AIMS AND CONTENT

LEARNING OUTCOMES

The purpose of the module is to define the basic and advanced elements of an automation system and its components, as well as their integration into the informational processes of a factory. In particular, it will cover the operational elements and design criteria for instrumentation, actuators, communication networks, control systems, and supervision elements, with a focus on the compliance with safety and cyber security requirements

AIMS AND LEARNING OUTCOMES

The objective is not an encyclopedic treatment of measurement technologies, but the development of a systemic and design-oriented perspective, focused on: integration of heterogeneous components, interoperability among devices and protocols, reliability and determinism, technical risk management and regulatory compliance in digital environments.
The teaching unit also contributes to develop the ability to critically interpret real industrial architectures, a systemic approach to design, awareness of the interaction between physical and digital domains, and the ability to connect technical regulations, system architecture, and implementation.

TEACHING METHODS

The teaching unit integrates theoretical topics with real use cases drawn from industrial plants, electrical networks and safety-critical products; concrete design examples derived from actually implemented architectures; practical exercises aimed at understanding real diagrams and system configurations; analysis of realistic scenarios (faults, EMC disturbance, communication issues, event management, safety).

For this reason, teaching includes hands-on activities carried out directly in the classroom using real industrial equipment and software. Specifically: live demonstration of a commercial SCADA system, including configuration, data visualization and alarm management; network troubleshooting and traffic analysis on a Profinet demo case equipped with a PLC and remote I/O modules; configuration of OPC-UA communication for data exchange between PLC and SCADA, replicating the integration architecture used in real industrial plants; configuration of the safety functions of a safety-rated PLC, covering the main requirements of IEC 61508 and IEC 61511. These activities complement the theoretical content and allow students to directly experience the design and diagnostic challenges of real automation systems.

Students with valid certifications for Specific Learning Disorders (SLD), disabilities, or other special educational needs are encouraged to contact the instructor and the School’s disability liaison at the beginning of the course to agree on any teaching arrangements that, while respecting the course objectives, take individual learning styles into account. The contact details for the School’s disability liaison are available at the following link: https://unige.it/commissioni/comitatoperlinclusionedeglistudenticondisabilita

SYLLABUS/CONTENT

MODULE 1 – Measurement basics for Industrial Automation

Special attention is devoted to the distinction between:

• Measurements for automatic control systems

• Typical chains sensor-transmitter-actuator

• Accuracy and uncertainty in industrial conditions

• Measurement for control: Used by PLC/DCS systems to regulate a process (e.g., PID control)

• Standard signals (e.g. 4-20 mA; digital I/O)

MODULE 2 – Measurements in Electrical and Process Systems

2.1 Measurements in Electrical Systems

• current and voltage transducers, instrument transformers

• measurements for protection, control and monitoring

2.2 Process Measurements

Overview of:

• temperature

• pressure

• flow

• level

• correct installation and reliability

MODULE 3 – Automation and Supervision Architectures

Analysis of real industrial architectures:

• automation levels

• PLC and DCS systems

• scan cycle

• SCADA systems

• RTUs and remote data acquisition

• redundant architectures

Clarification of the difference between:

• IT networks (data-centric, non-deterministic)

• OT networks (deterministic, control-oriented)

Introduction to determinism and industrial real-time concepts.

MODULE 4 – Industrial Communication and Telecontrol

4.1 Fundamentals

Brief overview of the ISO/OSI model and Ethernet.

Key concepts: latency, determinism & real time, synchronization, polling vs event-driven communication

4.2 Fieldbus

• Profibus (DP e PA)

• HART

• Details on characteristics: topology, scheduling, determinism, device profiles

4.3 Industrial Ethernet

• Profinet (RT and IRT)

• EtherNet/IP

• Modbus TCP

4.4 Telecontrol protocols for electrical systems

• IEC 60870-5-104

• DNP3

4.5 Interoperability

• OPC-UA

MODULE 5 – IEC 61850 – Distributed Substation Automation

5.1 Substations evolution

Wired and digital architectures. Separation of process and station bus.

5.2 IEC 61850 information model

• Objects

• Logical nodes

• Data objects and attrobutes

• File SCL

5.3 Communication services

• real-time services (GOOSE, Sampled Values), MMS

5.4 Distributed automation among IEDs

Integrated functions: protection, measurement, control, event logging

MODULE 6 – Functional Safety, EMC, and Safety of Machinery

6.1 Functional Safety

• Safety critical and mission critical systems

• Risk analysis (including qualitative and quantitative approaches, influence of environmental factors, etc.)

• Redundancy, Fail-safe architectures

• SIL (Safety Integrity Level)

• Normative: IEC 61508, IEC 61511, EN 50126, IEC 61000-1-2, IEEE Std. 1848

• Safety-related systems

6.2 Safety of Machinery

Machinery Regulation (EU) 2023/1230

• safety-related software

• digital systems

• cybersecurity

• artificial intelligence

MODULE 7 – Industrial Digitalization and OT Cybersecurity

• Cyber-Physical Systems

• Digital Twin

• Edge computing

• Predictive maintenance

• OT cybersecurity

• IEC 62443

RECOMMENDED READING/BIBLIOGRAPHY

The following bibliographic resources are suggested as reference.

1) Dunn, William C., Fundamentals of Industrial Instrumentation and Process Control, 2nd Edition. McGraw Hill, 2018. ISBN-13: 978-1260122251

2) Manoj, K. S., Industrial Automation with SCADA: Concepts, Communications and Security. Notion Press, 2019. ISBN-13: 978-1684668281

3) Sharma, K. L. S., Overview of Industrial Process Automation, 2nd Edition. Elsevier Science, 2016. ISBN-13: 978-0128053546

4) Knapp, Eric D., Langill, Joel, Industrial Network Security: Securing Critical Infrastructure Networks for Smart Grid, SCADA, and Other Industrial Control Systems, 3rd Edition. Elsevier Science & Technology Books, 2024. ISBN-13: 978-0443137389

5) Tacchini, A., Functional Safety of Machinery: How to Apply ISO 13849-1 and IEC 62061, Wiley-Blackwell, 2023. ISBN-13: 978-1119789048

TEACHERS AND EXAM BOARD

LESSONS

LESSONS START

 https://corsi.unige.it/en/corsi/11955/studenti-orario

Class schedule

The timetable for this course is available here: Portale EasyAcademy

EXAMS

EXAM DESCRIPTION

The exam is in written form, as a structured quiz. Each question has a weight that is indicated next to it; the total score is 30.

ASSESSMENT METHODS

Written examination: structured quiz (multiple-choice and short-answer questions) covering the main modules of the course. The test is intended to assess understanding of the key concepts and the ability to interpret industrial architectures and configurations.
Optional technical report: students may supplement the written exam with a written report on a topic agreed with the instructor. Reports may be developed individually or in small groups and may involve collaboration with industrial partners. This option is intended to encourage deeper engagement with real applications and, where appropriate, to support the development of the thesis.

FURTHER INFORMATION

Ask the Professor for other information not included in the teaching unit description