Automated systems in industry

Name:

Date:

Class:

Quick Questions

Shade in the A or B circle for each question.

1. In a chemical plant, which device measures the temperature of a reactor and sends the reading to the microprocessor?

A A temperature sensor

B A motor

2. A level sensor in a tank reads FULL. What should the microprocessor do next?

A Signal the actuator to open the filling valve wider

B Signal the actuator to close the filling valve

3. On a production line, what does an infra-red sensor do?

A Moves the item along the belt

B Detects when an item passes or is in position

4. Which of these is an actuator in an automated factory?

A A robotic arm

B A pressure sensor

5. Pressure in a chemical plant pipe rises above the safe limit. Which sequence is correct?

A Pressure sensor, then microprocessor, then actuator opens a release valve

B Actuator, then microprocessor, then pressure sensor

Match the Pairs

Draw a line connecting each item on the left to its match on the right.

Left column		Right column
1IF pressure > 8 THEN open_valve		AA sensor cannot close a valve. Sensors only send readings. The microprocessor decides and an actuator (the valve) does the action.
2IF level >= 100 THEN close_valve		BThe robotic arm is an actuator, so it is an output device. It does not take readings. A sensor should send the data and the microprocessor should control the arm.
3An infra-red sensor on a production line detects an item and the microprocessor starts a motor on the conveyor belt		CIF temp > 90 THEN heater_off
4A temperature sensor in a chemical plant is read repeatedly so the microprocessor can switch the heater off when it is too hot		DThe microprocessor compares the pressure sensor reading with a stored limit and opens a valve to release pressure in a chemical plant
5IF level >= 100 THEN sensor_close_valve		EIF item_detected THEN start_motor
6IF robot_arm_moved THEN read_temperature		FThe level sensor shows the tank is full, so the microprocessor closes the filling valve to stop the liquid

Definitions

Automated system in industry

Fill in the Blanks

Complete each line of code by filling in the missing parts.

IF temperature _ 80 THEN SWITCH_ON coolingPump ENDIF

WHILE level < 100 DO ____ fillValve ENDWHILE

IF proximitySensor < 5 THEN STOP _____________ ENDIF

IF pressure > ___________ THEN OPEN releaseValve ENDIF

IF partInPlace THEN MOVE __________ TO weldPoint ENDIF

Spot the Error

Shade in the letter of the line that contains an error.

Question 1

A temp ← READ(coolingValve)

B IF temp > 80 THEN

C SET(coolingValve, OPEN)

D ENDIF

Question 2

A level ← WRITE(levelSensor)

B WHILE level < 100

C SET(fillValve, OPEN)

D level ← READ(levelSensor)

E ENDWHILE

F SET(fillValve, CLOSED)

Question 3

A WHILE lineRunning = TRUE

B item ← READ(irSensor)

C IF item ← TRUE THEN

D SET(robotArm, PICK)

E ENDIF

F ENDWHILE

Question 4

A pressure ← READ(pressSensor)

B IF pressure < 200 THEN

C SET(reliefValve, OPEN)

D SET(alarm, ON)

E ENDIF

Question 5

A dist ← READ(proximitySensor)

B IF dist < 5 THEN

C SET(proximitySensor, OFF)

D ELSE

E SET(beltMotor, ON)

F ENDIF

Answer Key

Automated systems in industry

Section A: Quick Questions

A — A temperature sensor

B — Signal the actuator to close the filling valve

B — Detects when an item passes or is in position

A — A robotic arm

A — Pressure sensor, then microprocessor, then actuator opens a release valve

Section B: Match the Pairs

IF pressure > 8 THEN open_valve → The microprocessor compares the pressure sensor reading with a stored limit and opens a valve to release pressure in a chemical plant

IF level >= 100 THEN close_valve → The level sensor shows the tank is full, so the microprocessor closes the filling valve to stop the liquid

An infra-red sensor on a production line detects an item and the microprocessor starts a motor on the conveyor belt → IF item_detected THEN start_motor

A temperature sensor in a chemical plant is read repeatedly so the microprocessor can switch the heater off when it is too hot → IF temp > 90 THEN heater_off

IF level >= 100 THEN sensor_close_valve → A sensor cannot close a valve. Sensors only send readings. The microprocessor decides and an actuator (the valve) does the action.

IF robot_arm_moved THEN read_temperature → The robotic arm is an actuator, so it is an output device. It does not take readings. A sensor should send the data and the microprocessor should control the arm.

Section C: Definitions

Automated system in industry — Sensors send readings to a microprocessor, which controls actuators like motors, valves and robotic arms to run a production line or chemical plant with little human control.

Section D: Fill in the Blanks

IF temperature > 80 THEN
  SWITCH_ON coolingPump
ENDIF

WHILE level < 100 DO
  OPEN fillValve
ENDWHILE

IF proximitySensor < 5 THEN
  STOP conveyorMotor
ENDIF

IF pressure > maxPressure THEN
  OPEN releaseValve
ENDIF

IF partInPlace THEN
  MOVE roboticArm TO weldPoint
ENDIF

Section E: Spot the Error

A — The temperature must be read from the temperature sensor, not from the cooling valve. A valve is an actuator, so it is set, not read. It should be temp ← READ(tempSensor).

A — A level sensor only provides input to the microprocessor, so the program must READ from it. It cannot be written to. It should be level ← READ(levelSensor).

C — The arrow ← assigns a value. A condition needs the comparison operator =. It should be IF item = TRUE THEN, so the arm picks only when the infra-red sensor detects an item.

B — The wrong comparison operator would open the relief valve when the pressure is safely low. The check should be pressure > 200, so the valve opens when the pressure is too high.

C — A proximity sensor is an input device, so it cannot be switched by the program. The actuator that stops the belt is the motor. It should be SET(beltMotor, OFF).