the error signal and decides what action is to be taken.
Correction unit: the modified signal from the control unit will be received by the correction unit
which produces a change in the process to correct or change the controlled condition.
Process unit: Process unit is the unit which is being controlled.
Feedback Unit: Takes input from Process unit and sends the signal back for comparison to attain
high degree of control.
Example 1: Hand reaching an object.

This is an example of closed loop control system. A person wants to reach for an object. Position
of the object is given as reference; feedback signals and the eyes compare the actual position of
the hands with reference to the position of the object. Error signal is given to the brain. Brain
manipulates this error and gives signals to the hands. This process continues till the hand reaches
the object.
Example 2: Speed control of an automobile:

The driver observes the speedometer and based on the speed shown by the speedometer he decides

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whether the fuel supply should be increased or decreased or gear change is to be made. Here speed
shown a speedometer is feedback. A feedback signal from the eye compares the desire speed in
the memory of the driver. Error signals are given to brain. Brain manipulates the error signals and
gives it to hand and leg and increase the fuel supply if the speed is less than the desired speed,
otherwise decrease the fuel supply. Changing of gear and increase or decrease of fuel supply,
depends on whether it an upward or downward gradient respectively.
Advantages of closed loop control system:
1. More accurate.
2. Any change in system component can be taken care automatically.
3. Use of feedback system response is relatively insensitive to external disturbances and
internal variations in system parameters.
Disadvantages of closed loop control system:
Expensive and complicated to construction.
1.2.5 Difference between Open and Closed loop control system
Open loop control system Closed loop control system
1. Without feedback unit 1. With feedback unit
2. Output is depended on input 2. Input is depended on output
3. Less accurate 3. More accurate
4. Less expensive and easy to build 4. Expensive and Complex to build.
5. Slow in response to change in demand 5. High in response to change in demand
6. Stability can be ensured 6. May be an unstable at times
7. Input factor is the sole factor for 7. The control action is provided by the
providing the control action. difference between the input command
and corresponding output.
8. Control adjustment is depends upon 8. Control adjustment is depends upon
the human judgment and estimation output and feedback element.
9. Any change in system component 9. Any change in system component can
cannot be taken care automatically be taken care automatically
10. Example: ON/OFF of electric lamp, 10. Example: automatic washing
Controlling of fan speed, etc machine, digital camera, robots etc.,

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1.3 Basic Configurations of ROBOT

Work envelope or work volume of a robot can be defined as the space within the end effector of
the robot can operate or reach.
Based on the coordinate system of motion of the manipulator and end effector, there are four basic
configurations of robots:
1) Cartesian Configuration Robots (LOO)
2) Cylindrical Configuration Robots (TLO)
3) Polar (Spherical) Configuration Robots (TRL)
4) Jointed-Arm (Articulated) Configuration Robots
i. Revolute Robots (TRR) ii. SCARA Robots (VRO)
1.3.1 Cartesian Configuration Robots: (LOO)
Cartesian or rectangular coordinate configuration is constructed by three perpendicular slides,
giving only linear motions along the three principal axes. It consists of three prismatic joints. The
endpoints of the arm are capable of operating in a cuboidal space. The cartesian arm gives high
precision and is easy to program. These robots are also called XYZ robots because they are
equipped with three rotary joints to assemble XYZ axes.
Provides three linear motions along three mutually perpendicular axes: X, Y, and Z. However,
there is no rotary motion. Configuration provides rectangular work envelope. Used for assembly,
palletizing and machine tool loading.

Advantages
➢ Highly Accurate and speed
➢ Fewer costs
➢ Simple operating procedures
➢ High payloads
Limitations
➢ Less work envelope
➢ Low dexterity
Applications

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➢ Pick and Place

➢ Material handling
➢ Loading
➢ Unloading
1.3.2 Cylindrical Configuration Robots: (TLO)
Cylindrical configuration uses a vertical column and a slide that can be moved up or down along
the column. The robot arm is attached to the slide so that it can be moved with respect to the
column. By rotating the column, the robot is capable of achieving a work space that approximates
a cylinder
Provides two linear and one rotary motions. Configuration provides cylindrical work envelope,
has good work area to floor area ratio. Used for loading and unloading on machine tools.

Advantages
➢ It has higher load carrying capacity
➢ It provides high rigidity to the manipulator
➢ It is generally suitable for pick and place applications
Disadvantages
➢ It requires more floor space
➢ It has a reduced mechanical rigidity because robots with a rotary axis must overcome the
inertial of the object when rotating
Applications
➢ Conveyer pallet transfers
➢ Machine tool loading
➢ Forging applications

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➢ Packing operation
➢ Precision small assembly
1.3.3 Polar (Spherical) Configuration Robots: (TRL)
It uses a arm that can be raised or lowered about a horizontal pivot. The pivot is mounted on a
rotating base. The various joints provide the robot with capability to movie its arm within a
spherical space and hence it is also called as “Spherical Coordinate Robot” It has one linear and
two rotary motions.
Provides one linear and two rotary motions. Configuration provides spherical work envelope.
Used for spot welding and manipulation (Handling) of heavy loads.

Advantages
➢ Larger work envelope than the rectilinear or cylindrical configuration
➢ Vertical structure conserves less space
Disadvantages
➢ Repeatability and accuracy are also lower in the direction of rotary motion
➢ Requires more sophisticated control system
Applications
➢ Die casting
➢ Forging
➢ Glass handling
➢ Injection Moulding
➢ Stacking and unstacking
1.3.4 Jointed Arm Configuration / Revolute Robots: (TRR)
Widely-used jointed arm configuration is similar to that of a human arm. It comprises two straight
links representing the human forearm and upper arm and two rotary joints representing the elbow
and shoulder joints, which are mounted on a vertical rotary table corresponding to the human waist
joint. As a result, it can be controlled at any adjustments in the workspace.
Provides three rotary motions about three mutually perpendicular axes. Configuration is similar to
that of human arm. Consists of two straight links, corresponding to the human forearm and upper
arm, connected by a rotary joint. Provides spherical work envelope, has excellent work areas to

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floor area ratio. Used to spray painting, seam welding, spot welding, assembly, heavy material
handling, etc.

Advantages
➢ Increased flexibility,
➢ Huge work volume and
➢ Quick operation.
Disadvantages
➢ Very expensive
➢ Difficult operating procedures
➢ Plenty of components
Applications
➢ Spray Painting
➢ Spot Welding
➢ Arc Welding
1.3.5 Robot Applications
1. Robot are employed in a wide assortment of applications in industry. Today, most of the
applications are in manufacturing to move materials, parts, and tools of various types.
Nonmanufacturing tasks include exploration of space, defense, and medical care.
2. At some time in the near future, a household robot may become a mass produced item,
perhaps as commonplace as the automobile is today. Simple toy robot that can perform
simple reprogrammable functions are already commonplace.
3. For the present, most industrial applications of robots can be divided into the following
categories:
4. Material-handling and machine-loading and unloading applications – In these applications,
the robot’s function is to move materials or parts from one location in the work cell to some
other location.
5. Processing applications – This category includes spot welding, arc welding, spray painting,
and other operations in which the function of the robot is to manipulate a tool to accomplish
some manufacturing process in the work cell. Spot welding represents a particularly
important application in the processing category.

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6. Assembly and inspection – These are two separate operations which we include together
in this category. Robotic assembly is a field in which the industry is showing great interest
because of its economic potential.
7. Advanced applications – Rehabilitation, outer space, defense, pets, security, etc.
Work
Configurations Manipulator Motions Application
Envelope
Assembly, Palletizing Machine
Cartesian LOO 3 Linear Rectangular
Tool Loading
2 Linear,
Cylindrical TLO Loading & Unloading on Machine
1 Rotary Cylindrical
Tools
1 Linear,
Spherical (Polar) TRL Spot Welding , Handling of Heavy
2 Rotary Spherical
Loads.
Jointed Arm Spray Painting, Seam Welding,
Configuration / TRR 3 Rotary Spot Welding, Assembly, Heavy
Spherical
Revolute Material Handling
L = Linear; O = Orthogonal; R = Rotational; T = Twisting; V = Revolving

1.4 Elementary Sensors

Understanding elementary sensors forms the foundation for studying measurement systems and
automation. Three key sensors often used in basic instrumentation are the potentiometer,
capacitive sensor, and optical encoder.
1.4.1 Potentiometer
A potentiometer operates on the principle that the potential drop across a uniform resistance wire
is directly proportional to its length. This makes it a voltage divider used to control voltage, while
its applications include adjusting volume in audio devices, setting brightness and color in TVs,
and in laboratory settings, it's used to precisely measure an unknown voltage, internal resistance,
and compare the electromotive force (EMF) of cells.

V = voltage
I = current
R = resistance
G = Galvanometer
Rh = Rheostat
ρ (rho) = resistivity of the wire material
L = length of the wire
A = cross-sectional area of the wire

Working Principle of Potentiometer

Voltage Divider: A potentiometer is fundamentally a three-terminal variable resistor that works
as a voltage divider.

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Potential Proportional to Length: Its

operation is based on the principle that
the potential difference across a
uniform wire is directly proportional to
the length of the wire, provided a
constant current is flowing through it.
Wiper: A sliding contact (wiper)
moves along a resistive element. The
position of the wiper determines the
resistance between the wiper and the
two fixed ends, allowing for a variable
voltage output.
Applications of Potentiometer
1. Audio Control: Rotary and
slider potentiometers are widely
used to control volume and
other audio signals in radios, TVs, and musical instruments.
2. Electronics Adjustment: They are used in electronic devices like televisions to adjust
settings such as brightness, contrast, and color.
3. Laboratory Measurements: In physics labs, potentiometers are critical for:
• Comparing the electromotive force (EMF) of two cells.
• Precisely measuring the internal resistance of a cell.
• Measuring an unknown voltage by comparing it to a known voltage source.
4. Position and Displacement Sensing: Potentiometers, particularly linear ones, are used as
position sensors to measure displacement, which is valuable in control systems.
5. Control Systems: They are employed in servomechanisms and other closed-loop control
systems for position feedback.
1.4.2 Capacitive sensor
Capacitive sensors work by measuring changes in capacitance caused by an object entering their
electrostatic field, which alters the electrical properties between the sensor and the object. Their
applications include detecting the level of fluids, measuring position or displacement, and
providing touch-sensitive interfaces in consumer electronics like smartphones and tablets.
Working principle of Capacitive sensors
Capacitance: The sensor and the target object form a capacitor, where a high-frequency oscillator
circuit measures the change in capacitance.
Electric field: The sensor generates an electrostatic field from its active sensing surface.
Object interaction: When an object comes near, it modifies this electric field, which changes the
capacitance between the two "plates" of the capacitor (the sensor surface and the object).
Detection: The sensor detects this change in capacitance. The magnitude of the change depends
on the object's distance, size, and its dielectric constant.

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Output: The oscillator circuit's output changes once the capacitance reaches a certain threshold,
triggering the sensor's output signal.

Applications of Capacitive sensors

1. Industrial automation:
• Liquid level detection: Monitoring materials like water, oil, or chemicals in tanks or
hoppers, even through non-metallic barriers.
• Proximity sensing: Detecting the presence and position of parts on conveyor belts or
robotic arms.
• Flow and thickness measurement: Monitoring the flow rate or thickness of various
materials.
2. Consumer electronics:
• Touchscreens: Capacitive touchscreens in smartphones, tablets, and digital players use
the sensor to detect the presence and location of a finger.
• Replacement for mechanical buttons: Replacing traditional buttons with a sleek,
durable, and customizable touch-sensitive interface.
3. Measurement and control:
• Position and displacement sensing: High-precision sensors can measure linear
displacement with sub-micron resolution, used for tasks like machine tool positioning.
• Humidity measurement: Some sensors are designed to detect changes in humidity.
1.4.3 Optical encoders
Optical encoders work by converting linear or rotary motion into optical and then electrical
signals. They use a light source (like an LED) and a sensor (like a phototransistor) to detect the
presence or absence of light passing through or reflecting off a coded disc or scale with a pattern
of slits or markings. Applications include robotics, industrial automation, medical equipment, and
CNC machining, where they provide precise feedback on position, velocity, and acceleration.
Working principle of Optical encoders
Components: An optical encoder consists of a light source (LED), a coded disc or linear scale
with a pattern of transparent and opaque sections, and a photosensor.
Motion and light: As the shaft rotates or the scale moves, the pattern on the disc or scale moves
across the light source and sensor assembly.

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Signal generation: When the light passes through a transparent section, it hits the sensor. When
it is blocked by an opaque section, it does not. This on-off light pattern is converted into a series
of electrical pulses.

Signal conversion: The photosensor detects these pulses and converts them into electrical signals.
Position and motion determination: A motion control system counts these pulses to determine
the shaft's or scale's position, speed, and direction.
Incremental encoders: Output a series of pulses as the shaft moves, allowing the system to
calculate relative position and speed. An additional "Z" or index pulse is often provided once per
revolution to verify accuracy.
Absolute encoders: Use a unique gray-code pattern on the disc. As the disc rotates, the sensor
reads this code to output a unique binary number for each position, providing the absolute position
even after power loss.
Applications Optical encoders
1. Robotics: Provide high-precision feedback for motor control, enabling accurate
positioning and movement.
2. Industrial automation: Used in various automated systems for tasks like material handling,
packaging, and assembly.
3. CNC machining: Enable precise control over the position of tools and workpieces.
4. Medical and laboratory equipment: Used in devices that require precise motion, such as
pumps or scanners.
5. Elevators: Help control elevator car position and movement for safety and efficiency.
6. Optical networks: In telecommunications, optical encoders can be used to identify and
monitor Fiber optic links.

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2. Automation in Industry and Introduction to IIoT

2.1 Automation in Industry
2.1.1 Definition of Automation
The word 'Automation' is derived from Greek words "Auto"(self) and "Matos" (moving).
Automation can be defined as the set of technologies of carving out a process or procedure without
human assistance and achieves performance superior to manual operation.
2.1.2 Types of Automation
The automation of production systems can be classified into three basic types:
1. Fixed Automation or Hard Automation
2. Programmable Automation or Soft Automation
3. Flexible Automation

2.1.3 Fixed automation:

Fixed automation or hard automation is a type of automation which uses special purpose
equipment in order to automate a fixed sequence of processing or assembly operations. The
programmed commands are contained in the equipment in the form of cams, gears, wiring etc.
The equipment is designed to be efficient for the fixed set of operations. Usually each of the
operation in the sequence is simple involving a plain linear or rotational motion or both. But
integration and co-ordination of one or more operations can introduce complexity in the hard
automated system. This type of automation is highly recommended for mass production systems
that require high rate of production.
Examples are transfer lines found in the automotive industry, paint shops, distillation process,
automatic assembly processes, chemical processes, etc.
Advantages of Fixed Automation:
1. The production rates realized are high
2. Since goods are mass produced, the unit cost will be low.
3. Material handling is automated by the specialized equipment and thus special robot
intervention is not required
Disadvantages of Fixed Automation:
1. High initial investment for the special purpose equipment
2. Not flexible to accommodate product variety / product changes.

2.1.4 Programmable automation:

The Programmable automation or soft automation is chosen in production systems where the
volume of production is relatively low and there are a number of variety of products to be
produced. Here, the equipment for production is designed to be adaptable to variations in the
product styles/configuration.
The step-by-step instructions in the form of a program controls the sequence of operations and
these programs are read and interpreted by the system. For every new batch, the production
equipment must be re-programmed and changed over to as per the new product configuration.
Advantages of Programmable Automation:
1. Very much suitable for batch production

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2. Flexible to adapt to the changes in the product configuration since sequences can be
programmed and re-programmed.
Disadvantages of Programmable Automation:
1. The cost of the general-purpose equipment is high
2. Production time is lost due to frequent setup changes, loading of fixtures and also due to
reprogramming. This reduces production rate compared to fixed automation
Examples of Programmable automation include Numerically Controlled (NC) machine tools,
industrial robots, and Programmable Logic Controllers (PLC). In industries programmable
automation is found in production of brackets, hinges, locks, door knobs, musical instruments,
weaving, etc.
2.1.5 Flexible automation:
This type of automation is used for mid production size and combines the features of both fixed
automation and programmable automation. The flexible automated system is built in a way such
that it can both produce a variety of products and with almost no time lost for setup changes from
one configuration to another. Even reprogramming does not cause lost production time. This is
because programming is done off-line at a computer terminal without using the production
equipment itself. The system is therefore capable of producing many varieties in the product mix
under various schedules without need for batch changes.
Advantages of Flexible Automation:
1. For the variety of product configurations, continuous production is possible
2. Flexible to adapt to the changes in the product configuration in very less time using an off-
line computer terminal for programming and re-programming.
3. Improved quality of the product
Disadvantages of Flexible Automation:
1. The cost of investment is huge since the equipment is custom-built
2. Only medium production rates can be achieved unlike fixed automation
3. Compared to fixed automation, unit cost of the product is higher.
Example of a Flexible Automation System is the use of CNC Machine Tools along with Robots
and Automated Guided Vehicles (AGV). In industries, flexible automation systems are used in
fabrication, assembly and machining processes.
2.1.6 Basic Elements of an Automated System
An Automated system is the system that is used to realize automation.
As shown in below there are three basic elements of an automated system. The three basic
elements of an automated system are
1. A Power sources
2. A program of instructions
3. A control system
Principally in an automated system, the program of instructions is fed to the control system where
these instructions are executed and a power source is used to provide power to drive the process
as well as operate the control system. The process then becomes an "automated process"

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1. Power Source: An automated system is used to automatically complete the tasks in a process.
To accomplish this, a power source has to drive both the process and the controls.
The commonly used power source in an automated system is electric power.
Electric power is widely preferred power source for an automated system due to its wide
availability at reasonable cost, its ease of conversion into other forms of energy like mechanical,
thermal, hydraulic, pneumatic, etc., its easy storage I long-life high-performance batteries which
makes it conveniently available at any place and its usage at lower levels to carryout signal
transmission, information processing, data storage and communication.
Other power sources can be conventional sources such as fossil fuels, or non-conventional sources
such as solar energy, wind energy, etc. These are generally used in combination with electrical
power. Example: Fossil fuels are used to heat the furnace in casting. but electricity is used in the
control system to regulate temperature and time cycle.
Even other energy sources can be converted to electrical energy and used to operate the process
and its automation. Example: Conversion of Solar energy to electricity to operate an automated
system.
2. Program of Instructions: The set of actions that is accomplished by an automated system are
determined by the program of instructions. Each part produced in a manufacturing operation
requires following of sequential processing steps within a work cycle. These processing steps for
the work cycle are specified in a work cycle program. In NC machines, we call these as Part
Programs
Advantage of automation
1. Automation results in increase of productivity: Use of automated systems can increase the
efficiency in performing tasks which results in higher productivity.
2. Improvement in Product Quality: Automated systems perform the manufacturing process
with less variability compared to human workers and hence product quality is improved.
3. Increase in accuracy and repeatability: When an automated system is programmed to carry
out a task over and over again, the accuracy and repeatability compared to a human worker
is far greater.

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4. Improved safety at the workplace: Automated systems can perform tasks in hazardous and
unfriendly environment which when done by humans would be prone to injuries and
accidents. This improves workplace safety.
5. Reduction in manufacturing lead time: Automated Systems can reduce the lead time for
manufacturing due to speed, consistency and less/zero defects.
6. Reduced direct human labour costs and expenses: Using automated systems implies less
number of employees are required to get the job done. By having less number of
employees, there are numerous costs that are directly reduced such as payroll, benefits,
sick days, etc.
7. Mitigation of Potential Labour Shortages: Automation can mitigate the effects of potential
labour shortages. It decreases dependency on skilled labour and fills the void created due
to a skilled worker retirement.
8. Automated Systems can carry out processes that cannot be done manually. Example,
automated systems can carry out certain processes in a nuclear radiation environment
which is not possible by human labour.
9. Automation can reduce or eliminate day-to-day manual and clerical jobs.
Disadvantages of Automation
1. Though automation effectively replaces human labour in performing various tasks, it
results in increased unemployment and poverty which counters job creation efforts.
2. High initial cost: The initial investment involved in the automation of a new product or
plant is very large. Though the cost of automation may be amortized or spread among many
units of products over some time period, the unit cost of the product manufactured using
automation will still be higher compared to the product manufactured without automation.
This may be at competitive disadvantage.
3. Automated systems can pose Security Threats since with a limited level of intelligence it
is more susceptible to committing errors outside of its immediate scope of knowledge
(Example, lack of application of simple rules of logic to general propositions).
4. Additional Costs: Other than a high investment cost, automated systems also involve
excessive development costs due to research and development, preventive maintenance
and cost of training personnel to operate automated systems. These costs offset the costs
supposed to have been saved by automation.
5. With excessive automation, humans become slaves of automated machines creating too
much dependency on machines rather than human intelligence.

2.2 Industrial Internet of Things (IIoT)

“The industrial internet of things (IIoT) is the use of smart sensors, actuators and other
devices, such as radio frequency identification tags, to enhance manufacturing and industrial
processes. These devices are networked together to provide data collection, exchange and
analysis. Insights gained from this process aid in more efficiency and reliability”. Also known
as the industrial internet, IIoT is used in many industries, including manufacturing, energy
management, utilities, oil and gas.
Connected sensors and actuators enable companies to pick up on inefficiencies and problems
sooner, saving time and money while also supporting business intelligence efforts. In
manufacturing specifically, IIoT has the potential to provide quality control, sustainable and green

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practices, supply chain traceability and overall supply chain efficiency. In an industrial setting,
IIoT is key to processes such as predictive maintenance, enhanced field service, energy
management and asset tracking.
IIoT is a network of intelligent devices connected to form systems that monitor, collect, exchange
and analyze data. Each industrial IoT ecosystem consists of the following:

• Connected devices that can sense, communicate and store information about themselves.
• Public and private data communications infrastructure.
• Analytics and applications that generate business information from raw data.
• Storage for the data that's generated by the IIoT devices.
• People.
These edge devices and intelligent assets transmit information directly to the data communications
infrastructure, where it's converted into actionable information on how a certain piece of
machinery is operating. This information can be used for predictive maintenance, as well as to
optimize business processes

2.2.1 Characteristics of IIoT:

1. Connectivity: Devices, machines, and systems are connected through the internet (via
wired or wireless networks).
2. Data-Driven: Real-time data collection and analysis from sensors and devices.
3. Remote Monitoring and Control: Enables remote diagnostics, operations, and
maintenance.
4. Predictive Maintenance: Uses data analytics to predict equipment failures before they
occur.
5. Increased Efficiency: Optimizes resource usage and operational processes.
6. Integration with Cloud and Edge Computing: For scalable and real-time data processing.
7. Enhanced Safety and Compliance: Through continuous monitoring and automation.

2.2.2 Difference between IoT and IIoT

Although the internet of things and IIoT have many technologies in common -- including cloud
platforms, sensors, connectivity, machine-to-machine communications and data analytics --
they're used for different purposes.
IoT systems connect devices across multiple verticals, including agriculture, healthcare,
enterprise, consumer, utilities, government and cities. IoT technology includes smart devices,
fitness bands and other applications that generally don't create emergency situations if something
goes amiss.
IIoT applications, on the other hand, connect machines and devices in sectors such as oil and gas,
utilities and manufacturing. System failures and downtime in IIoT deployments can result in high-
risk or life-threatening situations. IIoT applications are also more concerned with improving
efficiency, health or safety versus the user-centric nature of IoT applications
Numerous industries use IIoT, including the following:
1. The automotive industry. This industry uses industrial robots, and IIoT can help proactively
maintain these systems and spot potential problems before they can disrupt production.

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The automotive industry also uses IIoT devices to collect data from customer systems,
sending it to the company's systems. That data is then used to identify potential
maintenance issues.
2. The agriculture industry. Industrial sensors collect data about soil nutrients, moisture and
other variables, enabling farmers to produce an optimal crop.
3. The oil and gas industry. Some oil companies maintain a fleet of autonomous aircraft that
use visual and thermal imaging to detect potential problems in pipelines. This information
is combined with data from other types of sensors to ensure safe operations.
4. Utilities. IIoT is used in electric, water and gas metering, as well as for the remote
monitoring of industrial utilities equipment such as transformers.
2.2.3 Benefits of IIoT
IIoT devices used in the manufacturing industry offer the following benefits:
1. Predictive maintenance. Organizations can use real-time data generated from IIoT systems
to predict when a machine needs to be serviced. That way, the necessary maintenance can
be performed before a failure occurs. This can be especially beneficial on a production
line, where the failure of a machine might result in a work stoppage and huge costs. By
proactively addressing maintenance issues, an organization can achieve better operational
efficiency.
2. More efficient field service. IIoT technologies help field service technicians identify
potential issues in customer equipment before they become major issues, enabling tech
3. To fix the problems before they affect customers. These technologies also provide field
service technicians with information about which parts they need to make a repair. This
ensures technicians have the necessary parts with them when making a service call.
4. Asset tracking. Suppliers, manufacturers and customers can use asset management systems
to track the location, status and condition of products throughout the supply chain. The
system sends instant alerts to stakeholders if the goods are damaged or at risk of being
damaged, giving them a chance to take immediate or preventive action to remedy the
situation.
5. Increased customer satisfaction. When products are connected to IoT, the manufacturer
can capture and analyze data about how customers use their products, enabling
manufacturers and product designers to build more customer-centric product roadmaps.
6. Improved facility management. Manufacturing equipment is susceptible to wear and tear,
which can be exacerbated by certain conditions in a factory. Sensors can monitor
vibrations, temperature and other factors that could lead to suboptimal operating
conditions.
2.2.4 Risks and challenges of IIoT
The biggest risks associated with IIoT use pertain to security. It's relatively common for IIoT
devices to continue using default passwords, even after they've been put into production. Similarly,
many IIoT devices transmit data as clear text. These conditions could make it relatively easy for
an attacker to intercept the data coming from an IIoT device. Similarly, an attacker could take over
an insecure IIoT device and use it as a platform for launching an attack against other network
resources.
Security and device management are major challenges for those who are responsible for an
organization's IIoT devices. As an organization adds more IIoT devices, it becomes increasingly
important to adopt an effective device management strategy. More specifically, organizations must

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be able to positively identify IIoT devices to prevent the use of rogue devices. Establishing a means
of identifying each individual device is also crucial for tasks such as replacing a failed device or
performing a device refresh.
Patch management presents another challenge with IIoT devices. It's becoming more common for
device manufacturers to issue periodic firmware updates. Organizations must have an efficient
way to check devices to see if they have the latest firmware installed and deploy new firmware if
necessary. In addition, such a tool must adhere to the organization's established maintenance
schedule so it doesn't disrupt operations.

2.3 Industry 4.0

“Industry 4.0 is the fourth industrial revolution, characterized by the integration of digital
technologies into manufacturing and industrial processes. It focuses on smart factories
where cyber-physical systems monitor processes and make decentralized decisions”. It
combines technologies such as IIoT, AI, machine learning, big data, robotics, and cloud computing
to create intelligent and automated systems.
2.3.1 Characteristics of Industry 4.0:
1. Smart Manufacturing: Use of intelligent systems for flexible, automated production.
2. Cyber-Physical Systems (CPS): Integration of computing, networking, and physical
processes.
3. Interconnectivity: Machines, devices, sensors, and people communicate via IoT.
4. Real-Time Data: Continuous data gathering and decision-making in real time.
5. Decentralization: Decision-making is distributed across the network rather than
centralized.
6. Customization and Flexibility: Mass customization is achievable with flexible production
lines.
7. Digital Twin Technology: Virtual models of physical assets for simulation and monitoring.
8. Enhanced Productivity and Innovation: Through automation and data analytics.
2.3.2 Relation Between IIoT and Industry 4.0:
IIoT is a core enabler of Industry 4.0.
While IIoT focuses more on the technology and infrastructure (sensors, networks, data), Industry
4.0 is a broader vision for transforming the entire industrial ecosystem using those technologies.

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