What is Process Automation?

Summary

This video explains the concept of automation, focusing on how machines and systems can be controlled using computers and sensors with minimal human intervention. It breaks down the process using examples like an automatic car wash, where sensors and controllers guide each step of the wash cycle. The video highlights how automation saves time, reduces human error, and creates high-paying jobs in fields like engineering and programming. It also discusses the role of PLCs in industrial automation and invites viewers to explore more learning resources for PLC programming at RealPars.

Takeaways

• 🤖 Automation refers to the use of automatic equipment in manufacturing or other production processes.
• 🛠 Automation often involves PLCs (Programmable Logic Controllers), sensors, robots, and motors.
• ⏳ Almost any process can be automated, leading to time and cost savings.
• 💡 Automation helps reduce human error and improves consistency in production.
• 💼 Automation creates high-paying jobs in fields like maintenance, engineering, and programming.
• 🚗 A car wash is a simple example of automation, where sensors and controllers manage the washing cycle.
• 🧠 PLCs take inputs (such as sensor signals or button presses) and run programs to control outputs like motors or pumps.
• 🔄 Sequential starting is a key concept in automation, where one step triggers the next.
• ⚙ Industrial robots are frequently used to replace humans in repetitive tasks like pallet loading.
• 🎓 Resources like RealPars offer training materials to help individuals learn PLC programming and succeed in the automation field.

Q & A

What does the term 'automation' refer to in the context of manufacturing or production processes?

Automation refers to the use of largely automatic equipment in a system of manufacturing or other production processes, typically involving PLCs, sensors, robots, and motors.

What are some benefits of automating industrial processes?

Automating industrial processes can save time and money, help eliminate human error, and create high-paying careers for maintenance workers, engineers, and programmers.

Can you provide a simple example of automation from everyday life?

An everyday example of automation is an automatic car wash, where the process is controlled by a controller and sensors to manage the washing cycle.

How does the car wash example illustrate the concept of automation?

The car wash example shows automation by using sensors to trigger the washing cycle, control the spray of water and chemicals, and signal the driver when to stop and proceed.

What is the role of a controller in an automated process?

A controller in an automated process runs the program selected by the user and manages the sequence of operations, activating pumps and controlling the flow of the wash cycle.

How does industrial automation differ from the car wash example?

Industrial automation works similarly to the car wash example but is applied to manufacturing processes and typically involves more complex systems and machinery.

What is a PLC and how does it function in automation?

A PLC (Programmable Logic Controller) is a digital operating device that makes decisions based on its programming and activates outputs such as motors, solenoids, heaters, or lights in response to inputs from sensors or switches.

What is sequential starting in the context of automation?

Sequential starting is a method in automation where one output device starts before the next is allowed to run, creating a chain reaction that keeps the process running.

How does an automated process know when to stop?

An automated process receives a stop signal, which can come from a physical input like a stop button or sensor, or from a programmed element such as a timer.

What is the role of human intervention in an automated process?

In an automated process, human intervention is minimal, usually limited to starting the process with an input device or programming the controller.

Why are industrial robots often used in automation?

Industrial robots are used in automation to replace humans in tasks such as pallet loading operations, improving efficiency, accuracy, and safety.

Outlines

00:00

🤖 Introduction to Automation and its Benefits

The video introduces the concept of automation, which involves using largely automatic equipment in production processes such as manufacturing. It explains that automation utilizes tools like PLCs (Programmable Logic Controllers), sensors, robots, and motors to save time, reduce costs, and minimize human error. The script highlights that automation can create high-paying jobs for maintenance workers, engineers, and programmers. A real-world example of automation, an automatic car wash, is broken down to show how inputs like sensor signals and outputs like water nozzles work together under a programmed controller to complete a task with minimal human intervention.

05:07

🤖 Understanding Industrial Automation and its Process

This section provides a deeper understanding of how industrial automation mirrors everyday automated processes like a car wash. It explains how various inputs, such as sensors or pushbuttons, are fed into a PLC, which then activates outputs like motors or solenoids based on its programming. The video emphasizes sequential starting, where one output triggers the next, forming a chain reaction to keep the process running smoothly. Automation continues until a stop signal is received from an input, such as a stop button or a programmed timer, illustrating how automation systems are designed to operate autonomously with minimal human input.

🤖 Industrial Robots in Automation and Learning PLC Programming

The video discusses industrial robots as a prime example of automation in industries, especially in tasks like pallet loading, where robots are replacing human labor. It encourages viewers to visit realpars.com for comprehensive training materials focused on PLC programming, which is essential for careers in Automation and Controls Engineering. The video promotes RealPars' training series to help learners acquire the skills needed for highly sought-after and well-paying jobs in this field.

Keywords

💡Automation

Automation refers to the use of automatic equipment to perform tasks in a production process with minimal human intervention. In the video, automation is explained as a system that uses devices like PLCs, sensors, and robots to make industrial processes more efficient. A relatable example provided is the automated car wash, where the driver only selects a wash, and the rest of the process runs automatically.

💡PLC (Programmable Logic Controller)

A PLC is a type of computer used to control automated processes by receiving inputs, making decisions based on programming, and activating outputs. The video highlights how PLCs are central to industrial automation, controlling things like motors and sensors, and ensuring that each part of the process happens sequentially, as programmed.

💡Sensors

Sensors are devices that detect changes in the environment and send signals to control systems, like PLCs. In the car wash example, sensors are used to detect the position of the car and signal when to start and stop various stages of the wash. This illustrates how sensors play a crucial role in automating processes by providing real-time inputs.

💡Industrial Process

An industrial process refers to a sequence of operations used to manufacture or produce goods. Automation can be applied to nearly any industrial process, as explained in the video, by using technology to streamline tasks and reduce human error. The car wash is used as an example to demonstrate how a routine process can be automated.

💡Sequential Starting

Sequential starting is the process where one task or action in an automated system triggers the next step, ensuring the system runs in an organized manner. The video explains that in automation, outputs are activated one after another, similar to a chain reaction, such as the way each stage of the car wash leads to the next.

💡Human Intervention

Human intervention refers to the actions taken by a person to influence or control a process. In the context of automation, the video points out that human involvement is minimal, typically only needed at the start, such as selecting a car wash option. Once the automation process begins, machines handle the rest.

💡Outputs

Outputs are the devices or machines that perform work based on the commands they receive from a PLC. Examples of outputs mentioned in the video include motors, pumps, and nozzles, which are activated during the car wash process to perform tasks like spraying water or chemicals on the vehicle.

💡Input Devices

Input devices are mechanisms that provide data or signals to a system, such as a pushbutton or sensor. The video discusses how these devices initiate an automated process by sending signals to the PLC, which then controls the machinery. For example, a sensor in a car wash signals when the car has reached the correct position.

💡Industrial Robots

Industrial robots are automated machines that carry out repetitive tasks in manufacturing settings, often replacing human workers. In the video, robots are mentioned as examples of automation in pallet loading operations, showing how automation reduces labor while increasing precision and efficiency in industrial processes.

💡Car Wash Automation

Car wash automation is used as an everyday example to explain how automation works. The video breaks down the steps of an automatic car wash, where sensors, controllers, and pumps work together to clean a car with minimal human input. This simple process illustrates the larger concept of how automated systems operate in various industries.

Highlights

Automation refers to the use of largely automatic equipment in manufacturing or production processes.

Automation typically involves PLCs, sensors, robots, and motors, depending on the process.

The primary benefits of automation include time and cost savings, and the reduction of human error.

Automation creates many high-paying career opportunities for maintenance workers, engineers, and programmers.

A simple example of automation is an automatic car wash, which is controlled by a program and sensors.

In an automatic car wash, the controller runs the wash cycle, triggered by sensors and programmed steps.

The controller activates pumps and nozzles to control the spraying of water and chemicals during the car wash.

Sequential starting is a key feature of automation, where one process must finish before another starts.

The only human intervention in an automated car wash is selecting the wash option at the beginning.

In industrial automation, processes are typically started by an input device like a sensor or pushbutton.

PLCs (Programmable Logic Controllers) are used to make decisions based on inputs and control outputs.

Outputs in automation can include devices like motors, solenoids, heaters, or lights.

Automation processes often involve a chain reaction, where outputs act as inputs to continue the process.

Automation continues until it receives a stop signal, which could be a physical input or a programmed timer.

Industrial robots, such as those used in pallet loading, are examples of automation replacing human labor.

Transcripts

We hear about new things and processes becoming automated almost every day.

But what does that actually mean?

If you enjoy these videos, be sure to click like and subscribe so you never miss a new one.

What exactly does automation mean?

Automation is the use of largely automatic equipment in a system of manufacturing or other production process.

This typically includes the use of PLCs, sensors, robots,

and motors among many other things depending on the automated process.

Almost any process can become automated.

It can save time and money to automate an industrial process.

It also helps eliminate human error.

Another upside is that the use of automation creates many high paying careers

for maintenance workers, engineers, and programmers.

A simple, everyday example of automation would be an ordinary pull in

and park automatic car wash.

If we break it down step by step,

it should help you understand how automation works.

Once you select your wash, that input will run a certain program on the controller.

Next, you drive forward until a sensor is flagged,

starting the wash cycle and another sensor tells the driver when to stop.

From there, the wash will continue through the cycle that the controller is running.

In a typical car wash, the nozzle spraying the water and chemicals

will travel alongside a vehicle and a sensor will detect when it is past the vehicle.

This saves time, water, and chemicals by controlling when the nozzles spray,

as well as serves as an input to advance to the next step of the wash.

Once the car is sprayed, the program tells the wash to spray the next chemical.

This is done by the controller turning on and off each pump as it is needed.

The controller then runs through the rest of the cycle and wash

that was selected in the beginning.

Once all steps have been completed,

the driver will be signaled to pull out of the wash.

Essentially, the only human intervention in the process is the driver selecting what wash they want.

Industrial automation works exactly the same way.

Each industrial process needs to be started by some sort of input.

That input can be a sensor, pushbutton, switch, among many other possibilities.

Typically a person will start the process with one of these input devices

or it could be a sensor that detects an object automatically.

Those inputs will go to a PLC to which will then make decisions based on how it was programmed.

The PLC will then activate whatever output the program says to run.

An output can be anything that does work such as a motor, solenoid, heater, or a light.

In an automated process, that output will typically act as an input to the PLC

and combined with other input devices or programming, to keep the process running.

With this programming, it can act like a chain reaction

with one output device starting before the next is allowed to run.

This is also called sequential starting.

Automation has to have many aspects working together in order to function properly.

An automated process will continue its cycle until it receives a stop signal.

That can come from a physical input such as a stop button or sensor,

or something programmed like a timer.

Let's look back at what we now know.

Automation is an automatic process, typically controlled by computers and sensors.

There is usually very little human intervention.

Input devices, such as sensors and switches,

will work with a controller or PLC to activate output devices like motors or other machinery.

The PLC will advance as it was programmed.

Industrial robots are great examples of process automation

as they are commonly being used to replace humans in pallet loading operations.

make sure that you head over to realpars.com

to find even more training material for all of your PLC Programming needs.

We offer many videos to assist you in learning PLC programming

and landing that job in the high paying,

highly sought after field of Automation and Controls Engineering.

Go to realpars.com and subscribe to our highly effective training series now.