What is an Automated System???

An automated system is a collection of devices working together to accomplish tasks or produce a product or family of products. EXAMPLE 1: Automatic door lock/unlock system. There is a biometric sensor to match the fingerprint which is connected to the control box as an input. Control box receives the signal and acts accordingly. EXAMPLE 2: Home burglar alarm system. Control box receives signal (image, switch input) and activates the alarm.

Modern Manufacturing Approaches and Technologies

Automation - automated equipment instead of labor Material handling technologies - because manufacturing usually involves a sequence of activities Manufacturing systems - integration and coordination of multiple automated or manual workstations Flexible manufacturing - to compete in the lowvolume/high-mix product categories Quality programs - to achieve the high quality expected by today's customers CIM - to integrate design, production, and logistics Lean production - more work with fewer resources

Production Systems
A production system is a collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company Two categories: Facilities the factory, the equipment in the factory and the way the equipment is organized (plant layout) Manufacturing support systems the set of procedures used by a company to manage production and to solve technical and logistics problems in ordering materials, moving work through the factory, and ensuring that products meet quality standards

The Production System

Production System Facilities

Facilities include the factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations Plant layout the way the equipment is physically arranged in the factory Manufacturing systems logical groupings of equipment and workers in the factory Production line Stand-alone workstation and worker

Manufacturing Systems
Three categories in terms of the human participation in the processes performed by the manufacturing system: 1. Manual work systems - a worker performing one or more tasks without the aid of powered tools, but sometimes using hand tools 2. Worker-machine systems - a worker operating powered equipment 3. Automated systems - a process performed by a machine without direct participation of a human

Manual Work System

Worker-Machine System

Automated System

Manufacturing Support Systems

Involves a cycle of information-processing activities that consists of four functions: 1. Business functions - sales and marketing, order entry, cost accounting, customer billing 2. Product design - research and development, design engineering, prototype shop 3. Manufacturing planning - process planning, production planning, Manufacturing Resource Planning (MRP), capacity planning 4. Manufacturing control - shop floor control, inventory control, quality control

Information Processing Cycle in Manufacturing Support Systems

Automation in Production Systems

Two categories of automation in the production system: 1. Automation of manufacturing systems in the factory 2. Computerization of the manufacturing support systems The two categories overlap because manufacturing support systems are connected to the factory manufacturing systems Computer-Integrated Manufacturing (CIM)

Computer Integrated Manufacturing

Automated Manufacturing Systems

Industrial automated system can be a single machine or a group of machine often referred as cell. Automated manufacturing systems include: Automated machine tools Automated 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

Automated Manufacturing Systems

Three basic types: 1. Fixed automation 2. Programmable automation 3. Flexible automation

Fixed Automation
A manufacturing system in which the sequence of processing (or assembly) operations is fixed by the equipment configuration Typical features: Suited to high production quantities High initial investment for custom-engineered equipment High production rates Relatively inflexible in accommodating product variety

Programmable Automation
A manufacturing system designed with the capability to change the sequence of operations to accommodate different product configurations Typical features: High investment in general purpose equipment Lower production rates than fixed automation Flexibility to deal with variations and changes in product configuration Most suitable for batch production Physical setup and part program must be changed between jobs (batches)

Flexible Automation
An extension of programmable automation in which the system is capable of changing over from one job to the next with no lost time between jobs Typical features: High investment for custom-engineered system Continuous production of variable mixes of products Medium production rates Flexibility to deal with soft product variety

Product Variety and Production Quantity for Three Automation Types

Needs for automation

Increased throughput or productivity. Improved quality. i.e accuracy Improved robustness (consistency), of processes or product. i.e Precision Reduce excess labour cost

Components of automation
Robots CNC Machines

Conveyers, palletizers [hard automation devices with little flexibilities] Control Devices [ PLCs, Microcontroller based]
Feedback Devices [Sensors, Vision systems]

Components of automation: ROBOT

Robots can be used for repetitive work such as pick and place operations. It can also be used for production work like Welding. Robots are very accurate and precise in repetitive work.

Components of automation: ROBOT

Classification of Robot based on actuation mechanism a) Electrical Fast and accurate Versatile operation (Positioning part, Welding etc) But Expensive b) Pneumatic Fast, accurate and also inexpensive Limited task Low payload c) Hydraulic Smooth operation (good for painting) Heavy pay load

Components of automation: CNC

Computer Numerical Control machines (CNC) are machines whose motions are controlled by a computer. They are programmable and they can produce wide range of parts. Example: CNC milling machine CNC Turning machine CNC electro-discharge machine (EDM) CNC wire electro-discharge machine (WEDM)

Components of automation: ASRS

ASRS => Automatic Storage and Retrieval Section Used to store parts Computer controls the storage of the parts

It knows which place is empty and which place is occupied through sensor feedback.

Components of automation: Conveyer

Conveyer used to move parts between cells. Conveyers may equipped with sensors to know which part is present and where it is needed to be moved. Parts are held by pallets on a conveyor.

Components of automation: PLCs

PLCs => Programmable Logic Controller is the brain of the industrial automated system. It can be programmed by ladder logic. This is a robust computer designed for industry and easily understandable by electricians and technicians.

Components of automation: Sensors

There are numerous types of sensors. Following are some examples

1. Analog e.g capacitive pressure sensor, temperature sensor, force sensor etc. 2. Digital sensors e.g limit switches, optical switches, counters etc. 3. Contact sensors e.g Limit switch (mechanical) 4. Non-contact or proximity sensor e.g Limit switch (optical)

Components of automation: Vision system

Vision system is used to check the product quality e.g holes on a PCB are properly positioned, components on the PCB are all present. Typical arrangement of the vision system is as follows a) Image capturing by camera (digital camera e.g CCD) b) Image acquisition to the computer. c) Image analysis by comparison d) Output (pass/fail) e) Result analysis

Components of automation: Vision system

Resolution of the vision system: Based on number of pixel on the part image. X

Sensor is 8 by 8 pixels No of Pixels (covered by the image) in X Px=3 No of Pixels in (covered by the image) in Y Py= 4.5

Components of automation: Vision system

X

Diameter of the part is d= 5mm. What is the resolution is X and Y direction? Resolution in X direction Rx= d/Px = 5/3 = 1.67 mm Resolution in Y direction Ry = d/Py = 5/4.5 = 1.11 mm

Classification of Components of Automation

Automation System Production Devices (Robot, CNCs) Support Equipments (Conveyor) Control Devices (PLCs) Feedback Devices (Sensors, Vision system)

Automation Principle
1. Understand the existing process Input/output analysis Value chain analysis /supply chain analysis Charting techniques and mathematical modeling 2. Simplify the process Reduce unnecessary steps and moves 3. Automate the process Ten strategies for automation and production systems Automation migration strategy

Automation Strategies
1. Specialization of operations 2. Combined operations 3. Simultaneous operations 4. Integration of operations 5. Increased flexibility 6. Improved material handling and storage 7. On-line inspection 8. Process control and optimization 9. Plant operations control 10. Computer-integrated manufacturing

Automation Migration Strategy

1. Phase 1 Manual production Single-station manned cells working independently 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

Automation Migration Strategy

Cost Justification
Automation system is installed when it saves money for the company Before installing any new automation system company must calculate the payback period

P = Payback period in years C = Total cost of the system including installations W = Annual wages of labour and fringe benefits for the workers who are replaced

Cost Justification
I = Savings in terms of productivity, quality, materials D = Depreciation allowance M = System maintenance cost. S = Additional staffing for maintenance, programming.

System Design
Start Key in no of shafts to be machined Robot load another part

Robot load part for QC

NO Scrap YES

Pass?

NO

Total number Achieved? YES END

System Design
Operator inputs no of shafts to be machined Robotic arm load the part on a CNC lathe machine Robot unload the part after machining and load it in a QC station (Vision system) The shaft diameter is measured and if it is outside the tolerance limit the part is scrapped. If it is within tolerance limit the finished part is counted. Robot loads the next part until it reaches the desired value.