Lecture

Lecture - 12 P I D Control

This module focuses on Proportional-Integral-Derivative (PID) control, a cornerstone in industrial automation. Students will learn:

  • Basics of PID controller design and operation.
  • Advantages and limitations of using PID control in practice.
  • Real-world applications and examples of PID control systems.

Mastering PID control principles is essential for effective control system design and implementation.


Course Lectures
  • Lecture - 1 Introduction
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module provides an introduction to the fundamental concepts of industrial automation, including its history and evolution. Students will explore:

    • The definition of industrial automation
    • Key components of automation systems
    • Benefits and challenges of automation
    • Current trends and future outlook in automation technology

    By the end of this module, students should have a solid understanding of the relevance of automation in modern industries and its impact on productivity and efficiency.

  • Lecture - 2 Architecture of Industrial Automation Systems
    Prof. S. Sen, Prof. S. Mukhopadhyay

    In this module, we delve into the architecture of various industrial automation systems. Key topics include:

    1. Types of automation architectures
    2. Components of control systems
    3. Integration of hardware and software in automation
    4. Case studies of successful automation implementations

    This understanding is crucial for designing and implementing effective automation systems in different industrial settings.

  • Lecture - 3 Measurement Systems Characteristics
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module introduces students to measurement systems used in industrial automation. It covers:

    • Characteristics of measurement systems
    • Types of sensors and their applications
    • Measurement accuracy and reliability
    • Common measurement challenges

    Students will learn how to select appropriate measurement systems for various industrial applications and the importance of accurate measurements in automation.

  • Lecture - 4 Temperature Measurement
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on temperature measurement techniques in industrial settings. Key topics include:

    1. Types of temperature sensors (thermocouples, RTDs, etc.)
    2. Principles of operation for each sensor type
    3. Calibration and error estimation in temperature measurement
    4. Application of temperature measurements in automation processes

    By understanding these techniques, students will be better equipped to apply temperature measurement solutions in their automation projects.

  • Lecture - 5 Pressure, Force and Torque Sensors
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module covers the principles and applications of pressure, force, and torque sensors in industrial automation. Students will explore:

    • The operation of pressure sensors and their applications
    • Force sensing technologies and their industrial uses
    • Torque measurement techniques and importance in automation
    • Integration of these sensors into automation systems

    Understanding these sensors is vital for ensuring accurate control and monitoring in various industrial processes.

  • Lecture - 6 Motion Sensing
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module introduces students to motion sensing technologies utilized in automation. Key areas of focus include:

    1. Types of motion sensors and their applications
    2. Principles of operation for each sensor type
    3. Integration of motion sensors into control systems
    4. Real-world applications and case studies of motion sensing

    Students will learn how to effectively implement motion sensing solutions to enhance automation efficiency.

  • lecture - 7 Flow Measurement
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module provides an overview of flow measurement techniques relevant to industrial automation. Students will learn about:

    • Different types of flow measurement devices
    • Principles of operation for flow sensors
    • Calibration processes for flow measurement
    • Applications of flow measurement in various industries

    Through hands-on examples, students will understand how to select and implement flow measurement solutions in their automation projects.

  • Lecture - 8 Signal Conditioning
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on the fundamental aspects of signal conditioning, which is essential for effective data acquisition in industrial automation. Key topics include:

    • Definition and importance of signal conditioning in industrial settings.
    • Types of signal conditioning techniques such as amplification, filtering, and converting.
    • Real-world applications of signal conditioning in sensor systems.

    Understanding signal conditioning is crucial for ensuring accurate and reliable measurements in automated systems.

  • Lecture - 9 Signal Conditioning (Contd.)
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module continues the exploration of signal conditioning, delving deeper into advanced techniques and their integration with data acquisition systems. Key learning points include:

    • Advanced filtering techniques to enhance signal quality.
    • Calibration methods to ensure measurement accuracy and reliability.
    • Integration of signal conditioning with digital data acquisition systems.

    By mastering these concepts, students will enhance their ability to develop robust automation solutions.

  • Lecture - 10 Data Acquisition Systems
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module introduces data acquisition systems, vital for modern industrial automation. Students will learn about:

    • Components of data acquisition systems including sensors and controllers.
    • Types of data acquisition systems: analog, digital, and mixed.
    • Process of collecting, processing, and analyzing data from various sources.

    Grasping these concepts will enable students to implement effective data acquisition strategies in real-world applications.

  • Lecture - 11 Introduction to Automatic Control
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module provides an overview of automatic control systems, highlighting their significance in industrial applications. Key topics include:

    • Fundamental principles of automatic control and its components.
    • The role of feedback in maintaining system stability.
    • Application examples of automatic control in various industries.

    Understanding these principles will empower students to design and analyze automatic control systems effectively.

  • Lecture - 12 P I D Control
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on Proportional-Integral-Derivative (PID) control, a cornerstone in industrial automation. Students will learn:

    • Basics of PID controller design and operation.
    • Advantages and limitations of using PID control in practice.
    • Real-world applications and examples of PID control systems.

    Mastering PID control principles is essential for effective control system design and implementation.

  • Lecture - 13 PID Control Tuning
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module covers PID control tuning, a critical aspect of optimizing control systems. Key content includes:

    • Methods for tuning PID controllers: Ziegler-Nichols, Cohen-Coon, and others.
    • Impact of tuning on system performance and response.
    • Hands-on tuning examples for practical understanding.

    Students will gain practical skills necessary for effective PID controller optimization in various settings.

  • Lecture - 14 Feedforward Control Ratio Control
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on Feedforward and Ratio control as advanced control strategies in automation systems. Topics include:

    • Definition and significance of feedforward control in improving system response.
    • Ratio control methods and their applications in industrial processes.
    • Comparative analysis of feedforward and feedback control strategies.

    Students will learn how to effectively implement these advanced control techniques to enhance process efficiency.

  • This module covers the essential concepts of time delay systems and inverse response systems in control engineering. Students will learn:

    • The definition and characteristics of time delay systems.
    • How to analyze and design systems with inverse responses.
    • Real-world examples of time delay systems in industrial applications.
    • Stability analysis and control strategies for these systems.

    By the end of this module, students will gain practical insights into managing time delays in control systems effectively.

  • Lecture - 16 Special Control Structures
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on special control structures that enhance the performance of control systems. Key topics include:

    • Understanding feedforward control and its advantages.
    • The principles of predictive control and its applications.
    • Strategies for controlling systems with inverse responses.
    • Cascade control and its implementation for complex systems.

    Students will engage in practical exercises to design and analyze these special control structures effectively.

  • Lecture - 17 Concluding Lesson on Process Control
    Prof. S. Sen, Prof. S. Mukhopadhyay

    The concluding lesson on process control encapsulates key learnings from previous modules. It provides an overview of:

    • The significance of process control in industrial automation.
    • Summary of various control techniques covered throughout the course.
    • Future trends in process control and automation technologies.
    • Discussion on real-life case studies demonstrating successful implementations.

    This module aims to solidify students' understanding and prepare them for real-world challenges in process control.

  • Lecture - 18 Introduction to Sequence Control, PLC , RLL
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module introduces sequence control, focusing on programmable logic controllers (PLCs) and relay ladder logic (RLL). Key topics include:

    • The fundamentals of sequence control in automation.
    • Understanding PLC architecture and its programming environment.
    • Basics of relay ladder logic syntax.
    • Common applications of PLCs in industrial settings.

    Students will learn how to design simple control sequences using RLL, enhancing their programming skills.

  • This module expands on sequence control, specifically the scan cycle and simple RLL programs. Students will explore:

    • The fundamental operation of the PLC scan cycle.
    • Creating and understanding simple RLL programs.
    • Debugging techniques for RLL code.
    • Practical examples and exercises to reinforce learning.

    By the end, students will be able to write simple RLL programs and understand their execution within PLCs.

  • This module introduces more advanced RLL elements and syntax, essential for effective sequence control programming. Key areas covered include:

    • Understanding advanced elements in relay ladder logic.
    • Implementing conditional logic in RLL programs.
    • Exploring timers, counters, and their applications.
    • Hands-on programming exercises to solidify understanding.

    Students will enhance their RLL programming capabilities, preparing them for complex automation tasks.

  • Lecture - 21 A Structured Design Approach to Sequence
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on structured design approaches to sequence control, enhancing programming efficiency. Key topics include:

    • The principles of structured design in control systems.
    • Creating modular RLL programs for reusability.
    • Best practices for documenting and organizing code.
    • Real-world applications of structured design in automation.

    Students will learn to implement structured approaches in their programming, leading to more reliable and maintainable control systems.

  • Lecture - 22 PLC Hardware Environment
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module covers the hardware environment essential for Programmable Logic Controllers (PLCs). Students will learn about various hardware components of PLC systems, including:

    • Input and Output devices
    • Power supply requirements
    • Communication interfaces
    • Mounting and installation considerations

    Additionally, the module will explore the integration of these hardware components into industrial applications, highlighting best practices for optimal performance and reliability.

  • Lecture - 23 Introduction To CNC Machines
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module introduces students to Computer Numerical Control (CNC) machines, essential in modern manufacturing processes. Key topics will include:

    • The basic principles of CNC machining
    • Types of CNC machines and their applications
    • Understanding G-code and its role in CNC programming
    • Setup and operation of CNC machines

    The module will emphasize the importance of CNC technology in enhancing precision, efficiency, and productivity in manufacturing.

  • Lecture - 24 Contour generation and Motion Control
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on contour generation and motion control in CNC machines. Students will delve into the methodologies used for generating paths and controlling the motion of machining tools. Key areas of study include:

    • Tool path generation techniques
    • Motion control algorithms
    • Interpolation methods for smooth motion
    • Implementation of acceleration and deceleration strategies

    By the end of this module, students will have a solid understanding of how to optimize machining processes through effective motion control.

  • Lecture - 25 Flow Control Valves
    Prof. S. Sen, Prof. S. Mukhopadhyay

    In this module, students will explore flow control valves, critical components in hydraulic systems that regulate fluid flow. The content will cover:

    • Types of flow control valves and their applications
    • Principles of operation and design considerations
    • Installation and maintenance of flow control valves
    • Impact of flow control on system performance

    Students will also engage in practical examples to understand how flow control valves enhance operational efficiency in various applications.

  • Lecture - 26 Hydraulic Control Systems - I
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module provides an in-depth understanding of hydraulic control systems. Students will learn about the fundamental principles, components, and symbols associated with hydraulic systems. Topics include:

    • Basic hydraulic principles and laws
    • Components of hydraulic systems such as pumps, cylinders, and motors
    • Hydraulic circuit design and analysis
    • Common symbols used in hydraulic schematics

    Through theoretical knowledge and practical applications, students will gain insights into designing effective hydraulic control systems.

  • Lecture - 27 Hydraulic Control Systems - II
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module continues exploring hydraulic control systems, focusing on advanced principles and applications. Students will examine:

    • Advanced hydraulic circuits and configurations
    • Control strategies for hydraulic systems
    • Integration of sensors and actuators in hydraulic applications
    • Real-world case studies demonstrating hydraulic system performance

    Students will enhance their analytical skills and practical knowledge, preparing them for real-world engineering challenges in hydraulic systems.

  • Lecture - 28 Industrial Hydraulic Circuit
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module provides a comprehensive overview of industrial hydraulic circuits. Students will learn to design and analyze hydraulic circuits used in various industrial applications, covering:

    • Standard hydraulic circuit designs
    • Common industrial applications of hydraulic circuits
    • Safety considerations and troubleshooting
    • Hands-on projects to build and test hydraulic circuits

    Practical experience will enable students to apply their knowledge in real-world scenarios, fostering a deeper understanding of hydraulic engineering.

  • Lecture - 29 Pneumatic Control Systems - I
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module covers the fundamentals of pneumatic control systems, which utilize compressed air to control machinery and processes. Key topics include:

    • The principles of pneumatic systems and their components
    • Types of actuators used in pneumatic applications
    • Advantages and limitations of pneumatic systems compared to other control systems
    • Basic circuit design and troubleshooting techniques

    Students will gain insights into how pneumatic systems can be implemented in various industrial settings, enhancing efficiency and performance.

  • Lecture - 30 Pneumatic Systems - II
    Prof. S. Sen, Prof. S. Mukhopadhyay

    In this module, students will delve deeper into pneumatic systems, exploring advanced topics that enhance system functionality and efficiency. Key areas include:

    • Control valves and their roles in pneumatic circuits
    • Integrated pneumatic control systems
    • Applications of pneumatic systems in various industries
    • Safety considerations and best practices for pneumatic system design and maintenance

    This hands-on module will equip students with practical skills to design and analyze complex pneumatic control systems.

  • Lecture - 31 Energy Savings with Variable Speed Drives
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on energy-saving techniques in variable speed drives, an essential aspect of modern industrial automation. The content includes:

    • Understanding the principles behind variable speed drives
    • Benefits of using adjustable speed drives in various applications
    • Strategies to optimize energy consumption and reduce costs
    • Case studies demonstrating successful energy-saving implementations

    Students will learn how to effectively integrate variable speed drives into existing systems to achieve substantial energy savings.

  • Lecture - 32 DC Motor Drives
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module introduces students to DC motor drives, focusing on their applications in industrial settings. Key topics include:

    • The principles of DC motor operation
    • Types of DC motors and their characteristics
    • DC-DC converters and their role in motor drive systems
    • Adjustable speed drive mechanisms for DC motors

    The module emphasizes practical applications and includes hands-on projects to provide real-world insights into DC motor control.

  • Lecture - 33 DC and BLDC Servo Drives
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module examines the operation and control of DC and Brushless DC (BLDC) servo drives, which are vital in precision applications. Key areas of focus include:

    • Principles of servo control and feedback mechanisms
    • Differences between DC and BLDC motors
    • Applications in robotics, CNC machines, and automation
    • Designing control systems for optimal performance

    Students will gain hands-on experience in configuring and programming servo drives for various applications.

  • Lecture - 34 Induction Motor Drives
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module provides an in-depth exploration of induction motor drives, a common type of electric drive system used in various applications. Topics covered include:

    • Understanding induction motor fundamentals and characteristics
    • Adjustable speed drive configurations
    • Common applications and performance analysis
    • Control methods for optimizing motor efficiency and performance

    Students will participate in practical exercises to understand the implementation and control of induction motor drives in industrial systems.

  • Lecture - 35 Step Motor Drives BLDC Drives
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module focuses on step motor drives and Brushless DC (BLDC) drives, which are essential in precise automation applications. Key topics include:

    • Principles of operation for step motors and their advantages
    • BLDC motor design and control strategies
    • Applications in automation, robotics, and CNC machinery
    • Programming and implementing control systems for step and BLDC motors

    Students will engage in hands-on projects, developing skills to select and implement the right motor systems for specific applications.

  • Lecture - 36 Embedded Systems
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module covers the essential aspects of Embedded Systems in the context of industrial automation. Participants will explore:

    • The definition and significance of embedded systems
    • Components and architecture of embedded systems
    • Real-time operating systems (RTOS) and their applications
    • Programming embedded systems using C/C++
    • Integration of embedded systems with industrial automation systems
    • Case studies highlighting the role of embedded systems in automation

    By the end of this module, participants will have a solid understanding of how embedded systems function and their critical role in modern industrial automation applications.

  • Lecture - 37 The Fieldbus Network - I
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module introduces learners to the Fieldbus Network, an essential technology in industrial automation. Topics include:

    • Overview of Fieldbus technology and its importance in automation
    • Types of Fieldbus networks and their applications
    • Communication protocols used in Fieldbus systems
    • Advantages of using Fieldbus over traditional wiring methods
    • Implementation strategies for a Fieldbus network
    • Challenges and considerations for successful deployment

    Participants will leave with a comprehensive understanding of how Fieldbus networks improve communication and efficiency in automation systems.

  • Lecture -38 The Fieldbus Network - II
    Prof. S. Sen, Prof. S. Mukhopadhyay

    Building on the previous module, this session delves deeper into advanced concepts of the Fieldbus Network. Key topics include:

    • Advanced communication protocols in Fieldbus systems
    • Fieldbus network design and architecture
    • Integration with existing automation systems
    • Diagnostics and troubleshooting for Fieldbus networks
    • Future trends in Fieldbus technology

    Through case studies and practical examples, learners will understand how to effectively leverage Fieldbus technology to enhance industrial processes.

  • Lecture - 39 Higher Level Automation Systems
    Prof. S. Sen, Prof. S. Mukhopadhyay

    This module discusses higher-level automation systems that integrate various components and technologies. It encompasses:

    • Overview of higher-level automation principles
    • Interconnection of devices and systems for enhanced functionality
    • Data management and processing in automation
    • System architecture and design considerations
    • Real-world applications of higher-level automation systems

    Students will explore how these advanced systems can optimize production and reduce operational costs.

  • Lecture - 40 Course Review and Conclusion
    Prof. S. Sen, Prof. S. Mukhopadhyay

    In the final module, a comprehensive review of the course content will be conducted, focusing on key learning outcomes. Highlights include:

    • Recap of essential concepts covered throughout the course
    • Discussion on real-world applications and implementations of learned material
    • Q&A sessions to clarify doubts and reinforce understanding
    • Guidance on further reading and resources for continued learning
    • Feedback collection to enhance future iterations of the course

    Participants will leave with a reinforced knowledge base and confidence to apply what they have learned in their professional settings.