By S. INDUSTRIAL AUTOMATION Venkatesan, ME, MISTER, researcher CSE, Anna University, Coimbatore. and Dr. M. Kärnan, ME, Ph.D., professor and chief of Tamil Nadu, Faculty of Engineering, Coimbatore. SUMMARY: Increased automation is key to the desired production. In the context of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators of the machines to help with the requirements of muscular work, automation greatly reduces the need for human sensory and mental demands. The processes and systems can also be automated. It plays an increasingly important role in the global economy and everyday experience. Engineers strive to combine automated systems with mathematical tools and organization to create complex systems for a wide range of rapid expansion of applications and human activities. Many roles for humans in industrial processes that are currently outside the scope of automation. Human-level pattern recognition, language recognition and language production ability are well beyond the capabilities of modern mechanical systems and equipment. In this presentation, we will have an overview of concepts such as the industrial manufacture of integrated computer automation, flexible manufacturing systems, industrial robots, artificial intelligence, Advanced Automatic Material Handling Systems, etc … INTRODUCTION: automation, which is the process of the following sequence of operations with little or no human labor, using specialized equipment and devices that produce and control the manufacturing process. (OR) of automation, the use of control systems (eg CNC, PLC and other industrial control systems), along with other applications of information technologies (eg computer aided technologies [CAD, CAM) to control industrial machinery and processes, reducing the need for human intervention. TYPES: Automating the complete partial mechanization: Mechanization can be defined in its simplest sense that the transfer of skills and crafts to operate the machine. AUTOMATION GOALS: TO IMPROVE THE QUALITY OF PRODUCTS TO REDUCE THE COST OF THE WORK TO IMPROVE SAFETY OF THE WORK TO REDUCE THE TIME TO TAKE LEAD avoid costly benefits not automate: The main advantage of automation is: Replacement of human operators in the tedious tasks. Replacing the man in the tasks to be performed in hazardous environments (fire, space, volcanoes, nuclear installations, underwater, etc) do the tasks that are beyond human capabilities, such as heavy loads substances objects too large, too hot or too cold or is required to do things too fast or too slowly. Improving Economy. Sometimes, certain types of automation include improved corporate economy, society, or most of humanity. For example, when a company has invested in automation technology to recover its investment, when a state or country increases its revenues by automating like Germany or Japan, or the 20th century when humanity can use the Internet, which turn on the use of satellites and other automobile engines. Disadvantages The main disadvantages of automation are the limits of technology. Current technology is not capable of automating all the tasks you want. Development costs unpredictable. 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 automation of a process only to discover that there is no economic incentive to do so. The initial costs are relatively high. The automation of a new product has required large investments in comparison with the unit cost of the product but the cost of automation is common in many batches of products. The automation of a factory requires an initial investment too, though this cost is divided into the products manufactured. Automation tools for different types of automation tools exists: ANN – artificial neural network DCS – Distributed Control System HMI – Human Machine Interface SCADA – Supervisory Control and Data Acquisition PAC – Programmable Automation Controller Instrumentation Motion Control Robotics P PLC – Programmable Logic Controller PLC: Programmable Logic Controller (PLC) or PLC is a digital computer used for automation of processes, electromechanical, s such as control of machinery on factory assembly lines, travel, or accessories. PLCs are used in many industries and machinery. Unlike general purpose computers, the PLC is designed for multiple entry and exit, expand temperature ranges, immunity to electrical noise and resistance to vibration and shock. Programs control machine operation are typically stored in battery backup or nonvolatile memory. A PLC is an example of a real time system since output results must be produced in response to input conditions within a defined timeframe, results of operation otherwise unwanted. SCADA supervisory control means and data acquisition. Usually refers to an industrial control system: a computer control system and control processes. The process can be industrial, infrastructure or facility based as described as industrial processes are the manufacturing, production, electricity production, processing and refining, and can operate continuously, batch, repetitive, or discrete modes . Infrastructure process can be public or private and include processing and distribution of water and wastewater, pipelines, transmission and distribution systems, electrical, civil defense, a siren and communication systems off. Facility processes occur both in public and private sectors, including buildings, airports, ships and space stations. That monitoring and HVAC control, access and power consumption. Computer Integrated Manufacturing Computer Integrated Manufacturing (CIM) is a method of manufacturing engineering in the production process is computer controlled. The process traditionally separate methods are united by a computer by the ICD. This integration allows the process of exchanging information between them and to take action. Through this integration, manufacturing may be faster with fewer errors. However, the main advantage is the ability to create automated manufacturing processes. Normally the ICE on the basis of closed-circuit monitoring process, based on feedback in real time by the sensors. We also know that the flexible design and manufacturing. Overview The term “Computer Integrated Manufacturing” is both a method of manufacture and the name of an automated computer system in which the individual functions of engineering, production, marketing and support of a manufacturing enterprise are organized. In the functional areas of the CIM as the design, analysis, planning, purchasing, accounting, inventory management and distribution are linked by computer with the functions of the ground floor of the materials handling and management, providing direct control and monitoring of all processing operations. As a method of manufacture of three distinct components of CIM manufacturing methods: mass storage, retrieval, manipulation and presentation of the state detection mechanisms and processes of change; Algorithms for assembling the data processing component with the sensor / change components. CIM is an example of the application of Information and Communication Technologies (ICT) in manufacturing. CIM means that there are at least two computers to exchange information, e. g. controller of a robot arm and a microcontroller with a CNC machine. Some factors involved when considering the application of the CISG is the volume of production, the experience of the firm or personnel to do the integration, the level of integration in the product itself and the integration of production processes. The ICM is most useful in a high level of ICT use in business or establishment, such as CAD / CAM systems, the availability of the planning process and its data. While there is nothing that says that this is correct. History: The idea of “digital manufacturing”, was featured in the 1980s, when integrated automation has been developed and promoted by manufacturers of machine tools and automated systems and the Association and the Society of Manufacturing Engineers (CASA / SMEs). “CIM is the integration of the total manufacturing enterprise by using integrated systems and data communications, together with the management culture to improve organizational efficiency and staff.” Topics ERHUM of Computer Integrated Manufacturing – Key challenges Three major challenges for the development of a smoothly functioning integrated computer manufacturing: the integration of components from different suppliers: when different machines such as CNC, conveyors and robots , using different communication protocols. For AGV, different lengths of time itself to charge the batteries can cause problems. Data Integrity: The higher the degree of automation, the most important is the integrity of the data used to control machines. While the CIM system of labor-saving machinery, human extra work required to ensure adequate protection for data signals used to control machines. Process Control: Computers can be used to help human operators of the plant, but always be a qualified engineer on site to deal with circumstances which could not be foreseen by the designers of the control software. Sub-systems in Computer Integrated Manufacturing COMPUTER SYSTEM Integrated Manufacturing is not the same as a factory Lights Out “, which would be completely independent of any human intervention, even if it is a big step in that direction. Part of the system consists of flexible manufacturing, where the plant can be quickly modified to produce different products, or when the volume of products can quickly change the use of computers. Some or all subsystems May following is an operation of the CIM: Computer-aided techniques: CAD (Computer Aided Design), CAE (Computer Aided Engineering), CAM (Computer Aided Manufacturing) CAPP (Computer Aided Process Planning) ACQ ( Computer Aided Quality Control) PPC (production planning and control) ERP (Enterprise Resource Planning) An integrated management system with a common database. Appliances and equipment: tool CNC Computer Numerical Control DNC, direct numerical control tool machines, programmable logic controllers Robotics Computer Software monitoring networks of the teams drivers Interface Technologies: FMS (flexible manufacturing system) ASRS of storage and retrieval systems AGV, automated guided vehicles in automated transportation systems as a robot Robotics is officially defined by ISO as an automatic, reprogrammable, multipurpose manipulator programmable in three axes. The field of robotics may be more appropriate to define as the study design and the use of robotic systems for industry (high-definition based on the prior definition of robot). Typical applications include welding robots, painting, assembly, pick and place, packaging and palletizing, product inspection and testing, all performed with great stamina, speed and accuracy. A flexible manufacturing system (FMS) is a manufacturing system in which there is a degree of flexibility that allows the system to react to foreseen or unforeseen changes. This flexibility is considered generally fall into two categories, which both contain many subcategories. The first category, the flexibility of the machine, the system includes the ability to be modified to produce new types of products and the ability to change the order of operations in a single hand. The second category is called maximum flexibility, which is the possibility of using several machines to perform the same operation in one hand and the system’s ability to absorb large scale changes, such as volume, capacity, or Most FMS capacity. includes three main systems. The work of the machines have been automated CNC machines are connected by a management system to optimize the flow of parts and the central control computer that controls movement and material flow system. 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 application of a FMS is to produce small series of products such as mass production. A flexible manufacturing system combines the advantages of high degree of automation and control systems – Accuracy of mass production – with the advantages of versatility, adjustable systems – Flexibility – L ‘uniqueness of the product A complete description of a flexible manufacturing system here follows: The cell to manufacture a flexible manufacturing cell (FMC) consists of two or more CNC machines, a laptop and a robot. L ‘team of the cell (typically a programmable logic controller) is an interface with the microprocessor of the robot and the CNCS. The driver of the cellular functions of the Comptroller of the cell include load balancing part-time work, and hardware flow control. Supervision and coordination between the different operations in a manufacturing cell is also performed by the laptop. The software includes features that allow the processing of machine failures, tool breakage and other specific situations. The robotic cell In many applications, the robot also makes the cells change tools and maintenance functions such as chip removal, holding tools in the tool changer, and inspection tools for breakage or wear expressive search. If necessary, the robot can also initiate emergency procedures, such as system shutdown. Parker Hannifin Corporation, Forrest City, North Carolina. The flexible manufacturing system – FMS flexible manufacturing system (FMS) is a configuration of the workstations where computer-controlled digital materials are handled automatically and load the machine. The flexible manufacturing system is used primarily for mid-volume (200 to 30,000 pieces per year) midrange (type 5-155 in part) of production. Components of Flexible Manufacturing Systems-two or more computer-controlled workstations perform digital series of transactions, an integrated 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 Targets Reduction of manufacturing costs by reducing the cost of the labor direct work and to minimize rework and scrap waste materials. Less skilled labor required. Reduce the amount of inventory processes, eliminating the need to reduce the batch production time for manufacturers to respond more quickly to the variability of process management market demand resulting in better quality consistent. Different levels of FMS are as follows: Flexible Manufacturing Module (FMM). Example: a NC machine, a pallet changer and a portion of cushioning, Flexible Manufacturing (Assembly) of the cell (F (M / A) C). Example: four RPM and an AGV (Automated Guided Vehicle), Flexible Manufacturing Group (FMG). Example: Two of the FMC, a meeting of prime ministers and two AGV to transport the pieces of a cargo area, through the party machine, part the discharge area, flexible production systems (FPS). Example: An ACS FMG and two AGV, an automated tool storage, and some automatic / Storage Assembly, Flexible Manufacturing Line (FML). Example: several stations in an online setting and VFA. Advantages and disadvantages of implementing FMS benefits faster and less variation in costs from one place to another to improve the use of a capital reduction of the costs of direct labor, due to reduction in the number of workers in inventory reduced due to planning and programming consistent accuracy and quality, due to the automatic control of the reduction in unit production costs due to increased productivity using the same number of workers savings indirect labor, the reduction errors, rework, repairs and rejects Disadvantages limited capacity to adapt to changes in the product or product (eg the mix. machines have limited capacity and necessary tools for products, if a family is not always possible in a given FMS) pre-planning of the activity considerably expensive, costing millions of dollars of technological problems and exact positioning component specifies the time required to process a component of FMS advanced manufacturing complexity and cost are the reasons for its slow acceptance industry. In most cases, the CSP will be promoted. A vehicle with automatic guided vehicles and automated guided vehicles (AGV) is a mobile robot following markers, or child on the floor, or the use of vision or laser. They are most often used in industrial applications to move materials around a factory or warehouse. Implementation of automated vehicles has expanded during the late 20th century and no longer limited to industrial environments. automated guided vehicles (AGV) 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 can bind independently. The trailers can be used to move raw materials or finished products. AGV can also store objects in a bed. Objects can be placed in a set of motorized rollers (conveyors) and then pushed them to invest. Some use AGV fork lifts to lift objects conservation. AGV is used in almost all industries, including pulp, paper, metals, newspapers, and manufacturing in general. The transport of materials such as food, clothing or medicines in hospitals were also conducted. Common applications of automatic guided vehicles AGV can be used in a wide variety of applications for the transportation of different types of material, including pallets, rollers, racks, carts and containers. AGV Excel applications with the following characteristics: repetitive materials for a distance of shipping regular stable income flow / volume If delivery is time critical and delivery delays have led to inefficient operations can handle at least two quarters of work in important monitoring equipment is artificial intelligence (AI) is the intelligence of machines and the branch of computer science whose goal is to create it. manuals define the field as the study and design of intelligent agents “where an intelligent agent is a system that perceives its environment and takes actions to maximize their 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 assertion that a central feature of human intelligence, wisdom of Homo sapiens may be precisely this question that can be simulated by a machine. This raises philosophical questions about the nature of the spirit and the limits of scientific pride issues that were addressed by the myth, fiction and philosophy from ancient times. The artificial intelligence has been optimistic, but also suffered setbacks, and today has become a essential part of the technology industry, providing most of the work of many of the hardest problems in computing. AI research is highly skilled, deeply divided into sub-fields often fail to communicate. Subfields have developed around particular institutions, the work of researchers, the solution of specific problems, ultimately the differences of opinion on how the avian flu should be done and the application of the considerable differences between the tools. The central problem 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 long time (some of research). Obotic Automation: Process Material Handling Material handling is the wider category of applications is to move the selection or the product packaging. materials handling robots are used to move, feed or disable parts or tools to or from one location or to transfer from one machine to another. Manipulating the dispensing process materials pick and place packaging Palletizing Load Transfer Assembly Materials Order Party choose a variation of a team of robotic manipulation used to build and unloading of units on a pallet. Manufacturing companies worldwide to implement handling robots, because they are faster, more accurate and effective. They offer unmatched quality and repeatability. palletizing and handling: Palletizing is the act of loading or unloading of material on pallets. The newspaper industry has been particularly affected by labor costs rose. Part of the solution to this problem is to use as Cincinnati Milacron robots used for palletising robot insertions advertising for newspapers. Many companies in the United States and Canada have been forced to close in areas such as casting and injection molding, because they could not compete with foreign companies. The introduction of robotics in this process has enabled these enterprises remain viable. In industrial establishments manufacturing semiconductor integrated circuit chips, the various processes taking place in a clean room. This requires that the staff and not to introduce robots dirt, dust or oil in the region. Due that robots do not breathe, sneeze or have dandruff, they are particularly suitable for clean room environment required by the semi-conductors. At first glance, the automation may seem to devalue labor through its replacement by machines less costly, however, the overall effect of this situation on the labor market as a whole remains unclear. Conclusion Today, the automation of the workforce is well underway and continues to move more quickly through the world affects the growing number of skilled jobs, however, during the same period, the overall welfare and quality of life for most people in the world (where political factors have not tarnished the image) have improved significantly. Today , for manufacturing companies, the purpose of automation has changed to increase productivity and reduce costs, to broader issues such as increasing the quality and flexibility in the manufacturing process. The emphasis on the use of automation age, simply to increase productivity and reduce costs are considered short-sighted because it is also necessary to provide a skilled workforce that can perform repairs and management of machines. Moreover, the initial costs of automation were high and frequency could not be recovered by the time entirely new manufacturing processes replaced the old. “(Japan, robot junkyards” were world famous in manufacturing.) Automation is now often applied primarily to increase quality in the manufacturing process, where automation can increase quality substantially.
Saturday July 31st 2010
