Automation of production processes is the main direction along which production is currently moving throughout the world. Everything that was previously performed by man himself, his functions, not only physical, but also intellectual, are gradually transferred to technology, which itself carries out technological cycles and controls them. This is the general direction now modern technologies. The role of a person in many industries is already reduced to only a controller behind an automatic controller.

In general, the concept of “process control” is understood as a set of operations necessary to start, stop the process, as well as maintain or change in the required direction physical quantities(process indicators). Individual machines, units, devices, devices, complexes of machines and devices that carry out technological processes that need to be controlled are called control objects or controlled objects in automation. Managed objects are very diverse in their purpose.

Automation technological processes – replacement of human physical labor spent on controlling mechanisms and machines with the work of special devices that ensure this control (regulation of various parameters, obtaining a given productivity and product quality without human intervention).

Automation of production processes makes it possible to increase labor productivity many times over, increase its safety, environmental friendliness, improve product quality and make more efficient use of production resources, including human potential.

Any technological process is created and carried out to achieve a specific goal. Manufacturing the final product, or to obtain an intermediate result. Thus, the purpose of automated production can be sorting, transportation, and packaging of a product. Automation of production can be complete, complex or partial.

Partial automation occurs when one operation or a separate production cycle is carried out automatically. At the same time, limited human participation in it is allowed. Most often, partial automation occurs when the process proceeds too quickly for the person himself to fully participate in it, while fairly primitive mechanical devices driven by electrical equipment cope well with it.

Partial automation, as a rule, is used on existing equipment and is an addition to it. However, it is most effective when included in common system automation from the very beginning - is immediately developed, manufactured and installed as its integral part.

Comprehensive automation should cover a separate large production area, this could be a separate workshop or power plant. In this case, the entire production operates in the mode of a single interconnected automated complex. Complex automation of production processes is not always advisable. Its field of application is modern highly developed production, which uses extremelyreliable equipment.

The breakdown of one of the machines or units immediately stops the entire production cycle. Such production must have self-regulation and self-organization, which is carried out according to a previously created program. In this case, a person takes part in the production process only as a permanent controller, monitoring the state of the entire system and its individual parts, and intervenes in production for start-up and when emergency situations arise, or when there is a threat of such an occurrence.

The highest level of automation of production processes – full automation . With it, the system itself carries out not only the production process, but also complete control over it, which is carried out by automatic control systems. Full automation is advisable in cost-effective, sustainable production with established technological processes with a constant operating mode.

All possible deviations from the norm must be previously foreseen, and systems for protecting against them must be developed. Full automation is also necessary for work that may threaten human life, his health, or is carried out in places inaccessible to him - under water, in an aggressive environment, in space.

Each system consists of components that perform specific functions. In an automated system, sensors take readings and transmit them to make a decision on system control; the command is carried out by the drive. Most often this is electrical equipment, since it is more expedient to carry out commands with the help of electric current.

It is necessary to distinguish between automated control systems and automatic ones. At automated control system the sensors transmit readings to the operator’s console, and he, having made a decision, transmits the command to the executive equipment. At automatic system– the signal is analyzed by electronic devices, and after making a decision, they give a command to the executing devices.

Human participation in automatic systems is still necessary, albeit as a controller. He has the ability to intervene in the technological process at any time, correct it or stop it.

So, the temperature sensor may fail and give incorrect readings. In this case, electronics will perceive its data as reliable without questioning it.

The human mind is many times greater than its capabilities electronic devices, although it is inferior to them in terms of response speed. The operator can understand that the sensor is faulty, assess the risks, and simply turn it off without interrupting the process. At the same time, he must be completely confident that this will not lead to an accident. Experience and intuition, which are inaccessible to machines, help him make a decision.

Such targeted intervention in automatic systems does not carry any serious risks if the decision is made by a professional. However, turning off all automation and switching the system to manual control mode is fraught with serious consequences due to the fact that a person cannot quickly respond to changing conditions.

A classic example is the accident at the Chernobyl nuclear power plant, which became the largest man-made disaster last century. It occurred precisely because the automatic mode was turned off, when the already developed programs to prevent emergency situations could not influence the development of the situation in the plant’s reactor.

Automation of individual processes began in industry back in the nineteenth century. Suffice it to recall the automatic centrifugal regulator for steam engines designed by Watt. But only with the beginning of the industrial use of electricity did wider automation become possible, not of individual processes, but of entire technological cycles. This is due to the fact that previously mechanical force was transmitted to machines using transmissions and drives.

Centralized production of electricity and its use in industry, by and large, began only in the twentieth century - before the First World War, when each machine was equipped with its own electric motor. It was this circumstance that made it possible to mechanize not only the production process on the machine, but also to mechanize its control. This was the first step towards creating automatic machines. The first samples of which appeared in the early 1930s. Then the term “automated production” itself arose.

In Russia - then still in the USSR - the first steps in this direction were taken in the 30-40s of the last century. For the first time, automatic machines were used in the production of bearing parts. Then came the world's first fully automated production of pistons for tractor engines.

Technological cycles were combined into a single automated process, starting with the loading of raw materials and ending with the packaging of finished parts. This became possible thanks to the widespread use of modern electrical equipment at that time, various relays, remote switches, and of course, drives.

And only the advent of the first electronic computers made it possible to reach a new level of automation. Now the technological process has ceased to be considered as simply a set of individual operations that must be performed in a certain sequence to obtain a result. Now the whole process has become one.

Currently, automatic control systems not only conduct the production process, but also control it and monitor the occurrence of abnormal and emergency situations. They start and stop technological equipment, monitor overloads, and work out actions in case of accidents.

IN Lately automatic control systems make it quite easy to rebuild equipment to produce new products. This is already a whole system, consisting of separate automatic multi-mode systems connected to a central computer, which links them into a single network and issues tasks for execution.

Each subsystem is a separate computer with its own software designed to perform its own tasks. It's already flexible production modules. They are called flexible because they can be reconfigured for other technological processes and thereby expand production and diversify it.

The pinnacle of automated production is. Automation has permeated production from top to bottom. The transport line for the delivery of raw materials for production operates automatically. Automated management and design. Human experience and intelligence are used only where electronics cannot replace it.

Ministry of Vocational Education

Tomsk Polytechnic University

Skorospeshkin M.V.

Basics of industrial process automation

Lecture notes

Part 1. Theory of Automatic Control (TAC)

1. Basic terms and definitions of TAU.

1.1. Basic concepts.

Control systems for modern technological processes are characterized by a large number of technological parameters, the number of which can reach several thousand. To maintain the required operating mode, and ultimately the quality of the products, all these quantities must be maintained constant or changed according to a certain law.

Physical quantities that determine the progress of a technological process are called process parameters . For example, process parameters can be: temperature, pressure, flow, voltage, etc.

A technological process parameter that must be maintained constant or changed according to a certain law is called controlled variable or adjustable parameter .

The value of the controlled quantity at the considered moment in time is called instantaneous value .

The value of the controlled quantity obtained at the considered moment in time based on the data of some measuring device is called its measured value .

Example 1. Scheme of manual temperature control of the drying cabinet.

It is necessary to manually maintain the temperature in the drying cabinet at the T set level.

The human operator, depending on the readings of the mercury thermometer RT, turns on or off the heating element H using the switch P. 

Based on this example, you can enter definitions:

Control object (object of regulation, OU) – a device whose required operating mode must be supported externally by specially organized control actions.

Control – formation of control actions that ensure the required operating mode of the op-amp.

Regulation – private view control, when the task is to ensure the constancy of any output value of the op-amp.

Automatic control – control carried out without direct human participation.

Input influence (X)– influence applied to the input of a system or device.

Output impact (Y) – the impact produced at the output of a system or device.

External influence – the impact of the external environment on the system.

The block diagram of the control system for example 1 is shown in Fig. 1.2.

Example 2. Scheme of automatic temperature control of the drying cabinet.

The circuit uses a mercury thermometer with RTK contacts. When the temperature rises to a given temperature, the contacts are closed by a column of mercury, the coil of the relay element RE is excited and the heater circuit H is opened by the contact RE. When the temperature drops, the contacts of the thermometer open, the relay is de-energized, resuming the supply of energy to the object (see Fig. 1.3). 

R
is. 1.3

Example 3. Temperature ASR circuit with measuring bridge.

When the temperature of the object is equal to the given one, the measuring bridge M (see Fig. 1.4) is balanced, no signal is received at the input of the electronic amplifier, and the system is in equilibrium. When the temperature deviates, the resistance of the thermistor R T changes and the balance of the bridge is disrupted. A voltage appears at the input of the EC, the phase of which depends on the sign of the temperature deviation from the set one. The voltage amplified in the EC is supplied to motor D, which moves the motor of the autotransformer AT in the appropriate direction. When the temperature reaches the set value, the bridge will be balanced and the engine will turn off.

(exercise)

The value of the set temperature value is set using resistor R set. 

Based on the examples described, it is possible to determine a typical block diagram of a single-circuit automatic control system (see Fig. 1.5). Accepted designations:

x - reference action (task), e = x - y - control error, u - control action, f - disturbing influence (disturbance).

Definitions:

Setting influence (the same as the input influence X) - the influence on the system that determines the required law of change of the controlled variable).

Control action (u) - the impact of the control device on the controlled object.

Control device (CD) - a device that influences the control object in order to ensure the required operating mode.

Disturbing influence (f) - an impact that tends to disrupt the required functional relationship between the reference impact and the controlled variable.

Control error (e = x - y) - the difference between the prescribed (x) and actual (y) values ​​of the controlled variable.

Regulator (P) - a set of devices connected to a regulated object and providing automatic maintenance of the set value of its controlled variable or its automatic change according to a certain law.

Automatic control system (ASR) - an automatic system with a closed circuit of influence, in which control (u) is generated as a result of comparing the true value of y with a given value of x.

An additional connection in the structural diagram of the ASR, directed from the output to the input of the considered section of the chain of influences, is called feedback (FE). Feedback can be negative or positive.

The textbook is devoted to the consideration of issues of automation of technological processes for the production of microelectronics products. The authors considered it appropriate to reflect such issues as the main technological processes of the processing phase of the production of microelectronic products to obtain integrated structures, process automation systems, technical means of automation and control, controllers and software and hardware systems from domestic and foreign manufacturers used in process control systems, dispatch systems management and data collection. For students studying in specialties 220201 (210100) “Management and computer science in technical systems"(specialist), 210104(200100) "Microelectronics and solid-state electronics" (specialist), 210107(200500) "Electronic mechanical engineering" (specialist), 220301(210200) "Automation of technological processes and production (by industry)" (specialist), 210100 (550700) “Electronics and Microelectronics” (Bachelor), 220200 (550200) “Automation and Control” (Bachelor) and can be useful for graduate students, researchers and engineers.

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The introduction of technical means into enterprises that allow automation of production processes is a basic condition for effective work. Diversity modern methods automation expands the range of their applications, while the costs of mechanization are usually justified end result in the form of increasing the volume of manufactured products, as well as improving their quality.

Organizations that follow the path of technological progress occupy leading positions in the market, provide better working conditions and minimize the need for raw materials. For this reason, it is no longer possible to imagine large enterprises without implementing mechanization projects - exceptions apply only to small craft industries, where automation of production does not justify itself due to the fundamental choice in favor of manual production. But even in such cases, it is possible to partially turn on automation at some stages of production.

Automation Basics

In a broad sense, automation involves the creation of such conditions in production that will allow certain tasks for the manufacture and release of products to be performed without human intervention. In this case, the operator’s role may be to solve the most critical tasks. Depending on the goals set, automation of technological processes and production can be complete, partial or comprehensive. The choice of a specific model is determined by the complexity of the technical modernization of the enterprise due to automatic filling.



In plants and factories where full automation is implemented, all production control functionality is usually transferred to mechanized and electronic control systems. This approach is most rational if operating conditions do not imply changes. In partial form, automation is implemented at individual stages of production or during the mechanization of an autonomous technical component, without requiring the creation of a complex infrastructure for managing the entire process. A comprehensive level of production automation is usually implemented in certain areas - this could be a department, workshop, line, etc. The operator in in this case controls the system itself without affecting the immediate workflow.

Automated control systems



To begin with, it is important to note that such systems assume complete control over an enterprise, factory or plant. Their functions can extend to a specific piece of equipment, conveyor, workshop or production area. In this case, process automation systems receive and process information from the serviced object and, based on this data, have a corrective effect. For example, if the operation of a production complex does not meet the parameters of technological standards, the system will use special channels to change its operating modes according to the requirements.

Automation objects and their parameters

The main task when introducing means of production mechanization is to maintain the quality parameters of the facility, which will ultimately affect the characteristics of the product. Today, experts try not to delve into the essence of the technical parameters of various objects, since theoretically the implementation of control systems is possible at any component of production. If we consider in this regard the basics of automation of technological processes, then the list of mechanization objects will include the same workshops, conveyors, all kinds of devices and installations. One can only compare the degree of complexity of implementing automation, which depends on the level and scale of the project.



Regarding the parameters with which automatic systems operate, we can distinguish input and output indicators. In the first case it is physical characteristics products, as well as the properties of the object itself. In the second, these are direct quality indicators of the finished product.

Regulating technical means

Devices that provide regulation are used in automation systems in the form of special alarms. Depending on their purpose, they can monitor and control various process parameters. In particular, automation of technological processes and production can include alarms for temperature, pressure, flow characteristics, etc. Technically, devices can be implemented as scale-free devices with electrical contact elements at the output.

The operating principle of the control alarms is also different. If we consider the most common temperature devices, we can distinguish manometric, mercury, bimetallic and thermistor models. Structural design, as a rule, is determined by the principle of operation, but operating conditions also have a significant influence on it. Depending on the direction of the enterprise’s work, automation of technological processes and production can be designed taking into account specific operating conditions. For this reason, control devices are designed with a focus on use in conditions of high humidity, physical pressure or the action of chemicals.

Programmable automation systems

The quality of management and control of production processes has noticeably increased against the background of the active supply of enterprises with computing devices and microprocessors. From the point of view of industrial needs, the capabilities of programmable hardware make it possible not only to ensure effective control of technological processes, but also to automate design, as well as conduct production tests and experiments.



Computer devices that are used in modern enterprises solve problems of regulation and control of technological processes in real time. Such production automation tools are called computing systems and operate on the principle of aggregation. The systems include unified functional blocks and modules, from which you can create various configurations and adapt the complex to work in certain conditions.

Units and mechanisms in automation systems

The direct execution of work operations is carried out by electrical, hydraulic and pneumatic devices. According to the principle of operation, the classification involves functional and portion mechanisms. IN Food Industry Such technologies are usually implemented. Automation of production in this case involves the introduction of electrical and pneumatic mechanisms, the designs of which may include electric drives and regulatory bodies.

Electric motors in automation systems

The basis of actuators is often formed by electric motors. According to the type of control, they can be presented in non-contact and contact versions. Units that are controlled by relay contact devices can change the direction of movement of the working parts when manipulated by the operator, but the speed of operations remains unchanged. If automation and mechanization of technological processes using non-contact devices is assumed, then semiconductor amplifiers are used - electrical or magnetic.

Panels and control panels

To install equipment that must provide control and monitoring production process At enterprises, special consoles and panels are installed. They place devices for automatic control and regulation, control and measuring equipment, defense mechanisms, as well as various elements of communication infrastructure. By design, such a shield can be a metal cabinet or a flat panel on which automation equipment is installed.



The remote control, in turn, is the center for remote control- this is a kind of control room or operator area. It is important to note that the automation of technological processes and production should also provide access to maintenance by personnel. It is this function that is largely determined by consoles and panels that allow you to make calculations, evaluate production indicators and generally monitor the work process.

Automation systems design

The main document that serves as a guide for the technological modernization of production for the purpose of automation is the diagram. It displays the structure, parameters and characteristics of devices, which will later act as means of automatic mechanization. In the standard version, the diagram displays the following data:

• level (scale) of automation at a specific enterprise;
• determining the operating parameters of the facility, which must be provided with means of control and regulation;
• control characteristics - full, remote, operator;
• possibility of blocking actuators and units;
• configuration of the location of technical equipment, including on consoles and panels.

Auxiliary automation tools



Despite minor role, additional devices provide important monitoring and control functions. Thanks to them, the same connection between actuators and a person is ensured. In terms of equipping with auxiliary devices, production automation may include push-button stations, control relays, various switches and command panels. There are many designs and varieties of these devices, but they are all focused on ergonomic and safe control of key units on site.