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Definition of Automation

 Automation is the technology by which a process or


Automation and Robotics (IM-408) procedure is accomplished without human assistance.
 It is implemented using a program of instructions
Books: combined with a control system that executes the
1. Automation, Production Systems and Computer- instructions.
Integrated Manufacturing by Mikell P. Groover  To automate a process, power is required, both to drive
2. Introduction to Robotics: Mechanics and Control the process itself and to operate the program and control
system.
(3rd edition) by John J. Craig
Instructor
Dr. Maqsood Ahmed Khan
Associate Professor (IMD)

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Power to Accomplish the
Basic Elements Automated Process

An automated system consists of three basic elements: An automated system is used to operate some process, and
1. Power to accomplish the process and operate the power is required to drive the process as well as the
automated system. controls. The principal source of power in automated
2. A program of instructions to direct the process, and systems is electricity.
3. A control system to actuate the instructions. Alternative power sources include fossil fuels, solar
energy, water, and wind. However, their exclusive use is rare
in automated systems. In many cases when alternative
power sources are used to drive the process itself, electrical
power is used for the controls that automate the operation.
For example, in casting or heat treatment, the furnace may
be heat by fossil fuels, but the control system to regulate
temperature and time cycle is electrical.

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Power to Accomplish the Power to Accomplish the
Automated Process Automated Process

Power for the process: Power for the process:


In production, the term process refers to the manufacturing
operation that is performed on a work unit. In the following
table a list of common manufacturing processes is
compiled along with the form of power required.

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Power to Accomplish the Power to accomplish the
Automated Process Automated Process

The power for each operation indicated in above table is Power for automation:
usually converted from electricity. Above and beyond the basic power requirements for the
In addition to driving the manufacturing process itself, power manufacturing operation, additional power is required for
is also required for the material handling function; (1)Loading automation. The additional power is used for the following
and unloading the work unit and (2) Material transport functions:
between operations. 1. Control unit
2. Power to move actuators
3. Data acquisition and information processing

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Program of Instructions Control System

The actions performed by an automated process are defined The control element of the automated system executes the
by a program of instructions. Each part or product style program of instructions.
requires one or more processing steps. The control system causes the process to accomplish its
These processing steps are performed during a work cycle. defined function.
A new part is completed during each work cycle. The controls in an automated system can be either closed
The particular processing steps for the work cycle are loop or open loop. A closed loop control system, also
specified in a work cycle program. known as a feedback control system. is one in which the
Work cycle programs are called part programs in numerical output variable is compared with an input parameter, and any
control. Other process control applications use different difference between the two is used to drive the output into
names for this type of program. agreement with the input.

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Control System Control System

As shown in the figure, a closed loop control system consists In contrast to the closed loop control system, an open loop
of six basic elements: (I) input parameter, (2) process, (3) control system operates without the feedback loop, as in the
output variable, (4) feedback sensor. (5) controller. and (6) following figure. In this case, the controls operate without
actuator. measuring the output variable, so no comparison is made
between the actual value of the output and the desired input
parameter.
The controller relies on an accurate model of the effect of its
actuator on the process variable. With an open loop system,
there is always the risk that the actuator will not have the
intended effect on the process, and that is the dis-advantage
of an open loop system. Its’ advantage is that it is generally
simpler and less expensive than a closed loop system.

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Control System Level of Automation

The concept of automated systems can be applied to various


levels of factory operations.
One normally associates automation with the individual
production machines. However, the production machine itself
is made up of subsystems that may themselves be
automated.
Open loop systems are usually appropriate when the For example, a modern numerical control (NC) machine tool
following conditions apply: (1) The actions performed by the is an automated system. However, the NC machine itself is
control system are simple, (2) the actuating function is very composed of multiple control systems. Any NC machine has
reliable, and (3) any reaction forces opposing the actuation at least two axes of motion, and some machines have up to
are small enough to have no effect on the actuation. If these five axes.
characteristics are not applicable, then a closed loop control
system may be more appropriate.

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Level of Automation Level of Automation

 Each of these axes operates as a positioning system and  Thus we have three levels of automation and control
is an automated system. included here:
 Similarly, a NC machine is often part of a larger 1. the positioning system level,
manufacturing system, and the larger system may itself be 2. the machine tool level, and
automated. For example, two or three machine tools may 3. the manufacturing system level.
be connected by an automated part handling system
operating under computer control. Therefore, we can identify five possible levels of automation
in a production plant.
 The machine tools also receive instructions (e.g., part
programs) from the computer.

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Level of Automation Level of Automation
Control functions at this level include performing the
Device level: sequence of steps in the program of instructions in the
This is the lowest level in automation hierarchy. It includes correct order and making sure that each step is properly
the actuators, sensors, and other hardware components executed.
that comprise the machine level. The devices are Cell or system level :
combined into the individual control loops of the machine;
This is the manufacturing cell or system level, which
for example, the feedback control loop for one axis of a
operates under instructions from the plant level. A
CNC machine or one joint of an industrial robot.
manufacturing cell or system is a group of machines or
Machine level: workstations connected and supported by a material
Hardware at the device level is assembled into individual handling system, computer, and other equipment
machines. Examples include CNC machine tools and appropriate to the manufacturing process. Production lines
similar production equipment, industrial robots, powered are included in this level.
conveyors, and automated guided vehicles.

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Level of Automation Level of Automation
Plant level:
This is the factory or production systems level. It receives
instructions from the corporate information system and
translates them into operational plans for production.
Likely functions include: order processing, process
planning, inventory control, purchasing, material
requirements planning, shop floor control, and quality
control.
 Enterprise level:
This is the highest level, consisting of the corporate
information system. It is concerned with all of the functions
necessary to manage the company: marketing and sales,
accounting, design, research, aggregate planning, and
master production scheduling.

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Types of Automated Manufacturing
Automated Manufacturing Systems Systems
Automated manufacturing systems operate in the factory on
the physical product. They perform operations such as Three basic types:
processing, assembly, inspection, or material handling, in 1. Fixed automation
some cases accomplishing more than one of these 2. Programmable automation
operations in the same system.
3. Flexible automation
Examples of automated manufacturing systems include:
 Automated machine tools
 Transfer lines
 Automated assembly systems
 Industrial robots that perform processing or assembly
operations
 Automated material handling and storage systems to
integrate manufacturing operations
 Automatic inspection systems for quality control

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Fixed Automation Programmable Automation
A manufacturing system in which the sequence of A manufacturing system designed with the capability
processing (or assembly) operations is fixed by the to change the sequence of operations to
equipment configuration accommodate different product configurations
Typical features: Typical features:
 Suited to high production quantities  High investment in general purpose equipment
 High initial investment for custom-engineered equipment  Lower production rates than fixed automation
 Flexibility to deal with variations and changes in
 High production rates product configuration
 Relatively inflexible in accommodating product variety  Most suitable for batch production
 Physical setup and part program must be changed
between jobs (batches)

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Flexible Automation Automation Definition
An extension of programmable automation in which the  Automation can be defined as:
system is capable of changing over from one job to the A technology concerned with the application of
next with no lost time between jobs mechanical, electronic, and computer-based systems to
Typical features: operate and control production.
 High investment for custom-engineered system
 Continuous production of variable mixes of products
 Medium production rates
 Flexibility to deal with soft product variety

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Reasons for Automating Automation Principles and Strategies

1. To increase labor productivity 1. The USA Principle


2. To reduce labor cost 2. Ten Strategies for Automation and Process
3. To mitigate the effects of labor shortages Improvement
4. To reduce or remove routine manual and clerical tasks 3. Automation Migration Strategy
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually

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Ten Strategies for Automation and
U.S.A Principle Process Improvement
1. Understand the existing process 1. Specialization of operations
 Input/output analysis 2. Combined operations
 Value chain analysis 3. Simultaneous operations
 Charting techniques and mathematical modeling 4. Integration of operations
2. Simplify the process 5. Increased flexibility
 Reduce unnecessary steps and moves 6. Improved material handling and storage
3. Automate the process 7. On-line inspection
 Ten strategies for automation and production 8. Process control and optimization
systems 9. Plant operations control
 Automation migration strategy 10. Computer-integrated manufacturing

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Automation Migration Strategy
For Introduction of New Products
1. Phase 1 – Manual production Automation
 Single-station manned cells working independently Migration
Strategy
 Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
 Single-station automated cells operating
independently
 As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
 Multi-station system with serial operations and
automated transfer of work units between stations

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