This document outlines an industrial automation workshop for engineering students. The workshop will provide both theoretical and hands-on experience with automation technologies including machine vision, programmable logic controllers, motion control, and integrating these systems. Students will learn skills like PLC programming, servo motor control, machine vision, and industrial robot programming. They will complete hands-on labs and have the opportunity to develop an independent student project applying concepts from the workshop.

1. Industrial Automation Workshop
California Polytechnic State University
Outline of Industrial
Automation Workshop during
summer
This workshop will cover a range of technologies used for
industrial automation. This is the automaton of industrial
processes (manufacturing, material handling, food production,
chemicals, etc.).
The objective was to provide engineering students with theoretical
and hands-on practical experience with automation technologies
that are of prime importance in industry: machine vision,
programmable logic controllers based on the IEC-61131 standard,
motion control and the integration of these technologies.
Developing applications and integration of state of the art
industrial automation technology (hardware and software) has
become fairly easy compared to only a few years ago.
Manufacturing engineering students, as well as all other
engineering students who will work on design and improvement of
automated processes should be exposed to these advanced
automation technologies.
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THE LOREM IPSUMS SUMMER 2016
Applications
Students should learn to deal with:
• Programmable logic controllers (PLC) including programming with
ladder logic, block diagrams and structured text
• Servo-motor control
• Stepper motor control
• Machine vision and image processing
• Industrial robot programming
During the past ten years, manufacturing automation has changed
dramatically. Developments in software and new standards allow
rapid development and integration of sophisticated automation
applications. It is possible now to develop applications that require
integration of machine vision, programmable logic controllers,
control of multi-axis servomotors, and robot manipulators from
multiple vendors in a fairly short amount of time. It has become an
accepted technology with many successful industrial applications.
These changes have occurred due to several factors: the growth in computing processor power and speed, growth in memory
capacity, significant cost reduction of computer and machine vision technologies, the availability of powerful and easy-to- use
PLC, machine vision and motion control software tools, and the development of industry standards such as the IEC 61131.
There is much interest in industry to recruit talented engineers with knowledge of automation of products and processes. It is
important to distinguish the difference between engineers who may work in automation of products, known as mechatronics
or embedded computers, and engineers who may work on automation of processes, known as factory automation. There are
similarities in the body of knowledge for both of these automation engineers, and both are very much in demand. The
difference between engineers who work in automation of products (mechatronics) and automation of processes, becomes
evident when we look into the development cost, number of copies into which the automation will be implemented and cost
per unit. When developing an automated product, for example a refrigerator that is “internet ready”, the cost of development
and cost of hardware will be prorated among many thousand copies of the product, so the cost per unit will be small enough
to be attractive to consumers and competitive. When developing an automated process or production line, it is likely that
there will be one or very few productions lines, but what is important is
that the development of the automated system is completed in a short
time, is robust, reliable, safe, easy to integrate to existing networks, easy
to repair, and easy to modify. This paper is concerned with developing a
sequence of two courses and laboratory experiences to prepare
engineering students for the automation of processes and production
lines.

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THE LOREM IPSUMS SUMMER 2016
Lab Facilities
There are 12 workstations
in the laboratory, which
can accommodate up to 24
students working in teams
of two students per
workstation. We have at
least twelve copies of all
the equipment available in
the laboratory.
Rockwell Automation (Allen Bradley)
CompactLogix PLC Trainer
Yaskawa 2-Axis Servo-Motor Control Trainer
Keyence Machine Vision Controller and
CompactLogix PLC
Keyence Cameras for Machine Vision System
Pneumatic Cylinder Control Trainer Setup Linear Slide with Rockwell Automation Kinetix Servo-Motor

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THE LOREM IPSUMS SUMMER 2016
Contents
Lecture: Introduction to automation and PLC’s.
Safety.
Lab: Programming PLC using ladder logic
Lecture: State-machine diagrams
Lab: Use of timer and counters. Pneumatics
Converting a state-machine diagram into a PLC
program
Lecture: Stepper motors and servomotor control
Lab: Programming motion with servomotors
Lecture: Machine vision and image processing
concepts
Lab: Programming a machine vision system
Lecture: Machine vision (continued). Safety
Lab: Machine vision and image processing.
Robotics.
Students’ projects
Students may be asked to develop a project in which
they are expected to apply concepts learned in this class.
All projects are self-selected. Students are encouraged to
generate their own ideas for a project and to discuss
these ideas with the instructors. There are some benefits
as well as potential difficulties of this approach which
instructors should be aware. The biggest benefit of self-
selected projects is the high level of enthusiasm and
motivation of the students once they start working on
their project ideas. Students should make their project
idea work and will come to the lab more frequently to
ensure the success of their project.
A potential difficulty is that students unfamiliar with
the technology may find it difficult to select a project
idea. If the indecision is carried too far into the term,
there may not be adequate time to develop or complete
a quality project. Providing examples of project ideas,
especially past projects for the same class, allows
students to more easily move forward.
Student Project - Inspection of sliced apples
to detect if they have seeds
Student Project – Copy machine to reproduce an image
Student Project – when all five fingers are
detected, it directs a servomotor to move a
cardboard hand to give a “high five”.