Categories of Manufacturing Systems

Types of Automated Manufacturing

Systems
Continuous Control Systems
All production is identical there are no starting and
finishing points except at the end of a long production
campaign. These were historically the first applications
of automation. Designed to perform a limited range of
functions, these systems are quite specialised and hard
to reprogram. They are optimised for tough
environments, reliability and repeatability.
Examples: steel mills, water treatment, oil refining.
Types of Automated Manufacturing
Systems
Batch Control Systems
These systems are characterised by limited
production runs, with scope for changing some
parameters between runs, e.g. change of
composition, change of colour, change of
dimensions, change of packaging.
Examples: food and beverage processing, fastener
manufacturing, electronic components.
Types of Automated Manufacturing
Systems
Discrete Control Systems
Each production run is unique, control systems are
inherently flexible. Reprogramming is fast. Usually one
item or one customer order is produced at one time.
Historically these were the last manufacturing
processes to be automated.
Example: a custom kitchen design consisting of joinery,
cabinets, doors and kickboards all designed and cut by
CAD/ CAM (computer aided manufacturing).
Automated Manufacturing Systems
rely on information technology
The last 20 years has seen a convergence of LAN technology with automation
Sensors in Automated Manufacturing
Systems
Examples of input SENSORS.
Camera
Pressure sensor
Force sensor
Flow sensor (fluids)
Temperature sensor
Rotation speed (period) sensor
Direction sensor
Acceleration sensor
Movement sensor (non-contact)


Height sensor
Angular movement encoder
Linear movement encoder
Voltage or current sensor
Light sensor (LDR)
Proximity sensor
Magnetic sensor
Barcode reader
RFID tag reader

Input sensors collect information for processing.
Actuators in Automated
Manufacturing Systems
Examples of output ACTUATORS.

Hydraulic or pneumatic cylinder
Pneumatic valve
Piston or lever
Heater or cooler
Brake
Paint spray nozzle
Servo-motor


Fuel regulator
Electric relay contacts
Light beam
Solenoid (electromagnet)
Air jet (non-contact push)
Vacuum gripper
Swinging gate
Camera (image acquisition)

and there are many more

Link to Festo sensor and actuator catalogue
There are many ways of generating a control
output, some are purely mechanical. For
example, a mechanical speed governor
(right). James Watts mechanical speed
governor is an example of a negative
feedback actuator used on steam engines.

Feedback is the output fed back to the input.
To correct high or low speed we need
negative feedback. If the speed is low, the
control should be increasing, if speed is high
the control should be decreasing.
Inputs and outputs in control systems
For the computer control system to work there must be inputs and
outputs. The controller is taking the input and doing something with
it - modifying it in some way - and producing an output.
Inputs and outputs to control systems
In a computer control
system the processing will
be done in real time (i.e.
almost immediately) by a
microprocessor of some
kind. Commercial units are
available off the shelf, they
are called Programmable
Logic Controllers (PLCs).

Control Systems Open loop
EXAMPLE driving a car AIM to keep car at a steady speed
this is an example of an open-loop control system. Identify potential problems.
Control Systems Closed loop
EXAMPLE car cruise control AIM to keep car at a steady speed
this is an example of a closed-loop control system
Control system block diagram
Block diagrams are used to represent a control system
graphically. They are similar to a flowchart in that they represent
the flow of an algorithm. Circles represent sensors and actuators.
Each block in the diagram represents a logical function in the
system, including the controller and processes. All components
are necessary, and a controller must be shown in all block
diagrams.
Control system block diagram
The general form of a feedback control system
Controlled system response to change
Real controlled systems cannot respond instantly to a
disturbance or change. Electronic control signals can change
millions of times per second, but most manufacturing
systems cannot match such high rates of change.

If the system relied on motors and solenoids, for example,
these parts would need to be built for incredible rates of
acceleration, making them larger, heavier and making them
consume more power. In addition, the large acting forces
may damage parts of the system, or mean that structures
and actuators must be built stronger than necessary.

Clearly the system needs finite time to respond.
But how much time is optimum?
Examples of system response to change
A pendulum returns
to its equilibrium
centre position. By
adding varying
amounts of damping,
we can optimise the
system settling time.
Controlled system response to change
The curves show controlled
system response to a step
change from Zero to the
new set point 1.0

The red curve shows under-
damping and rapid over-
shoot of the set point.
The green curve shows
overdamping and slow
convergence to the set
point.
In the blue curve the set
point is obtained in the
minimum time. This is
known as critical damping.
Control Systems Open and Closed
ISSUES that can occur within feedback control systems.

Delayed sensor response, due to either inertia in the physical system or
delay in the sensor or control system (a.k.a hysteresis).
Discrete control (on-off) control may lead to the controlled system never
achieving the set point, but always being either above or below (a
condition known as hunting). Proportional control is usually better.
PID (Proportional + Integral + Differential) control is usually best.

Failure of a feedback loop can lead to dangerous uncontrolled system
behaviour. Hence, systems need to be fail safe.
Vibration and other forms of interference can introduce noise in sensors.
Conversion of sensor signals by analogue to digital conversion may lead to
quantisation errors (analogue signals can change by arbitrary steps, but the
smallest amount that a digital signal can change is 1 bit).
Noise signal conditioning
Signals may need to be boosted (amplified).
Signals may need to be Filtered.
Lowpass removes high frequency interference
Highpass removes low frequency (baseband) interference
Bandpass selects the wanted signal from a narrow range
Bandstop - blocks a narrow range of interfering signals
Parametric bandpass filters central frequency can be controlled
Lowpass Highpass Bandpass Bandstop
Control Systems signal conversion
Before signals from sensors can be used by computer
control systems, they must be converted to a form that the
computer can use.
The majority of sensors produce analogue (continuously
variable) output.
The analogue signal passes through Analogue to Digital (ADC)
conversion. Binary data is then input to the computer control
system.

The output from the control system is binary data. The majority
of actuators are analogue devices. Therefore another step of
Digital to Analogue (DAC) conversion is usually required before
the signal can be used by actuators.
Supervisory Control And Data
Acquisition systems (SCADA)
SCADA systems are another type of automation. SCADA can be used
to monitor and control any kind of equipment, process, or operation.
Most commonly, SCADA is found in outdoor industrial processes
where 24-hour remote monitoring and control by human operators is
impractical:
electric power generation, transmission, and distribution
water, sewage and pumping
buildings, facilities, and environments
mining, materials handling and manufacturing
public transport, railways
traffic signals

Signals from sensors are encoded and transmitted through networks
over long distances. Signals return over the network and control the
actuators. The electric power grid is controlled this way.
Document Workflow Automation
Business to Business e-Commerce.
EDI (Electronic Document Interchange) is a key part of 2-way
Business-To-Business automation. Manufacturers and their
suppliers agree on a common commercial document format for
computer-based ordering and supplying of parts. EDI is one of the
inputs to Computer-Aided-Manufacturing (CAM) systems.
Web-based ordering gateways.
Suppliers provide approved customers with direct access to their
order input and quotation systems. Customer uploads a PDF of
their job for automated quotation. Customer approves quotation,
and places the order into a queue. Customer receives updates via
e-mail of order status. More and more commercial printing of
books and magazines is occurring this way.
Local businesses using Computer
Aided Manufacturing Systems
http://www.interlockitchens.com.au/

Computer Simulation for Manufacturing
Trial for a semi-automated assembly of automotive dashboard
Computer Simulation for Manufacturing
Simulation of a robotic welding cell to detect potential collisions and improve productivity
Emerging technologies
Computer Simulation for Mining and
Manufacturing
Link to Rio Tinto Mine of the Future.

Link to Siemens virtual manufacturing video, Hanover Trade Fair