AUTOMATION
It is the technology by which a process or procedure is performed with nominal human assistance. Automation or automatic control is the use of various control systems for operating equipment such as machinery, processes in factories, boilers and heat treating ovens, switching on telephone networks, steering and stabilization of ships, aircraft and other applications and vehicles with minimal or reduced human intervention.
Automation in the industry provides the advantages of improving productivity and quality while reducing errors and waste, increasing safety, and adding flexibility to the manufacturing process. In the end, industrial automation yields increased safety, reliability, and profitability.
Automation covers applications ranging from a household thermostat controlling a boiler, to a large industrial control system with tens of thousands of input measurements and output control signals. In control complexity, it can range from simple on-off control to multi variable high-level algorithms.
Needs of Automation
The industrial world is facing many technological changes which increased the urgent demand for the premium quality products and services that can only be supplied by a high level of productivity. This requirement needs process engineering systems, automated manufacturing. and industrial automation. Following are the some of the important points due to which it is needed in industrial workplace.
● Globalization : Global industrial automation market demands superior and practical services.
● Productivity : Automation enhances the productivity of Industry. Industrial automation is all about working smarter, faster, and proficiently. This makes automation more powerful and that's why customers are looking for pioneering, end-to-end technologies with open, modern architecture and new data from new connections As the industrial automation industry comprehends the advantages of the Internet of Things (lot), it is becoming essential that organizations adopt these technologies.
● Industrial Automation Becomes a 'Solutions' Business: Industrial automation refers the categorization of software and hardware and a mechanism that combines them (hardware & software) Automation can be achieved by installing automated devices or embedded systems as well as automation software performing the logical tasks and control the operation processes.
● Reduce Worker Fatigue and Effort or Labor Intensive Operation : Humans dislike ordinary, repetitive tasks. However, computer systems perform them without complaint If the task requires conditions not suited to human comfort or focus, consider automation.
● Prevent Products or Materials from Being Damaged or Destroyed : Human being may make mistakes when they tired. This represents the sentiment of the "human condition." Mistakes using tools mean damaging raw materials, components, assemblies, and end products.
● Prevent Non-conforming Product from Shipment : Computers controlling robots do not forget steps Automated systems will not violate the instruction set. Moreover, automated systems may employ inspection capabilities. Tune the system and allow the data to roll in without preference or bias.
● Save Money : Inventing in industrial automation yields cost savings through making processes more regular and collecting data for making confident decisions.
3. Basic elements of automated system :
An automated system consists of three basic elements:
(1) Power to accomplish the process and operate the system.
(2) Program of instructions to direct the process, and
(3) Control system to actuate the instructions.
An automated system is used to operate some process, and power is required to drive the program instructions as well as the controls The principal source of power in automated systems is electricity. Electric power has many advantages in automated as well as non automated processes
1. Power source: An automated system is used to operate some process and power is required to drive the process as well as controls. There are many sources of power available, but the most commonly used power is electricity, The actions performed by automated systems are generally of two types :
(a) Processing
(b) Transfer and positioning
2. Program of instructions: The actions performed by an automated process are defined by a set of instructions known as process. The programmed instructions determine the set of actions that is to be done automatically by the system. The program specifies what automated system should do and how its various components must function in order to accomplish the desired results
3. Control system: The control element of the automated system executes the program of instructions. The controls in an automated system can be:
(a) Closed loop
(b) Open loop
(a) Closed loop control system: It is also known as a feedback control system. In this system the output variable is compared with an input parameter and any difference between the two is used to drive the output into agreement with input.
1. Input parameter: as set point, represents the desired value of output.
2. Output variables: actual value of parameter.
3. Sensors: A sensor is used to measure the output variable and close the loop.
4. Between input and output: It performs feedback function.
5. Controller: The controller compares the output with the input and makes the required adjustment in the process to reduce the difference between them.
6. Actuator: The adjustment being done with one or more actuator which are the hardware devices that physically carry out the control actions such as electric motor, cylinder etc.
(b) Open loop control system: It is without the feedback loop. In this case the controls operates without measuring the output variables, so no comparison is made between the actual value of the output and desired input parameters. There is always risk that the actuator will not have intended effect on the process.
4. Automation Principles and Strategies:
The USA Principle is a common sense approach to automation projects. Similar procedures have been suggested in the manufacturing and automation trade literature, but none has a more appealing title than this one. USA stands for :
1. Understand the existing process
2. Simplify the process
3. Automate the process.
1. Understand the existing process
USA approach is to understand the current process in all of its details.
a. What are the inputs? What are the outputs?
b. What exactly happens to the work unit between input and output?
c. What is the function of the process?
d. How does it add value to the product?
e. What are the upstream and downstream operations in the production sequence, and can they be combined with the process under consideration?
2. Simplify the process
Once the existing process is understood, then the search can begin for ways to simplify. This often involves a checklist of questions about the existing process.
a. What is the purpose of this step or this transport?
b. Is this step necessary?
c. Can this step be eliminated?
d. Is the most appropriate technology being used in this step?
e. How can this step be simplified?
f. Are there unnecessary steps in the process that might be eliminated without detracting from function?
3. Automate the Process
Once the process has been reduced to its simplest form, then automation can be considered. The possible forms of automation include strategies discussed below.
5. Strategies of Automation
TEN Strategies for Automation and Process Improvement
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 operation control
10. CIM
1. Specialization of operations
The first strategy involves the use of special purpose equipment designed to perform one operation with the greatest possible efficiency. This is analogous to the concept of labor specialization, which is employed to improve labor productivity.
2. Combined operations
Production occurs as a sequence of operations Complex parts may require dozens, or even hundreds of processing steps. The strategy of combined operations involves reducing the number of distinct production machines or workstations through which the part must be routed. This is accomplished by performing more than one operation at a given machine, thereby reducing the number of separate machines needed.
3. Simultaneous operations
A logical extension of the combined operations strategy is to simultaneously perform the operations that are combined at one workstation. In effect, two or more processing (or assembly) operations are being performed simultaneously on the same work part, thus reducing total processing time.
4. Integration of operations
Another strategy is to link several workstations together into a single integrated mechanism. using automated work handling devices to transfer parts between stations. In effect, this reduces the number of separate machines through which the product must be scheduled. With more than one workstation, several parts can be processed simultaneously, thereby increasing the overall output of the system.
5. Increased flexibility.
This strategy attempts to achieve maximum utilization of equipment for job shop and medium volume situations by using the same equipment for a variety of parts or products. It invoices the use of the flexible automation concepts. Prime objectives are to reduce setup time and programming time for the production machine. This normally translates into lower manufacturing lead time and less work-in-process.
6. Improved material handling and storage.
A great opportunity for reducing nonproductive time exists in the use of automated material handling and storage systems. Typical benefits include reduced work-in-process and shorter manufacturing lead times.
7. Online inspection
Inspection for quality of work is traditionally performed after the process is completed. This means that any poor quality product has already been produced by the time it is inspected. Incorporating inspection into the manufacturing process permits corrections to the process as the product is being made. This reduces scrap and brings the overall quality of product closer to the nominal specifications intended by the designer.
8. Process control and optimization.
This includes a wide range of control schemes intended to operate the individual processes and associated equipment more efficiently. By this strategy, the individual process times can be reduced and product quality improved.
9. Plant operations control
Whereas the previous strategy was concerned with the control of the individual manufacturing process, this strategy is concerned with control at the plant level. It attempts to manage and coordinate the aggregate operations in the plant more efficiently. Its implementation usually involves a high level of computer networking within the factory.
10. Computer Integrated Manufacturing (CIM).
Taking the previous strategy one level higher, we have the integration of factory operations with engineering design and the business functions of the firm. CIM involves extensive use of computer applications, computer data bases, and computer networking throughout the enterprise
Automation Migration Strategy
Formalized planned for evolving the manufacturing systems used to produce new products as demand grows.
A typical automation migration strategy is the following:
Phase 1: Manual production using single station manned cells operating independently. This IS used for introduction of the new product for reasons already mentioned quick and low cost tooling to get started.
Phase 2: Automated production using single station automated cells operating independently. As demand for the product grows and it becomes clear that automation can be justified, then sigie stations are automated to reduce labor and increase production rate. Work units are still moved between workstations manually.
Phase 3: Automated integrated production using a multi-station automated system with serial operations and automated transfer of work units between stations. When the company is certain that the product will be produced in mass quantities and for several years, then integration of the single station automated cells is warranted to further reduce labor and increase production rate.
Merits and Demerits of Automation
Perhaps the most cited advantage of automation in industry is that it is associated with faster production and cheaper labor costs. Another benefit could be that it replaces hard, physical, or repetitive work Additionally, tasks that take place in hazardous environments or that are otherwise beyond human capabilities can be done by machines, as machines can operate even under extreme temperatures or in atmospheres that are radioactive or toxic. They can also be maintained with simple quality checks However, at the time being not all tasks can be automated, and some tasks are more expensive to automate than others. Initial costs of installing the machinery in factory settings are high and failure to maintain a system could result in the loss of the product itself Moreover, some studies seem to indicate that industrial automation could impose ill effects beyond operational concerns, including worker displacement due to systemic loss of employment and compounded environmental damage. however, these findings are both convoluted and controversial in nature and could potentially be avoided.
The main Merits of Automation are -
● Increased throughput or productivity.
● Improved quality or increased predictability of quality.
● Improved healthiness of processes or product.
● Increased consistency of output.
● Reduced direct human labor costs and expenses.
● Installation in operations reduces cycle time.
● Can complete tasks where a high degree of accuracy is required.
● Replaces human operators in tasks that involve hard physical or monotonous work (e.g. using one forklift with a single driver instead of a team of multiple workers to lift a heavy object).
● Reduces some work-related injuries (eg, fewer strained backs from lifting heavy objects).
● Replaces humans in tasks done in dangerous environments (i e. fire, space, volcanoes, nuclear facilities, underwater, etc.)
● Performs tasks that are beyond human capabilities of size, weight, speed, endurance, etc.
● Reduces operation time and work handling time significantly .
● Frees up workers to take on other roles.
● Provides higher level jobs in the development, development maintenance and running of the automated processes.
The main Demerits of Automation are -
● Possible security threats/vulnerability.
● Due to increased relative susceptibility for committing errors.
● Unpredictable or excessive development costs.
● High initial cost.
● Displaced workers due to job replacement.
Types of Automation
Automated production systems are classified into three basic types :
1. Fixed automation,
2. Programmable automation, and
3. Flexible automation
Fixed Automation
It is a system in which the sequence of processing (or assembly) operations is fixed by the equipment configuration. The operations in the sequence are usually simple. It is the integration and coordination of many such operations into one piece of equipment that makes the system complex.
The typical features of fixed automation are:
a. High initial investment for custom-Engineered equipment,
b. High production rates, and
c. Relatively inflexible in accommodating product changes.
Programmable Automation
In this the production equipment is designed with the capability to change the sequence of operations to accommodate different product configurations. The operation sequence is controlled by a program, which is a set of instructions coded so that the system can read and interpret them. New programs can be prepared and entered into the equipment to produce new products.
Some of the features that characterize programmable automation are:
a. High investment in general-purpose equipment:
b. Low production rates relative to fixed automation;
c. Flexibility to deal with changes in product configuration,and
d. Most suitable for batch production.
Flexible Automation.
It is an extension of programmable automation. A flexible automated system is one that is capable of producing a variety of products with virtually no time lost for changeovers from one product to the next There is no production time lost while reprogramming the system and altering the physical setup. Consequently, the system can produce various combinations and schedules of products instead of requiring that they be made in separate batches. The features of flexible automation can be summarized as follows:
a. High investment for a custom-engineered system.
b. Continuous production of variable mixtures of products.
c. Medium production rates.
d. Flexibility to deal with product design variations.
The essential features that distinguish flexible automation from programmable automation are:
1. The capacity to change part programs with no lost production time, and
2. The capability to change over the physical setup, again with no lost production time. These features allow the automated production system to continue production without the downtime between batches that is characteristic of programmable automation. The relative positions of the three types of automation for different production volumes and product variations are depicted in the following figure
Hard and Soft Automation
Soft or Programmable Automation is the more developed cousin to Hard Automation. It includes equipment that has been designed to accommodate a variety of product configurations. If you have facility that manufactures a limited range of similar products that are run in batches. Soft Automation may be your best choice.
a. Hard Automation
Hard automation is used for a specific production purpose where the processes are fixed. It is best suited for automated equipment that mass produced high volume products with few alterations or little changeovers. This type of automation has a high initial investment and high production rates, most typically automated assembly line machines.The Society of Mechatronics Engineering & Technology (SOMETECH) points out that each of the operations in a fixed sequence is usually simple and involves a plain linear or rotational motion, for example, or a combination of two such motions. Despite the simple operations involved, it is relatively difficult to make changes in the product design.
Advantages of hard automation, according to SOMETECH, include low unit cost, automated material handling and a high production rate.
The disadvantages are a high initial investment and the relative inflexibility in accommodating product changes.
b. Soft Automation
Soft automation can be used to produce a variety of parts with virtually no time lost for changeovers from one part style to another or for multiple small batches of a single product No lost production time results when reprogramming the system.
Advantages include continuous production of variable mixtures of product and flexibility to accommodate varying product designs.
Disadvantages are a medium production rate high long term production costs and a high unit cost compared with hard automation.
Recent and Emerging applications of Automation.
● Automated power production
Technologies like solar panels, wind turbines, and other renewable energy sources, together with smart grids, microgrids, battery storage - can automate power production.
● Automated retail Food and drink industry
The food retail industry has started to apply automation to the ordering process, McDonald's has introduced touch screen ordering and payment systems in many of its restaurants, reducing the need for as many cashier employees. Some Cafes and restaurants have utilized mobile and tablet "apps" to make the ordering process more efficient by customers ordering and paying on their device. Some restaurants have automated food delivery to customers tables using a Conveyor belt system. The use of robots is sometimes employed to replace waiting staff.
● Automated mining
Automated mining involves the removal of human labor from the mining process. The mining industry is currently in the transition towards automation Currently, it can still require a large amount of human capital, particularly in the third world where labor costs are low so there is less incentive for increasing efficiency through automation.
● Automated video surveillance
Automated video surveillance monitors people and vehicles in real time within a busy environment. Existing automated surveillance systems are based on the environment they are primarily designed to observe, i.e., indoor, outdoor or airborne, the number of sensors that the automated system can handle and the mobility of sensor, ie, stationary camera vs mobile camera. The purpose of a surveillance system is to record properties and trajectories of objects in a given area, generate warnings or notify designated authority in case of occurrence of particular events.
● Automated highway systems
As demands, for safety and mobility have grown and technological possibilities have multiplied, interest in automation has grown.
● Automated waste management
Automated waste collection trucks prevent the need for as many workers as well as easing level of labor required to provide the service.
● Business process automation
Business process automation (BPA) is the technology-enabled automation of iek business processes. It can help to streamline a business for simplicity, achieve digital transformation, increase service quality, improve service delivery or contain costs.
● Home automation
Home automation designates an emerging practice of increased automation of household appliances and features in residential dwellings, particularly through electronic means that allow for things impracticable, overly expensive or simply not possible in recent past decades The rise in the usage of home automation solutions has taken a turn reflecting the increased dependency of people on such automation solutions However, the increased comfort that gets added through these automation solutions is remarkable.
● Laboratory automation
Automation is essential for many scientific and clinical applications. Therefore, automation has been extensively employed in laboratories.
● Industrial automation
Industrial automation deals primarily with the automation of manufacturing, quality control and material handling processes General purpose controllers for industrial processes include Programmable logic controllers, stand-alone I/O modules, and computers. Industrial automation is to replace the decision making of humans and manual command-response activities with the use of mechanized equipment and logical programming commands.
