2 Introduction to Automation
-
Upload
syaiful-mansyur -
Category
Documents
-
view
231 -
download
2
Transcript of 2 Introduction to Automation
-
7/27/2019 2 Introduction to Automation
1/29
Introduction to AutomationBasic Elements of an Automated SystemAdvanced Automation Functions
Level of Automation
-
7/27/2019 2 Introduction to Automation
2/29
Introduction
Automation is technology by which a process or procedure is accomplished
without human assistanceAutomation is implemented using a
program of instruction combined with acontrol system that executes the instructionPower is required to drive the process andto operate the program and control system
-
7/27/2019 2 Introduction to Automation
3/29
Basic Element of an Automated
SystemAn automated system consists of three basic
elements
Power to accomplish the process andoperate the systemA program of instruction to direct the
processA control system to actuate the instructions
-
7/27/2019 2 Introduction to Automation
4/29
Elements of Automated System
Power
Program of
instructions
Control
systemProcess
-
7/27/2019 2 Introduction to Automation
5/29
Power to accomplish the
Automated ProcessAdvantage of Electrical Power
Widely available at moderate cost
Can be readily converted to alternativeenergy form like mechanical, thermal, light,acoustic, hydraulic & pneumaticAt a low level can be used to accomplishfunction like signal transmission,information processing, data storageCan be storage in long-live batteries
-
7/27/2019 2 Introduction to Automation
6/29
Power for the Process
In production, the term of process refers tothe manufacturing operation that is
performed on a work unit. Most of the power in manufacturing is thermal,electrical, and mechanicalThe power source is often converted fromelectricity
-
7/27/2019 2 Introduction to Automation
7/29
Common Manufacturing Process
and Their Power RequirementsProcess power formCasting thermalEDM electricalForging mechanicalHeat treating thermalInjection molding thermal & mechanical
Machining mechanicalPunching & blanking mechanicalWelding thermal
-
7/27/2019 2 Introduction to Automation
8/29
Additional process in manufacturing
Loading and unloading the work unitMaterial transport between operations
-
7/27/2019 2 Introduction to Automation
9/29
Power for Automation
Controller unit Modern industrial controller are based on digital
computer
Power to actuate the control signals The command send by the control unit are carried out
by mean of electromechanical devices (switch, motor,
actuator)Data acquisition and information processing Data must be collected from process and used as input
to the control algorithm. This data acquisition and
record keeping function require power
-
7/27/2019 2 Introduction to Automation
10/29
Program of Instructions
The actions performed by an automated process are defined by a program of instructionsThese processing steps are performedduring a work cycleA new part is completed during each work
cycle (sometimes more than one part produced during the work cycle ex multicavity plastic part)
-
7/27/2019 2 Introduction to Automation
11/29
Work cycle programs
In the simple automated process the work cycle consist of single step process
In the more complicated system typically: Load the part into the production machine Perform the process
Unload the partDuring each step there are one or moreactivities or more process parameter
-
7/27/2019 2 Introduction to Automation
12/29
Process parameters
Process parameters are inputs to the process:
Temperature setting Coordinate axis value in positioning system Valve opened/closed in a fluid flow system
Motor on/off
-
7/27/2019 2 Introduction to Automation
13/29
Feature of the work Cycle
The number and sequence of processingsteps
Process parameter changes in each step
-
7/27/2019 2 Introduction to Automation
14/29
Decision-Making in the
Programmed Work CycleOperator interaction Ex automated engraving operation (operator may have to enter
the alphanumeric character)
Difference part or product style processed by the system The automated system is programmed to perform different work cycle on the different part or product
Ex industrial robot for spot welding (often designed to builddifferent body style)
Variations in the starting work unit The starting work units are not consistent Ex starting work unit machining operation for sand casting
material
-
7/27/2019 2 Introduction to Automation
15/29
Summary the features of work
cycle program Number of steps in work cycle Load, process and unload
Manual participation in the work cycleProcess parameter Operator interaction
Variations in part or product styleVariations in starting work units
-
7/27/2019 2 Introduction to Automation
16/29
Control System
The control elemen of the automatedsystem executes the program of
instructionsThe control in an automated system Open loop control system
Closed loop control system or a feedback control system
-
7/27/2019 2 Introduction to Automation
17/29
Open loop
Conditions in open loop system The action performed by the control system
are simple
The actuating function is very reliable Any reaction opposing the actuator are smallenough to have no effect on the actuating
Input parameter
controller actuator process Outputvariable
-
7/27/2019 2 Introduction to Automation
18/29
Close loopInput
parameter controller actuator process Output
variable
Feedback sensor
-
7/27/2019 2 Introduction to Automation
19/29
Advanced Automation Functions
In additional, an automated system may becapable of executing advanced functions
that are not specific to a particular work unitFunction
safety monitoring Maintenance and repair diagnostic Error detection and recovery
-
7/27/2019 2 Introduction to Automation
20/29
safety monitoring
Reason To protect human workers in the vicinity of
the system To protect the equipment associated with the
system
Safety monitoring means more than theconventional safety measures taken in amanufacturing operation
-
7/27/2019 2 Introduction to Automation
21/29
Possible responses to various
hazardsCompletely stopping the automated systemSounding an alarm
Reducing the operating speed of the processTaking corrective actions to recover from
the safety violation
-
7/27/2019 2 Introduction to Automation
22/29
-
7/27/2019 2 Introduction to Automation
23/29
Maintenance and repair diagnostic
Statues monitoringFailure diagnostics
Recommendation of repair procedure
-
7/27/2019 2 Introduction to Automation
24/29
Levels of AutomationEnterprise Level
Plant Level
Cell or System Level
Machine Level
Device Level
Corporate InformationSystem
Production System
Manufacturing systemgroup of machine
Individual Level
Sensor, actuators, other hardware element
Flow of data
-
7/27/2019 2 Introduction to Automation
25/29
Device Level
It includes the actuators, sensors, and other hardware components that comprise the
machine levelThe device are combined into theindividual control loops of the machineFor example the feed back control loop for one axis of a CNC machine
-
7/27/2019 2 Introduction to Automation
26/29
Machine Level
Hardware in the device level is assembledinto individual machine
CNC machine tools and similar productionequipment, industrial robots, power conveyor, and automated guided vehicleControl level at this level include
performing the sequence of steps in the program of instructions in the correct order and making sure that steps is properlyexecuted
-
7/27/2019 2 Introduction to Automation
27/29
Cell or System Level
A manufacturing cell or system is a groupof machines or work stations connectedand supported by a material handlingsystem, computer, and other equipmentappropriated to the manufacturing processConsist of production lines, partdispatching, machine loading, materialhandling system, coordinating amongmachines, colecting data, and evaluatinginspection data
-
7/27/2019 2 Introduction to Automation
28/29
Plant Level
This is the factory or production systemslevel
Consist of order processing, process planning, inventory control, purchasing,MRP, shop floor control, and qualitycontrol
-
7/27/2019 2 Introduction to Automation
29/29
Enterprise Level
Consist of the corporate informationsystem
It is concerned with all the functipnnecessary to manage the companyIncludes marketing, sales, accounting,design, research, aggregate planning, andmaster production scheduling