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MMSE 602-05 Automated Control of
Manufacturing Systems
(Current course number: ETLS 770)
Dr.
Vernon M. Cottles
Fall Semester 2003
| Instructor: | Vernon M. Cottles, PhD | |
| Time: | Tuesday Evenings, 6:00 - 9:00 p.m. | |
| Location: | St. Paul Campus Lecture OSS Room 111 Lab Demonstrations OSS LL13 |
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| Telephone: | (651) 704-5340 (Work) (651) 962-6419 (UST Fax) vmcottles@stthomas.edu (E-Mail) |
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| Instructor's Office: | MMSE Office, OSS Room 105 | |
| Required Text: |
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| Other Requirements: | The student must be capable of accessing some course materials through the UST Engineering Department web site. Access to and reasonable proficiency with MS Office applications (Word and Excel) are required. An undergraduate degree in Engineering is presumed. Experience in a manufacturing environment is presumed. | |
| Course Description: | An introduction to the key elements of control
systems employed in manufacturing with examples from both batch and continuous-process
applications. First, the fundamental theory of operation for closed loop (binary and
analog) control systems is developed. Students will explore using PLCs to implement modern
systems and become familiar with a PLC programming language. Second, the theory of
operation and performance limits of sensors and actuators used in the industrial
environment is explored. Some sensors to be considered measure position, speed,
temperature, flowrate, level, and force. Some actuators to be considered include pumps,
hydraulic and pneumatic cylinders, heaters, valves, stepping motors, and AC and DC motors.
Future trends in control systems targeted for the manufacturing plant will be presented.
Students will demonstrate their ability to automate a manufacturing cell and quantify the
cost impact of the project on the manufacturing example chosen in a term paper. Prerequisite: Instructor's permission for MS, Certificate and MBA students. |
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| Course Objectives: | To provide the student with an understanding of the modern manufacturing control system. The emphasis is on the theory and practice of closed loop systems that are in current use in the manufacturing environment. The student will also be prepared to understand the new trends emerging in factory control systems. | |
| Learning Outcomes: | Knowledge: Demonstrate an understanding of what
constitutes an efficient and safe manufacturing cell. Understand the process of gaining
information about a cell and its components. (TP,CP) Program Outcome Reference: SE5, SE6, SE13 – MS1,MS6 Comprehension : Demonstrate the
ability to technically analyze a manufacturing cell and quantify its contribution to
product cost. (T,TP,CP) Application : Demonstrate the ability to analyze a manufacturing cell, then propose an
automation upgrade, and determine if the upgrade would provide a cost benefit to the
manufacturing entity. (T,TP,CP) Analysis : Demonstrate the ability to define the purpose of a manufacturing cell in a
product's manufacturing cycle. Demonstrate the ability to quantify that cell with regards
to inputs, outputs, and safety. (T,TP,CP) Synthesis : Demonstrate the ability to propose a new design for an automated
manufacturing cell using available components that would represent a best current effort.
(T,TP,CP) Evaluation : Demonstrate the ability to make a judgment to proceed or not proceed with
an automation project based on its impact on quality, cost, performance, and safety. (TP) |
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| Course Methodology: | The components that make-up a control system will
be "defined" and mathematical models will be developed to show the
interrelation and function of the system components. Example systems of increasing
complexity will be explored to introduce and expand important concepts and applications.
Exposure to a variety of sensors, actuators, and controllers will allow students to
generate questions for discussion. This is a classic lecture format course. Guest lecturers (when available) will provide in-depth lectures on the practical aspects of control systems and on automation products entering the marketplace today. |
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| Major Assignments: | Mid-term Exam (T) Term Paper (TP) Final Exam (T) (Bonus Option) Mini Project (TP) |
20% of grade 60% of grade 20% of grade 10% (TBD) |
| Web Site: | Much of the web based course materials and course
news updates will be posted on the MMSE602 Web Site (Accessible only for registered students.) The student is responsible for checking this site regularly. |
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| Grading Policy: |
95+ A (maximum possible is 110%) >=90 <95 A- >=85 <90 B+ >=80 <85 B >=75 <80 B- >=70 <75 C+ Late Term Papers will have 5% (maximum starting value is 60%) deducted from their score for each week, or fraction thereof, that they are submitted late. No late Mini Projects are accepted. |
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| Academic Integrity: | All students are expected understand and follow
the University of St. Thomas policies on Academic Integrity. These are described at:
www.stthomas.edu/engineering/graduate/policies |
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| Attendance Policy: | Students are expected to attend all class sessions. Circumstances that prevent attendance will be honored up to two instances. Absences in excess of two times may result in a lowered grade for the course. Contact the instructor when a special situation arises. All absences require that the instructor be informed in advance. | |
MMSE 602 Automatic Control of Manufacturing Systems
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Date |
Topics |
| Session 1 - Sep. 9 |
1) General description of the course, course expectations,
course pre requisites, and student introductions 2) Scope of course and information resources 3) Informal "definition" of control systems 4) Technology base of modern systems |
| Session 2 - Sep. 16 |
1) Formal "definition" of closed loop control
systems 2) State variables, analog computers, and digital computers 3) Timing diagrams and other depiction methods 4) Working "definition" of a sensor 5) Working "definition" of an actuator 6) Boolean algebra and differential equations for modeling closed loop control systems 7) Boolean elements and their properties 8) Boolean representations |
| Session 3 - Sep. 23 |
1) Overview of general equations of closed loop control
systems 2) Example of a binary system 3) Example of an analog system 4) Characterization of control loop elements |
| Session 4 - Sep. 30 |
1) Programmable logic controller - Boolean and Analog
capability 2) Implementation of a PLC with a microprocessor - simulation and/or emulation 3) PLC programmed with ladder diagrams - example and demonstration for a pure Boolean example |
| Session 5 - Oct. 7 |
1) Overview of linear systems 2) Solution of differential equations using Laplace transforms 3) Analog computing elements 4) Closed loop analog control system 5) Closed loop control system based on an analog computer - example and demonstration |
| Session 6 - Oct. 14 |
1) The "digital" computer as a discrete time
emulator for the binary or analog control computer 2) Analog/digital/analog conversion - functional introduction 3) The making of Widgets - A complete example of a typical course project 4) Binary and analog control with a single computer - example and demonstration |
| Session 7 - Oct. 21 |
1) Mid-course evaluation 2) Mid-term examination 3) Student term paper abstracts due and reviewed (for each student) |
| Session 8 - Oct. 28 |
1) Historical overview of sensors and actuators 2) Sensor/actuator - characterization and calibration 3) Least squares linearization for analog elements 4) Time response of sensors and actuators |
| Session 9 - Nov. 4 |
1) Defining sensors and actuators for a process 2) Considerations in specific applications 3) Communications to a controller Possible St. Thomas - Vendor Show XIV (exact date is pending vendor availability) |
| Session 10 - Nov. 11 |
1) Interface protocols for modern controllers 2) Cascaded systems and actuators with embedded controllers 3) Communications considerations for plant-wide integrations Best Possible St. Thomas - Vendor Show XIV (exact date is pending vendor availability |
| Session 11 - Nov. 18 |
1) Operating principles of widely used sensors 2) Operating principles of widely used actuators 3) Discussions on sensors and actuators identified by students Possible St. Thomas - Vendor Show XIV (exact date is pending vendor availability |
| Session 12 - Nov. 25 |
1) AC motors 2) DC motors 3) Stepping motors 4) Servomotors |
| Session 13 - Dec 2 |
1) Trends and advances in sensor and actuator technology 2) Emerging "industrial PC" based cell controllers Term Paper is Due! |
| Session 14 - Dec 9 |
1) Course evaluation 2) Final examination |
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