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INDUSTRIAL AUTOMATION

INDUSTRIAL AUTOMATION

By S. Venkatesan, ME, MISTER, researcher / CSE, Anna University, Coimbatore.

and

Dr.M.Karnan, ME, Ph.D., professor and chief of Tamil Nadu College of Engineering, Coimbatore.

SUMMARY: Increased automation is the key to increasing production desired. In the context of industrialization, automation is a step beyond mechanization. Considering the mechanization of man as well as machine operators to assist with the requirements of muscular work, automation greatly reduces the need for human sensory demands and mental as well. The processes and systems can also be automated. It plays increasingly important role in the global economy and in everyday experience. Engineers strive to combine automated systems with mathematical tools and organization to create complex systems for a rapidly expanding range of applications and human activities. Many roles for humans in industrial processes presently lie beyond the scope of automation. Human-level pattern recognition, language recognition and language production capacity is well beyond the capabilities of modern mechanical and computer systems. In this presentation, we will have an overview concepts of industrial automation as a computer integrated manufacturing, flexible manufacturing systems, industrial robots, intelligent artificial Advanced Automatic Material Handling Systems, etc …

INTRODUCTION: AUTOMATION is the process the following sequence of operations human labor with little or no, using specialized equipment and devices that produce and control the manufacturing process. (OR) Automation is the use of control systems (such as CNC, PLCs and other industrial control systems) together with other applications of information technologies (such as computer-aided technologies [CAD, CAM), control machines and industrial processes, reducing the need for human intervention. TYPES: partial MECHANIZATION Complete Automation: Mechanization can be defined in its simplest sense that the transfer of skills and crafts to operate the machine.

OBJECTIVES OF AUTOMATION: IMPROVING THE QUALITY OF PRODUCTS TO REDUCE THE COST OF WORK FOR IMPROVING THE SAFETY OF WORK FOR REDUCING THE TIME OF MAKING LEAD avoid costs high DO NOT AUTOMATE Advantages:

The main benefit of automation is: Replacement of human operators in the tedious tasks. Replacing the man in the tasks should be performed in hazardous environments (fire, space, volcanoes, plants nuclear, underwater, etc.) make the tasks that are beyond human capabilities such as handling heavy loads, objects too large, too hot or too cold substances or the requirement to make things too quickly or too slowly. Economy improvement. Sometimes, certain types of automation implies improves corporate economy, society, or most of humanity. For example, when a company has invested in technology Automation recover its investment, when a state or country increases its revenues by automating like Germany or Japan in the 20th century or when mankind can use the Internet, which in turn use in satellites and other auto engine. The main drawbacks disadvantages of automation are:

Technology limits. The current technology is not able to automate all the tasks you want. Unpredictable development costs. Research and development costs of the automation process is difficult to predict accurately in advance. Given that this cost can have a significant impact on profitability, it is possible to complete the automation process for discovering there is no economic advantage to do so. The initial costs are relatively high. The automation of a new product need a huge initial investment compared with the unit cost of product, although the cost of automation is prevalent in many batches of products. Automation plant required an initial investment too, although this cost is distributed products to produce. The different automation tools types of automation tools exists: ANN – DCS artificial neural network – Distributed Control System HMI – Human Machine Interface SCADA – Supervisory Control and Acquisition Data PAC – Programmable Automation Controller Instrumentation Motion Control Robotics P PLC – Programmable Logic Controller PLC: A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of processes, electromechanical, s such as control of machinery on the assembly lines plants, rides, or fixtures. PLCs are used in many industries and machinery. Unlike computers for general purposes, the PLC is designed for multiple entry and exit, extended temperature ranges, immunity to electrical noise and vibration and shock. Programs to control machine operation are typically stored in battery-backed or non-volatile memory.

A PLC is an example of a real-time system since output results must be produced in response to conditions of entry time bounded, operation otherwise unintended result. SCADA stands for supervisory control and data acquisition. It generally refers to an industrial control system: a computer system monitoring and control processes. The process can be industrial, infrastructure or facility based as described as industrial processes include those in manufacturing, production, electricity generation, processing and refining, and may run in continuous, batch, repetitive, or discrete modes. Infrastructure process may be public or private and include the processing and distribution of water, wastewater collection and treatment, pipelines, transmission and distribution electric civil defense siren systems and large communication systems. Facility processes occur both in public and private including buildings, airports, ships and space stations. They monitor and control HVAC, access and consumption of energy.

Computer Integrated Manufacturing Computer-Integrated Manufacturing (CIM) Engineering is a manufacturing method in which the production process is controlled by computer. The process traditionally separate methods are united by a computer by the ICD. This integration allows the process to exchange information with each other and enable them to undertake action. Through this integration, manufacturing may be faster and with fewer errors. However, the main advantage is the ability to create automated manufacturing processes. Typically ICD based on closed-circuit monitoring process, based on input Time real sensors. It is also known that the flexible design and manufacturing. Overview The term "Computer Integrated Manufacturing In" is both a method of manufacture and the name of an automated computer system where individual engineering, production, marketing and support functions of a manufacturing enterprise are organized. In a CIM functional areas such as design, analysis, planning, procurement, accounting analytical, inventory management and distribution are linked by computer to the factory floor functions such as handling and management, providing control direct and monitor all operations process. As a method of manufacture, ICD distinguish three components from other manufacturing methods: Means of data storage, retrieval, manipulation and presentation, mechanisms of detection of the state and modification processes; Algorithms to assemble the data processing component with the sensor / component change. CIM is an example of the implementation of Information and Communication Technology (ICT) in manufacturing.

CIM implies that there are at least two computers to exchange information, for example, the controller arm robot and a microcontroller with a CNC machine. Some factors involved when considering implementation CIM are the volume of production experience Company or personnel to do the integration, the level of integration in the product itself and the process integration production. The ICM is most useful where a high level of ICT use in business or facility, such as systems CAD / CAM, the availability of the planning process and its data. Although nothing that says this is correct. History: The idea of "Digital Manufacturing" was prominent in the 1980s, when Computer Integrated Manufacturing has been developed and promoted by manufacturers of machine tools and computer and Automatic Systems Association and the Society of Manufacturing Engineers (CASA / SME). "CIM is the integration of the total manufacturing enterprise by using integrated systems and data communications coupled with new management philosophies that improve organizational effectiveness and staff. "ERHUM subjects Computer integrated manufacturing – Key Challenges There are three major challenges to developing a functioning system of Computer Integrated Manufacturing: Integration of components from different suppliers: when different machines such as CNC, conveyors and robots, using different communication protocols. In the case of AGVs, different lengths of time itself to charge the batteries may cause problems.

Data Integrity: The higher the degree of automation, the more critical is the integrity of data used to control machines. While the CIM system saves on labor of operating machines, it requires additional work to ensure human there are good safeguards for data signals that are used to control machines. Process control: Computers may be used to help human operators of the plant, but it must always be a qualified engineer on site to deal with circumstances which could not be provided by designers of software control. Subsystems in a Computer Integrated Manufacturing Computer Integrated Manufacturing System is not the same as a "Lights Out" factory, which would be totally independent of any human intervention, even if it is a big step in that direction. Part of the system involves flexible manufacturing, where the plant can be quickly modified to produce different products, or when the volume of products can be changed rapidly with computers.

Some or all of the following subsystems in May is in a CIM operation: Computer-aided techniques: CAD (Computer Aided Design) CAE (Computer Aided Engineering) CAM (Computer Aided Manufacturing) CAPP (Computer Aided Process Planning) CAQ (Computer-Aided Quality Assurance) PPC (production planning and control) ERP (Enterprise Resource Planning) An integrated management system with a base common data. Devices and equipment needed: CNC, computer numerical control tools of the machine DNC, direct numerical control tools machine controllers, programmable logic controllers Robotics Computer Software Controllers equipment monitoring networks Interfacing Technologies: (FMS system flexible manufacturing) ASRS, automated storage and retrieval systems AGV, automated guided vehicles Robotics automated transport systems of industrial robot is officially defined by ISO as an automatic, reprogrammable, multipurpose manipulator programmable in three axes. The domain robotics may be more convenient defined as the study design and the use of robotic systems for manufacturing (a high level of definition based on the prior definition of robot). Typical applications of robots include welding, painting, assembly, pick and place, packaging and palletizing, product inspection and testing, all performed with great stamina, speed and precision.

A flexible manufacturing system (FMS) is a manufacturing system in which there is a certain degree of flexibility that allows the system to react to changes planned or unplanned. This flexibility is generally considered fall into two categories, which both contain many sub-categories. The first category, the machine flexibility, covers the ability of the system be modified to produce new types of products and the ability change the order of operations performed on one hand. The second category is called routing flexibility, which is the possibility of using more machines to perform the same operation on a part, and the system's ability to absorb large-scale changes, such as volume, capacity, or capacity. Most FMS consists of three main systems. The machines work are often automated CNC machines are connected a handling system to optimize the flow of parts and the central control computer that controls material movement and flow of machine. The main advantages of an FMS is its flexibility in managing manufacturing resources such as time and effort to manufacture a new product. The best implementation of an FMS is in the production of small series of products as those of mass production.

A flexible manufacturing system combines the advantages of highly automated and controlled systems – Precision – The mass production with the benefits of versatile, adjustable Systems – Flexibility – The uniqueness of product A comprehensive description of a flexible manufacturing system here follows: The production of cells A flexible manufacturing cell (FMC) consists of two or more CNC machines, a laptop and a robot. The computer of the cell (usually a logic controller programmable) is interfaced with the microprocessor of the robot and the CNCS. The controller of the cell functions of the Comptroller of the cell include balancing workload, hours party, and flow control equipment. The supervision and coordination between the different operations in a manufacturing cell is also carried by the laptop. The software includes features that allow the processing of machine breakdown, tool breakage and other situations specific. The Robot Cell In many applications, the robot also makes cells change tools and housekeeping functions such as chip removal, holding tools in the tool changer, and inspection tools break or wear expressive. If necessary, the robot may also initiate emergency procedures such as system shutdown. Parker-Hannifin Corporation, Forrest City, North Carolina.

The system Flexible Manufacturing – The FMS flexible manufacturing system (FMS) is a configuration of the managed computer workstation where the digital materials are handled automatically and the machine loaded. The flexible manufacturing system is used primarily to mid-volume (200 to 30,000 pieces per year) mid-range (types 5 to 155 in part) production. Flexible Manufacturing System Components-two or more computer-controlled work stations that perform digital a series of transactions; An integrated system of transport equipment and a computer that controls the flow of materials, tools and information (eg data processing and malfunctioning machines) throughout the system; workstations auxiliary loading and unloading, cleaning, inspection, etc. flexible manufacturing system aims to reduce manufacturing costs by lowering labor costs and direct minimizing scrap re-work and waste materials. Less skilled labor required. Reduced work-in-process inventory eliminating the need to reduce the batch in production time for manufacturers to respond more quickly to the variability Process Better market demand, resulting in consistent quality.

Different levels FMS are: Flexible Manufacturing Module (FMM). Example: an NC machine, a pallet changer and a buffer portion; Flexible Manufacturing (Assembly) Cell (F (M / A) C). Example: Four RPM and an AGV (Automated Guided Vehicle); Flexible Manufacturing Group (FMG). Example: Two FMC, a meeting of premiers and two AGV which will transport parts from a loading area, the part through machines, part unloading area; flexible production systems (FPS). Example: A FMG and ACS, two AGVs, an automated system Storage of tools and some automatic / Storage Assembly, Flexible Manufacturing Line (FML). Example: several stations in a production line and AGV. Advantages and disadvantages of implementing FMS Benefits Faster, less the cost changes from one place to another that will improve the use of capital Reduced direct labor costs, due to the reduction in the number of workers reduced inventory due to planning and programming consistent precision and better quality, thanks to the automated control of the cost reduction per unit of production, due to greater productivity using the same number of workers savings of indirect labor, reducing errors, rework, repairs and rejects Disadvantages limited capacity to adapt to changes in product or product line (eg machines have limited capacity and the tools necessary for products, whether a family is not always feasible in a given FMS) pre-planning substantial expensive activity, costing millions of dollars technological problems pane exact positioning and timing very accurate and necessary to treat a component manufacturing sophisticated FMS complexity and cost are the reasons for their slow acceptance by industry.

In most cases, the CSP will be promoted. An automatic guided vehicle or automatic guided vehicles (AGV) is a mobile robot following markers or son in the floor, or using vision or lasers. They are most often used in industrial applications to move materials around a factory or warehouse. Vehicle Application Automatic Guided expanded during the late 20th century and they are no longer limited to industrial environments. Automatic Guided Vehicles (VFA) to increase efficiency and reduce costs by helping to automate a manufacturing facility or warehouse. AGV can carry loads or towing objects behind them in trailers that they can autonomously join. The trailers can be used to move raw materials or finished products. The AGV can also store items on a bed. Objects can be placed on a set of motorized rollers (conveyors) and then pushed off by reversing them. Some AGVs use fork lifts to lift objects for storage. AGVs are used in almost every industry, including pulp, paper, metals, newspapers, and general manufacturing. The transport of materials such as food, clothes or medicine in hospitals was also conducted. Common Applications AGV Automated Guided Vehicles may be used in a wide variety of applications for transporting various types of material, including pallets, rolls, racks, carts and containers. AGV excel in applications with features following repeated movements of materials for a distance of regular delivery charges stable income flow / volume If delivery time is critical and delivery delays have caused the inefficiency of operations with process at least two quarters of work where the monitoring hardware is important artificial intelligence (AI) is the intelligence of machines and the branch of computer science that seeks to create.

Manuals set the field as the study and design of intelligent agents "where an intelligent agent is a system that perceives its environment and takes actions that maximize the chances of success. John McCarthy, who coined the term in 1956, defines it as "science and engineering of making intelligent machines". The field was based on the claim that a central property of human intelligence-the wisdom of Homo sapiens may be described so precisely that it can be simulated by a machine. This raises philosophical questions about the nature of the mind and limits pride scientific issues have been addressed by the myth, fiction and philosophy since antiquity. Artificial intelligence has been optimistic, but it has also suffered setbacks, and today has become an essential part of the technology industry, providing the hard work for many of the most difficult problems in computer science. AI research is highly technical and specialized, deeply divided into sub-fields which often fail to communicate with each other. Sub-areas have developed around particular institutions, the work of individual researchers, the solution specific problems, the long-standing differences of opinion on how the avian influenza must be done and the application of considerable differences between the tools. The central problem of AI are features such as reasoning, knowledge, planning, learning, communication, perception and the ability to move and manipulate objects. The general intelligence (or "strong AI") is still a goal long term (some research). Obotic Automation: Process Material Handling Material handling is the wider category of applications that involve moving, the selection and packaging of products. Robots handling of materials are used to move, feed or withdraw from parts or tools to or from a location or to transfer from one machine to another. Process material handling Pick and Place Part Dispensing Packaging Palletizing Load Transfer Assembly Materials Order Picking A variation of a robotic handling equipment is used to build and unload the units on a pallet. Manufacturing companies around the world are implementing material due to handling robots, they are faster, more accurate and more efficient.

They offer unmatched quality and repeatability. Palletizing and handling: palletizing Act, loading or unloading equipment on pallets. The newspaper industry has been particularly affected by labor costs increased. Part of the solution to this problem is to use robots like Cincinnati Milacron robot used for the palletising of advertisements for newspaper. Many companies in the United States and Canada have been forced to close in areas such as die casting and injection molding because they could not compete with foreign companies. The introduction of robotics in this process has enabled these companies to remain viable. In institutions chip industry manufacturing semiconductor integrated circuit, various processes take place in a clean room. This requires that staff and that robots not to introduce dirt, dust or oil in the region. Because robots do not breathe, sneeze or have films, they are particularly suitable for clean room environment required by the semi-conductors. At first glance, the automation may appear to devalue labor through its replacement with less-expensive machines, but the overall effect of this on the market work as a whole remains unclear.

Conclusion

Today, the automation of the workforce is quite advanced, and continues to move more quickly across the world and impinges on the growing number of skilled jobs, yet during the same period, the well-being General and quality of life for most people in the world (where political factors have not tarnished the image) have improved so spectacular. Currently, for manufacturing companies, the purpose of automation has changed to increase productivity and reduce costs, to broader issues such as improving the quality and flexibility in the manufacturing process. The emphasis on the use of old automation simply to increase productivity and reduce costs was seen to be short-sighted because it is also necessary to provide a workforce qualified who can make repairs and manage the machines. In addition, the initial costs of automation were high and often not be recovered by the time new manufacturing processes completely replaced the old. (Japan's "robot junkyards" who were known worldwide in manufacturing.) Automation is now often applied primarily to increase quality in the process manufacturing where automation can increase quality substantially.

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