Introduction to Industrial Automation



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Introduction to Industrial Automation by Stamatios Manesis, George

xiii

Preface

The book that you are holding is the result of many efforts in teaching the concept of industrial 

automation to young and promising engineers during the last few decades in academia. The authors 

aimed to create a system so that engineers will have a full and in-depth overview of the industrial 

automation field, with a strong connection to real-life applications and that will provide a con-

stant inspiration for the problems that are commonly found in an industrial environment. In the 

adopted teaching approach, one of the fundamental learning outcomes was to enable independent 

and outside-the-box creative thinking for automation engineers, in order to produce functional 

solutions to difficult problems. In all these years, the authors have identified that there has not been 

a book in the existing literature that provides all the necessary learning directions for students and 

with a full focus on real-life demands, a book that could prepare them immediately and with the 

fundamental deep knowledge to deal with the field of industrial automation. Thus, the book that 

you are holding now is the outcome of a writing and integration process that lasted more than 

three years, a book that we hope to be a constant reference in the field of industrial automation.

Industrial automation is a multidisciplinary subject that requires knowledge and expertise 

from various engineering sectors, such as electrical, electronics, chemical, mechanical, commu-

nications, process, and software engineering. Nowadays, the application of industrial automation 

has been transformed into an ubiquitous infrastructure that automates and improves everyday 

life. Characteristic examples of industrial automation systems can be found in the car industry, 

the aviation sector, the marine industry, healthcare industry, rail transportation, electrical power 

production and distribution, the pulp and paper industry, and numerous other applications. Our 

society has become so dependent on automation, that it is difficult to imagine what life would be 

like without automation engineering. With the current developments in the field of Industry 4.0, 

industrial automation is unified with the concept of the Internet of things, embedded systems, 

and Cyber-Physical systems, in order to create an integrated ecosystem with the vision to enable 

pure automation for all aspects of life, a future in which everything will be connected, integrated, 

and automated.

Nowadays, the concept of automation in an industrial production process is a very attractive 

subject for electrical engineers, because it perfectly combines all the principles and methods of 

classic automatic control with microcomputer or microprocessor technology. The introduction 

of microcomputer technology in the field of industrial production, coupled with development in 

the area of robotics, resulted in the creation of a special scientific field known as “automation and 

robotics”. Although this field appears to be separated from “automatic control”, this is mainly due 

to its great extent and not to the differentiation of its theoretical principles. The rapid development 

of automation and robotics in today’s technological world has made it necessary for some time to 

introduce industrial automation and robotics courses in the curriculum of various electrical and 

computer engineering departments.



xiv

 



 Preface

Each industrial production process consists of a series of simple or complex machines through 

which the raw material undergoes a sequential treatment in order to achieve the production of 

an end product, while satisfying the goal of increased production, improving product quality, 

lowering costs, and increasing production flexibility. Initially, industrial automation systems 

were implemented in a conventional way, i.e., with independent specific devices (timers, coun-

ters, auxiliary relays, etc.), and wiring them according to the desired operating mode. Today, the 

implementation of an industrial automation system takes place in specific digital devices called 

programmable logic controllers (PLCs). The key feature of PLC technology is the need for pro-

gramming (versus wiring) the control logic of the industrial system. The multiple advantages of 

PLCs have made them the leading tool for controlling an industrial system, but also for other 

non-industrial systems that we encounter in our everyday lives, such as traffic control for a street 

intersection, a tower elevator, an automated car wash, etc.

The first part of the book, including Chapters 1, 2, 3, 4, 5 and 6, presents the basic devices, 

sensors, and actuators, in which the aid of an automation system is implemented, as well as the 

heuristic composition of automation arrangements and the methodical design of automation cir-

cuits. Also, the basic elements of electro-pneumatic technology are introduced. The second part 

of the book, including Chapters 6, 7, 8, 9 and 10, presents the extended subject of PLCs, whose 

hardware and software are both described in detail. The basic concepts of industrial networks for 

networking PLCs or other controllers and the applied use of the Proportional-Integral-Derivative 

(PID) control law in the industry are also presented. Appendix A presents briefly the arithmetic 

systems required for PLC programming, while Appendix B introduces the subject of analog input 

and output values scaling. This book was written based on the assumption that the reader has no 

prior experience in industrial automation systems, but should be easy to understand if they have 

any background knowledge related to motor control, digital logic, and digital electronics.

The projected learning outcomes after reading this book will be to understand the function-

ality of the basic elements of automated systems and the fundamental principles of operation; 

analyze real-life problems from an industrial automation perspective and understand what is effec-

tive and what is not, based on engineering and cost-oriented thinking; identify and select proper 

sensory and actuation equipment for synthesizing and integrating industrial automation tasks; 

integrate and synthesize a classical relay-based industrial automation; integrate, synthesize, and 

program a PLC based on industrial automation; and gain fundamental knowledge in the field of 

electro-pneumatic automation, industrial networks, and PID control in the industry.





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