Module_1_Lecture_1_Introduction_To_Automation_In_Production_Systems2023.ppt

Industrial automation

1. MT308 Industrial Automation
Mechatronics Engineering Department
Faculty of Engineering
Sana’a University
Dr. Khalil A. Al-Hatab

2. Week # Module Name Lecture # & Heading Reading Sections
1-3
Module 1: Introduction and Basic Concept
of Automation
Lecture 1: introduction & Basic Concept of Lecture 1: introduction & Basic Concept of
AutomationAutomation
Ch. 1 & Ch. 4Ch. 1 & Ch. 4
Lecture 2: Components & Applications of Lecture 2: Components & Applications of
Automation SystemAutomation System
Ch1
*
Lecture 3: Overview of Manufacturing: Lecture 3: Overview of Manufacturing:
Operations, Metrics and Economics Operations, Metrics and Economics
Ch. 2 & Ch. 3Ch. 2 & Ch. 3
4
Module 2: Mechanical System:
Components, Dynamics & Modeling
Lecture1: Mechanical System: Components, Lecture1: Mechanical System: Components,
Dynamics & ModelingDynamics & Modeling
Ch3
*
5 Module 3: Industrial Control SystemsLecture1: Industrial Control SystemsLecture1: Industrial Control Systems Ch. 6 & Ch. 6 & Ch5
*
6-10
Module 4: Hardware Components
for Automation
Lecture1-2: Automation Sensory DevicesLecture1-2: Automation Sensory Devices Ch. 6 & Ch. 6 & Ch5
*
Lecture3-4: Control of Actuators in Automation Lecture3-4: Control of Actuators in Automation
MechanismsMechanisms
Ch. 6 & Ch. 6 & Ch4
*
Lecture5: Digital Data Acquisition (DDA)Lecture5: Digital Data Acquisition (DDA) Ch. 6Ch. 6
10-14Module 5: Industrial Automation Systems
Lecture1: Design an Example for Industrial Lecture1: Design an Example for Industrial
Automation SystemAutomation System
Ch6
*
Lecture2-3: Numerical ControlLecture2-3: Numerical Control Ch. 7 Ch. 7
Lecture4: Material Handling & IdentificationsLecture4: Material Handling & Identifications Ch. 10-Ch. 12Ch. 10-Ch. 12
Lecture5: Single-Station Manufacturing CellsLecture5: Single-Station Manufacturing Cells Ch. 13 & Ch. 14Ch. 13 & Ch. 14
15 Review for Final Exam
*: Industrial Automation: An Engineering Approach*: Industrial Automation: An Engineering Approach
2
Brief Course Contents

3. Course Information
Instructor
Associate Professor Dr. Khalil Al-Hatab, (PhD)
[email protected]
Time and place
Lecture: Monday 8-12, xxx Wed. 8-10d. 10-12
Lab (class & practicing): Lab 2Wed. 12-2
Grading Policy
Homework & Attendance: 10%
Quizzes: 10%
Labs: 10%
Mid-term: 20%
Mini-Projects 10%
Final Exam: 40%
Textbook
1.Mikel P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing,
4
th
ed., Pearson Higher Education, 2015.
2.Lecture Notes: Industrial Automation: An Engineering Approach, JM 608 INDUSTRIAL
AUTOMATION, Politeknik Port Dickson, 2013 3

4. Module 1 - Lecture 1: Module 1 - Lecture 1:
Introduction To Automation Introduction To Automation
In Production SystemsIn Production Systems
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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 5
Module 1 - Lecture 1: Introduction To Module 1 - Lecture 1: Introduction To
Automation In Production SystemsAutomation In Production Systems
Sections:
Definitions & Overview of Industrial Automation
Production Systems
Automation in production systems
Manual Labor in Production Systems
Types of Automation
Basic Elements of an Automated System
Control System
Advanced Automation Functions
Reason for automated and not automated
Automation Principles and Strategies
Levels of Automation

6. Objectives:
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•Upon completion of this course, students should be able
to:-
To explain the definition and classification of automation in
industry of automation in industry
Explain the basic concept of automation terminology
To classify the element of automation function and level
To define the reason of automation.

7. Definition of industrial automation
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Automation as a technologytechnology that is concerned with use
of mechanical, electronic and computer-based systems
in the operationoperation and controlcontrol of production.

Technology development processTechnology development process continuous improve
until human started introduce the usage of NC machine NC machine
toolstools and roboticrobotic, CAD/CAMCAD/CAM, Flexible manufacturing Flexible manufacturing
system (FMS)system (FMS) and others technology to increase human
quality of life and increase productivity in the industrial.

8. Definition of industrial automation
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The word ‘AutomationAutomation’ is derived from Greek words “AutoAuto”(selfself) and
“MatosMatos” (movingmoving). AutomationAutomation therefore is the mechanism for systems
that “move by itself”. However, apart from this original sense of the word,
automated systemsautomated systems also achieve significantly superior performance than
what is possible with manual systems, in terms of powerpower, precisionprecision and
speedspeed of operation
Automation is a set of technologies that results in operation of machines
and systems without significant human intervention and achieves
performance superior to manual operation
Automation is the use of control systems and information technologies to is the use of control systems and information technologies to
reduce the need for human work in the production of goods and servicesreduce the need for human work in the production of goods and services.
Automation is defined as “The creation & application of technology to
monitor & control the production and delivery of products and services.”

9. Definition of industrial automation
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
AutomationAutomation can be defined as the technology by which a process
or procedure is accomplished without human assistance.

Industrial:Industrial: In a general sense the term “Industry” is defined as
follows: Systematic Economic Activity that could be related to
Manufacture/Service/ Trade. In this course, we shall be concerned
with Manufacturing Industries only
Mechanization refers to the use of machinery (usually powered) to
assist or replace human workers in performing physical tasks, but
human workers are still required to accomplish the cognitive and
sensory elements of the tasks. By contrast, automation refers to the
use of mechanized equipment that performs the physical tasks
without the need for oversight by a human worker.

10. OVERVIEW OF INDUSTRIAL
AUTOMATION
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How to improve PRODUCTIVITYPRODUCTIVITY?
By MECHANIZATIONMECHANIZATION : operation runs with the use of various
mechanicalmechanical, hydraulichydraulic, pneumaticpneumatic, or electricalelectrical devices.
But still operator have to control the process and check the
machine’s performance, thus to IMPROVEIMPROVE THE
EFFICIENCYEFFICIENCY of manufacturing processmanufacturing process = AUTOMATIONAUTOMATION .

11. OVERVIEW OF INDUSTRIAL
AUTOMATION
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1950s, manufacturing operations used traditional machinery:
Lacked flexibility,
Required high skilled labor,
Have to retooled the machinery on each different product
manufactured,
The movement of materials have to be rearranged,
Product with complex shapes required trial and error attempts by
the operator in order to set the proper processing parameters on the
machine,
Time-consuming
Labor cost and production cost increase.

12. OVERVIEW OF INDUSTRIAL
AUTOMATION
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13. OVERVIEW OF INDUSTRIAL
AUTOMATION
An automated systemautomated system is a collection of devices working
together to accomplish tasks or produce a product or family of
products.
Industrial automated systemsIndustrial automated systems can be one machine or a group
of machines called a cellcell.
The term “programmable automation technology” actually
refers to three individually distinct technologies individually distinct technologies that have a
common thread: programmability. These technologies are
computer numerical control (CNC) technology, robotics
technology, and programmable logic control (PLC).
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The Realities of Modern Manufacturing
Globalization - Once underdeveloped countries (e.g., China,
India, Mexico) are becoming major players in manufacturing
International outsourcing - Parts and products once made in
the United States by American companies are now being made
offshore (overseas) or near-shore (in Mexico and Central
America)
Local outsourcing - Use of suppliers within the U.S. to provide
parts and services

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More Realities of Modern Manufacturing
Contract manufacturing - Companies that specialize
in manufacturing entire products, not just parts, under
contract to other companies
Trend -toward the service sector (economy)
Quality expectations - Customers, both consumer and
corporate, demand products of the highest quality
Need for operational efficiency - manufacturers must
be efficient in in their operations to overcome the labor
cost advantage of international competitors

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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
low-volume/high-mix product categories
Quality programs - to achieve the high quality expected by
today's customers
CIM - to integrate designdesign, productionproduction, and logisticslogistics
Lean production - more work with fewer resourcesmore work with fewer resources

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Manual Labor in Production
Systems
Is there a place for manual labor in the modern
production system?
Answer: YES
Two aspects:
1.Manual labor in factory operations
2.Labor in manufacturing support systems

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Manual Labor in Factory
Operations
The long term trend is toward greater use of automated
systems to substitute for manual labor.
When is manual labor justified?
Some countries have very low labor rates and automation
cannot be justified
Task is too technologically difficult to automate
Short product life cycle
Customized product requires human flexibility
To cope with ups and downs in demand
To reduce risk of product failure
Lack of capital.

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Labor in Manufacturing
Support Systems
Product designers: who bring creativity to the design
task
Manufacturing engineers: who
Design the production equipment and tooling, and
Plan the production methods and routings
Equipment maintenance
Programming and computer operation
Engineering project work
Plant management

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Production System Defined
Production System is a collectioncollection of peoplepeople,
equipmentequipment, and proceduresprocedures organizedorganized to accomplish
the manufacturing operations of a company
Two categories:
Facilities: the factoryfactory and equipmentequipment in the facility and
the wayway the facility is organizedorganized (plant layoutplant layout)
Manufacturing support systems: the setset ofof proceduresprocedures
usedused by a company to managemanage production and to solvesolve
technical and logistics problems in ordering materialsordering materials,
moving work moving work through the factory, and ensuringensuring that
products meet quality standards

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The Production System
Fig. 1.1

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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 equipmentlogical groupings of equipment and
workersworkers in the factory
Production line: More complex manufacturing systems
consist of collections of machines and workers.
Stand-alone workstation and worker

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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
(i.e. A quality control inspector using a micrometer to measure the
diameter of a shaft)
2.Worker-machine systems - a worker operating powered equipment.
A combinations of one or more workers and one or more pieces of
equipment (i.e. A machinist operating an engine lathe to fabricate a
part for a product)
3.Automated systems - a process performed by a machine without
direct participation of a human. Automation is implemented using a
program, control system & Power. Two levels of automation can be
identified: semiautomated and fully automated.

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Manual Work System
Fig. 1.2 (a)

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Worker-Machine System
Fig. 1.2 (b)

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Automated System
Fig. 1.2. (c)

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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 - The informationinformation and documentationdocumentation that constitute
the product design flows into the manufacturing planning functionmanufacturing planning function. The
information- processing activities in manufacturing planning include: process
planning, master scheduling, material requirements planning, and capacity
planning.
4.Manufacturing control - is concerned with managingmanaging and controllingcontrolling the
physical operations in the factory to implement the manufacturing plans. The
flow of information is from planningplanning to controlcontrol. Included in this function are
shop floor control, inventory control & quality control

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Information Processing Cycle in
Manufacturing Support Systems
Fig. 1.3

29. Automation in Production Systems
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•Examples of industries for automation:
Manufacturing (e.g. on factory shop floors)
Services (e.g. voice menus for banks)
Transport (e.g. planes, ships, cars)
Process control (e.g. nuclear/electrical power stations,
chemical plants)
Offices (e.g. word processing, spreadsheets, photocopying,
email)
•Automation and robots are two closely related technologies.
Both are connected with the use and control of production
operations.

30. Automation in Production Systems
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Example of this technology in Automated Manufacturing
System includes:
Transfer lines that perform a series of machining operation
Mechanical assembly machines
Feedback control systems
Numerically controlled machine tools
Logistic support tools
Automated inspection system for quality control
Automated material handling system and storage system to
integrate manufacturing operation
CAD/CAM system and robots- robots are mechatronic devices that
assist industrial automation.

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Automation in Production Systems
The automated elements of the production system can be
separated into two categories:
1.1.AutomationAutomation of manufacturing systemsof manufacturing systems in the factory
2.2.ComputerizationComputerization of the manufacturing support systems
In modern manufacturing systems, the two categories overlapoverlap
because the automated manufacturing system operating on the
factory floor are often implemented by computer systems; and
connected to the computerized manufacturing support system
and management information system operating plant and
enterprise level.
Computer-Integrated Manufacturing (CIM)

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Computer Integrated
Manufacturing (CIM)
Fig. 1.4

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Objectives of Computerized
Manufacturing Support Systems
 To reduce the amount of manualmanual and clerical effortclerical effort in product designproduct design,
manufacturing planningmanufacturing planning and controlcontrol, and the business functionsbusiness functions.
Computer technology is used to implement automation of the manufacturing
systems in the factory.
CIM (computer integrated manufacturing) denotes the pervasive use of computer
system to design the products, plan the production, control the operations, and
perform the various business-related functions in one system that operates
throughout the enterprise.
CIM includes CAD/CAM and the business functions of the firm
Integrates computer-aided design (CAD) and computer-aided manufacturing
(CAM) in CAD/CAM. CAD denotes the use of computer systems to support the
product design function. CAM denotes the use of computer systems to perform
function related to manufacturing engineering such as process planning and
numerical control part programming.

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Automated Manufacturing Systems
Three basic types:Three basic types:
1.1.Fixed automationFixed automation
2.2.Programmable automationProgrammable automation
3.3.Flexible automationFlexible automation

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Fixed Automation
Fixed Automation is a manufacturing system in which the sequence sequence
of processingof processing (or assemblyassembly) operationsoperations is fixedis fixed by the equipment by the equipment
configurationconfiguration. The operationoperation are usually simple, it usedused with high
demand rates and inflexible product design.
Typical features:
Suited to high production quantities
High initial investment for custom-engineered equipment
High production rates.
It is therefore appropriate to design specialized equipmentdesign specialized equipment to process
products at high production rates and low cost (custom-engineered with
special purpose equipment to automate a fixed sequence of operation
Relatively inflexible in accommodating product variety

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Fixed Automation
•A good example of fixed automation can be found in the automobile
industry, where highly integrated transfer lines are used to perform
machining operation on engine and transmission component.
•The economics of fixed automation is such that the cost of the special
equipment can be divided over a large number of units produced, so that
the resulting units cost can be lower relative to alternative method of
production.
•The risk encountered with fixed automation is that the initial investment
cost is high and if the volume of production turns out to lower than
anticipated, then the unit costs become greater.
•Another problem with fixed automation is that the equipment is specially
designed to produce only one product and after that product’s life cycle is
finished, the equipment is likely to become obsolete. Therefore, for Therefore, for
products with short life cycles, fixed automation is not economicalproducts with short life cycles, fixed automation is not economical.

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Programmable Automation
 A manufacturing system designed with the capability to changechange the sequencesequence
of operationsoperations to accommodateaccommodate different product configurationsdifferent product configurations.
The operation sequenceoperation sequence is controlledcontrolled by a program which is a set of instructions
coded so that they can be read and interpreted by the system. New programs can
be preparedprepared and entered into the equipment entered into the equipment to produce new products.
The physical setup of the machine must also be changed, tools must be loaded.
Fixtures must be attached to the machine table and the required machine setting
must be entered. This change over procedure takes time.
Typical features:
High investment in general purpose equipmentgeneral purpose equipment. The production equipment is
designed to be adaptableadaptable to variationsvariations in a product configuration.
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)

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Programmable Automation
•This adaptabilityadaptability featurefeature is accomplished by operating the equipment
under the control of a “program” of instructions that has been
prepared especially for a given product.The program is read into the
production equipment and the equipment performs that particular
sequence of operations to make that product.
•The system must be reprogrammedreprogrammed with the set machine instructionsset machine instructions
that correspondent to the new product when a new batch of different
product needs to produce. Physical setup of the machine must be
changed:
Tool must be loaded
Fixtures must be attached to the machine table
Required machine setting must be entered.

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Programmable Automation
•In terms of economics, the cost of the programmable
equipment can be spread over a large number of products even
though the products are different. Because of the programming
feature and the resulting adaptability of the equipment, may
different and unique products can be processed economically
in small batches (batches production and medium volume).
ExampleExample : SMT production line in PCBA manufacturing
- SMT : Surface Mount Technology
- PCBA : Printed Circuit Board Assembly

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Flexible Automation
Flexible Automation is an extension of programmableprogrammable automationautomation in
which the system is capable of changing over from one job to the next the system is capable of changing over from one job to the next
with no lost time between jobswith no lost time between jobs.
•There is no lost production timeno lost production time while reprogramming the system
and altering the physical combination and schedules of parts or
products instead of requiring that they be made in batchesbatches.
•It is designed to manufacture a variety of product or parts with low low
production ratesproduction rates, varying product designvarying product design and demanddemand.
Typical features:
High investment for custom-engineered systemHigh investment for custom-engineered system
Continuous production of variable mixes of productsContinuous production of variable mixes of products
Medium production ratesMedium production rates
Flexibility to deal with soft product varietyFlexibility to deal with soft product variety

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Flexible Automation
•Most suitable for the mid-volume production rangemid-volume production range.
•Flexible automationFlexible automation possessespossesses some of the features of both fixed and
programmable automation.
•Other terms used for flexible automation include FMSFMS and CIMCIM.
•Flexible automationFlexible automation typically consists of a series of workstations that are
interconnectedinterconnected by material-handling and storage equipment to process process
different product configurationsdifferent product configurations at the same time on the same
manufacturing system.
•A central computer is used to control the various activities that occur in
the system, routing the various parts to the appropriate stations and
controlling the programmed operations at the different stations.
•One of the features that distinguishdistinguish programmable automation programmable automation from
flexible automationflexible automation is that with programmable automation the products
are made in batchesbatches. When one batch is completed, the equipment is
reprogrammed to process the next batch.
•Flex. Auto can produce one of a kind, batches not required

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Flexible Automation
•With flexible automation, different products can be made at the same
time on the same system. This feature allows a level of versatility that is
not available in pure programmable automation.
•This means that products can be produced on a flexible system in
batches, if desirable, or that several products can mix on the same
system. The computational power of the control computer is what makes
this versatility possible.
•Flexible Automation advantagesFlexible Automation advantages:
1. Increased speed and productivity.
2. Reduced manual labor.
3. Improved consistency.
4. Greater reliability.
5. Greater accuracy and consistency.
6. Reduced cost of assembly

43. Automation Comparison
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Automation When to considerAdvantages Disadvantages
Fixed -High demand
volume,
-Long product life
cycles
-Maximum
efficiency
-Low unit cost
-Large initial
investment
-Inflexibility
Programmable -Batch production,
-Product with
different options.
-Flexibility to deal
with changes in
product.
-Low unit cost for
large batches.
-New products
requires long setup
time.
- High unit cost
relative to fixed
automation.
Flexible -Low production
rates.
-Varying demand.
-Short product life
cycles.
-Flexibility to deal
with designs
variations.
-Customized
products.
-Large initial
investment .
-High unit cost.

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Product Variety and Production Product Variety and Production
Quantity for Three Automation TypesQuantity for Three Automation Types
Fig. 1.5

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Elements of an Automated SystemElements of an Automated System
1)1)PowerPower
2)2)Program InstructionProgram Instruction
3)3)ControlControl System System

46. 1) Power to accomplish the automated processPower to accomplish the automated process
•An automated system is used to operate some process and
power is required to drive the processprocess as well as the controlscontrols.
•The principal source of power is electricity:
Available at moderate cost.
Can be readily converted to alternative energy forms
(mechanical, thermal, light, acoustic, hydraulic and
pneumatic).
Low level power can be used to accomplish functions
such as signal transmission, information processing and
data storage and communication.
Can be stored in long-life batteries for use in remote
locations
Basic Elements of an Automated System

47. a) Power for the Process
The term ‘process’ refers to the manufacturing operation
that is performed on work unit as follows:
Manufacturing process and their power requirements
Material handling functions:
Loading and unloading the work unit
Material transport between operations
PowerPower

48. b) Power for Automation
Controller unit:
Need electrical power to read the program of instructions,
calculations and execute the instructions by transmitting the
proper commands to actuating devices.
Power to actuate the control signals:
Controller sent the commands by means of low-voltage
control signal to provide the proper power level for actuating
device (motor).
Data acquisition and information processing:
 Keeping the records of process performance or product
quality.
PowerPower

49. 2) Program of instructions
The action performed by an automated process are defined
by a program of instructions. Whether the manufacturing
operation involves low, medium or high production, each part
require oneone or moremore processing steps performed during the
work cyclework cycle.
The particular processing steps for the work cycle are
specified in a work cycle program.
Work cycle programs are called part programspart programs in
numerical control.
Program is a set of commands that specify the sequence of
steps in the work cycle and the detailsdetails of each step.
Program of instructions

50. Work cycle programs
•The simplest automated processes, the work cycle consists of
1 step (set point control). The more complicated systems
consist of multiple steps.
•The set point is the value of the process parameter or desired
value of the controlled variable in the process.
•The process parameter changes in each step. A
 
process
parameter is an input to the process, whereas a process
variable is the corresponding output of the process.
Decision making in the Programmed Work Cycle
•Each work cycle consists of the same steps and associated
process changes with no variation from one cycle to the next.
•Operator interaction Different part or product styles are
processed by the system  Variations in the starting work unit.
Program of instructions

51. 51
Work Cycle programsWork Cycle programs
In the simplest automated processes, the work cycle consists of essentially one one
stepstep, which is to maintain a single process parameter at a defined levelwhich is to maintain a single process parameter at a defined level. It is
assumed that loading and unloading of the work units into and from the furnace
is performed manually and is therefore not part of the automatic cycle.
Process parameter : is an input to the process, such as the temperature dial is an input to the process, such as the temperature dial
settingsetting.
Process variable: is the corresponding output of the process, which is the actual
temperature of the furnace
During each step, there are one or more activities involving changes in one or
more process parameters
Examples of process parameters include: desired coordinate axis value in a
positioning system, valve open or closed in a fluid flow system, and motor on
or off.
 Examples of corresponding process variables include the actual position of
the coordinate axis, flow rate of fluid in the pipe, and rotational speed of the
motor.

52. Five Categories Of Work
Cycle Programs
Set-point control, in which the process parameter value is
constant during the work cycle (as in the furnace example).
Logic control, in which the process parameter value depends on
the values of other variables in the process.
Sequence control, in which the value of the process parameter
changes as a function of timechanges as a function of time. The process parameter values can
be either discretediscrete (a sequence of step values) or continuously continuously
variablevariable.
Interactive program, in which interaction occurs between a in which interaction occurs between a
human operator and the control system during the work cyclehuman operator and the control system during the work cycle.
Intelligent program, in which the control system exhibits aspects in which the control system exhibits aspects
of human intelligence (e.g., logic, decision making, cognition, of human intelligence (e.g., logic, decision making, cognition,
learning) as a result of the work cycle programlearning) as a result of the work cycle program.
5252

53. Five Categories Of Work
Cycle Programs
A work cycle consisting of multiple steps that are repeated with no deviation from
one cycle to the next. Most discrete part manufacturing operations are in this
category.
A typical sequence of steps (simplified) is the following: (1) load the part into the load the part into the
production machine,production machine, (2) perform the processperform the process, and (3) unload the partunload the part.
During each step, there are one or more activities that involve changes in one or
more process parameters.
5353
Example 4.1 An Automated Turning OperationExample 4.1 An Automated Turning Operation
Consider an automated turning operation that generates a cone-shaped
product The system is automated and a robot loads and unloads the work
units. The work cycle consists of the following steps: (1) load starting
workpiece, (2) position cutting tool prior to turning, (3) turn, (4) reposition
tool to a safe location at end of turning, and (5) unload finished workpiece.
Identify the activities and process parameters for each step of the operation.

54. Example 4.1 An Automated Example 4.1 An Automated
Turning OperationTurning Operation
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step # Activities Process parameters
(1) Robot
manipulator
reaching, lifting and positioning the
raw work part, then retreating to safe
position.
axis values, gripper value (open or
closed), chuck jaw value (open or
closed).
(2) cutting
tool
movement to a “ready” position. x- and z-axis position of the tool.
(3) turning
operation
workpiece rotation, cutting tool feed &
position, cut the conical shape,
finishing operation (multiple turning
passes).
speed (rev/min), (mm/rev), radial
distance (changed continuously at a
constant rate /revolution)
For a consistent finish on the surface,
the rotational speed must be
continuously adjusted to maintain a
constant surface speed (m/min)
4 are the reverse of steps (2) and (1),
respectively
process parameters are the same.
5

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The two features of the work cycle were:
(1)The number and sequence of processing steps and
(2)The process parameter changes in each step.
The following are examples of automated work cycles in which
decision making is required:
Operator interaction (input data)
Automated teller machine
Different part or product styles processed by the system
Robot welding cycle for two-door vs. four door car models
Variations in the starting work units
Additional machining pass for oversized sand casting
Features of a Work Cycle Features of a Work Cycle
ProgramProgram

56. 56
Features of a Work Cycle Features of a Work Cycle
ProgramProgram
The following summarizes the features of work cycle programswork cycle programs (part programspart programs)
used to direct the operations of an automated system:
1.1.Number of steps Number of steps in the work cycle: A general sequence in discrete production
operations is (1) load, (2), process, (3) unload, but the process may include
multiple steps.
2.2.Manual participation Manual participation in the work cycle (e.g., loading and unloading workparts)
3.3.Process parameters Process parameters - How many process parameters must be controlled during
each step? Are the process parameters continuous or discrete? Do they change
during the step?
4.4.Operator interaction Operator interaction - does the operator enter processing data?
5.5.Variations in part or product stylesVariations in part or product styles
6.6.Variations in starting work units Variations in starting work units - some adjustments in process parameters
may be required to compensate for differences in starting units

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Control System – Two Types
The control system causes the process to accomplish its defined
function, which is to perform some manufacturing operation.
The control element of the automated system executes the program of
instructions.
1.Closed-loop (feedback) control system – a system in which the
output variable is compared with an input parameter, and any
difference between the two is used to drive the output into agreement
with the input
2.Open-loop control system – operates without the feedback loop, so
no comparison is made between the actual value of the output and the
desired input parameter.
Simpler and less expensive
Risk that the actuator will not have the intended effect

58. Closed-loop (Feedback) Closed-loop (Feedback)
Control System Control System
1.The input parameter often referred to as the set point, represents the desired value desired value of the output.
2.The process is the operation or function being controlledbeing controlled.
3.The output variable (process variable) that is being controlledcontrolled in the loop, perhaps a critical performance
measure in the process, such as temperature or force or flow rate.
4.A
 
sensor is used to measure the output variable and close the loop between input and output. Sensors
perform the feedback function in a closed-loop control system.
5.The controller compares the output with the input and makes the required adjustmentrequired adjustment in the process to
reduce the difference between them.
6.Actuator: These are the hardwarehardware devicesdevices which perform the required job. The adjustment is accomplished
using one or more actuators, which are the hardware devices that physically carry out the control actionscontrol actions,
such as electric motorsas electric motors or flowflow valvesvalves.
58/75
Figure 4.3 shows only
one loop. Most
industrial processes
require multiple loops,
one for each process
variable that must be
controlled

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Open-Loop Control System Open-Loop Control System
In this case, the controls operate without measuring the
output variable.
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 disadvantage 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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Positioning System Using
Feedback Control
A one-axis position control system consisting of a leadscrew driven by
a servomotor and using an optical encoder as the feedback sensor.
For the open-loop case, the diagram for the positioning system would be similar to the
preceding, except that no feedback loop is present and a stepper motor would be used in
place of the dc servomotor. A stepper motor is designed to rotate a precise fraction of a
turn for each pulse received from the controller. Since the motor shaft is connected to the
leadscrew, and the leadscrew drives the worktable, each pulse converts into a small
constant linear movement of the table. To move the table a desired distance, the number
of pulses corresponding to that distance is sent to the motor. Given the proper application,
whose characteristics match the preceding list of operating conditions, an open-loop
positioning system works with high reliability.

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When to Use an
Open-Loop Control System
Open-loop systems are usually appropriate when the following
conditions apply:
Actions performed by the control system are simple
Actuating function is very reliable
Any reaction forces opposing the actuation are small enough as to
have no effect on the actuation
If these conditions do not apply, then a closed-loop control system
should be used

62. 62
Advanced Automation Advanced Automation
FunctionsFunctions
In addition to executing work cycle programsexecuting work cycle programs, an automated system may be capable of
executing advanced functions executing advanced functions that are not specific to a particular work unit. Advanced Advanced
automation functions automation functions include the following:
(1)(1)Safety monitoringSafety monitoring,
(2)(2)Maintenance and repair diagnosticsMaintenance and repair diagnostics, and
(3)(3)Error detection and recovery, Error detection and recovery,
These functions are made possible by special subroutines included in the program of These functions are made possible by special subroutines included in the program of
instructions.instructions.
Safety Monitoring:Safety Monitoring: is the use of sensors to track the system's operation and identify is the use of sensors to track the system's operation and identify
conditions that are unsafe or potentially unsafeconditions that are unsafe or potentially unsafe.
Reasons for safety monitoring: To protect workers and equipmentTo protect workers and equipment
Possible responses to hazards:
Complete stoppage of the systemComplete stoppage of the system
Sounding an alarmSounding an alarm
Reducing operating speed of processReducing operating speed of process
Taking corrective action to recover from the safety violationTaking corrective action to recover from the safety violation

63. Safety Monitoring
•An automated system is often installed to perform a potentially dangerous operation
that would otherwise be accomplished manually. Two reasons for providing an
automated system with a safety monitoring capabilitysafety monitoring capability:
a)To protect human workers in the vicinity of the system
b)To protect the equipment associated with the system
Example: Emergency stop buttons, Limit switches, photoelectric sensors,
temperature sensors, heat or smoke detectors, pressure-sensitive floor pads and
machine vision systems.
Maintenance and repair diagnostics: Three modes of operation are typical of a Three modes of operation are typical of a
modern maintenance and repair diagnostics subsystemmodern maintenance and repair diagnostics subsystem:
1)Status monitoring: To monitor and record the status of key sensors and parameter of
the system during normal operation.
2)Failure diagnostics: The failure diagnostics mode is invoked when a malfunction or
failure occurs.
3)Recommendation of repair procedure: The subsystem provides a recommendation
procedure to the repair crew as to the steps that should be taken to effects repairs.
Status monitoringStatus monitoring serves two important functions in machine diagnostics: (1)
providing information for diagnosing a current failure and (2) providing data to
predict a future malfunction or failure
Advanced Automation FunctionsAdvanced Automation Functions

64. Advanced Automation Advanced Automation
FunctionsFunctions
3)Error Detection and Recovery:
Error detection – in analyzing a given production operation, the possible errors can be
classified into one of three general categories:
1.Random errors, occur when the process is in statistical control. Large variations in part
dimensions, even when the production process is in statistical control, can cause problems in
downstream operations.
2.Systematic errors, are those that result from some assignable cause such as a change in raw
material or drift in an equipment setting.
3.Aberrations errors that results from either an equipment failure or a human mistake
Functions:
Use the system’s available sensors to determine when a deviation or malfunction has
occurred
Correctly interpret the sensor signal
Classify the error
The two main design problems in error detection are (1) anticipating all of the possible
errors that can occur in a given process, and (2) specifying the appropriate sensor systems
and associated interpretive software so that the system is capable of recognizing each
error

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Advanced Automation FunctionsAdvanced Automation Functions
Error recovery: is concerned with applying the is concerned with applying the
necessary corrective action to overcome the error necessary corrective action to overcome the error
and bring the system back to normal operationand bring the system back to normal operation.
Possible strategies:
Make adjustments at end of work cycleMake adjustments at end of work cycle
Make adjustments during current work cycleMake adjustments during current work cycle
Stop the process to invoke corrective actionStop the process to invoke corrective action
Stop the process and call for helpStop the process and call for help

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Reasons for Automating
Companies undertake projects in automation and computer-integrated
manufacturing for good reasons, some of which are the following:
1.To increase labor productivity
2.To reduce labor cost
3.To mitigate the effects of labor shortages
4.To reduce or remove routine manual and clerical tasks
5.To improve worker safety
6.To improve product quality
7.To reduce manufacturing lead time
8.To accomplish what cannot be done manually
9.To avoid the high cost of not automating

69. REASON FOR AUTOMATED
•Improved product quality: Automation performs the manufacturing
process with greater uniformity and conformity to quality specifications.
Reduction of fraction defect rate is one of the chief benefits of
automation.
•To accomplish processes that cannot be done manually: Certain
operation cannot be accomplished without the aid of a machine. These
processes have requirements for precision, miniaturization or
complexity of geometry that cannot be achieved manually. Example:
manufacturing process based on CAD models and rapid prototyping.
•Increased labor productivity:
Value of output per person per hour increases
Automating a manufacturing operation usually increases
production rate and labor productivity.
Reason for Automated and Not Automated

70. •Reduce labor cost:
Higher investment in automation has become economically
justifiable to replace manual operation. Machines are increasingly
being substituted for human labor to reduce unit product cost.
•To reduce or eliminate routine manual and clerical tasks:
An argument can be put forth that there is social value in automating
operations that routine, boring, fatiguing and possibly irksome.
Automating such tasks serves a purpose of improving the general
level of working conditions.
•Lower costs: Reduce scrap, lower in-process inventory, superior
quality, shorter lines.
•Reducing manufacturing lead time and reduces work-in-
progress: Respond quickly to the customers’ needs and rapid
response to changes in design.
•Improve worker safety: By automating a given operation and
transferring the worker from activate participation in the process to a
supervisory role, the work is made safer.

71. •To avoid the high cost of not automating:
•The advantage of automating cannot easily be demonstrated on a
company’s authorized from. The benefits of automation often show
up in unexpected and intangible ways, such as improved quality,
higher sales, better labor relationship and better company image.
•Companies that do not automate are likely to find themselves at a
competitive disadvantage with their customers, their employees
and the general public.
•Competition: Lower prices, better product, better image, better labor
relation.
•New process technologies require automation: Example; Robot
controlled thermal spray torch for coating engine blocks.
•Potential for mass customization and reduced inventory.
•High cost of raw materials

72. Reason for not automated
•Labor resistance
•Cost of upgraded labor :
Example : Chrysler Detroit plant spend 1 million hours of
retraining
•Initial investment
•Management of process improvement
•Intellectual assets versus technological assets
•Appropriate use of technology
•A system approachsystem approach to automation is important
•Equipment incompatibilities

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Automation Principles and Strategies
1.The USA Principle
2.Ten Strategies for Automation and Process Improvement
3.Automation Migration Strategy

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U.S.A Principle
1.Understand the existing process:
Input/output analysis: What are the inputs? What are the outputs? What
exactly happens to the work unit between input and output? What is the
function of the process?
Value chain analysis: How does it add value to the product? What are the
upstream and downstream operations in the production sequence, and can
they be combined with the process under consideration?
Charting techniques(such as the operation chart and the flow process
chart) 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

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 75
Ten Strategies for Automation and
Process Improvement
If automation seems a feasible solution to improving productivity, quality, or other
measure of performance, then the following ten strategies provide a road map to
search for these improvements
1.Specialization of operations: use of special-purpose equipment
2.Combined operations: performing more than one operation at a given machine,
thereby reducing the number of separate machines needed.
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

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Automation Migration Strategy
For Introduction of New Products
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

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Automation
Migration
Strategy

78. Levels of Automation
Cell or system level
Machine level
Device level
Plant level
Enterprise level

79. 1) Device
•The lowest level and it includes the actuators, sensors and other hardware
components that comprise machine level.
•The devices are combined into the individual control loops of the machine.
Example: the feedback control loop for one axis of a CNC machine.
2) Machine
•Hardware at the device level is assembled into individual machines.
Example: CNC machine tools and similar production equipment, industrial
robot and AGV.
•Control function at this level includes performing the sequence of steps in
the program of instructions in correct order and making sure that each step is
properly executed.
3) Cell or system
•Manufacturing cell or system level, this cell operates under instructions from
the plant level. It is a group of machines or workstations connected and
supported by a material handling system, computers, and other equipment
appropriate to the manufacturing process.
Levels of Automation

80. 4) Plant level
•This is the factory or production systems level. It received instructions
from the corporate information system and translates them into
operational plans for production.
•The functions include: order processing, process planning, inventory
control, purchasing, material requirement planning, shop floor control
and quality control.
5) Enterprise level
•This is the highest level, consisting of the corporate information
system. It concerned with all of the function necessary to manage the
company: marketing and sales, accounting, design, research, aggregate
planning and master production scheduling.
A manufacturing system manufacturing system is defined in this book as a collection of
integrated equipment designed for some special mission, such as
machining a defined part family or assembling a certain product.
Manufacturing systems include people. The manufacturing systems in
a factory are components of a larger production system,
Levels of Automation

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Levels of AutomationLevels of Automation
Fig. 4.6 Production system, which is defined as
the people, equipment, and procedures that
are organized for the combination of
materials and processes that comprise a
company’s manufacturing operations.
Production systems are at level 4, the plant
level, while manufacturing systems are at
level 3 in the automation hierarchy.
Production systems include not only the
groups of machines and workstations in
the factory but also the support procedures
that make them work.
Procedures include process planningprocess planning,
production control, inventory control & production control, inventory control &
material requirements planning, shop material requirements planning, shop

82. Homework Homework
1)A beverages plant plan to mass produce orange flavor drink
for 4 different brands. All 4 brands using the same aluminium
can size but different in printing label on the can. In your
opinion what types of automated manufacturing system is
most suitable to produce 10,000 can/day and each brand is
different in quantity?
2)Identify the situations in which manual labor is preferred over
automation?
3)Review questions: 1.1 to 1.16 & 4.1 to 4.10
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