Automations in Toolings

8/9/2019 Automations in Toolings

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BY

MARUTHI BHAJANTRI

GTTC-HUBLI


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Automation is basically the delegation of human control

function to technical equipment for

Increasing Productivity

Increasing Quality

Reducing Cost

Increasing Safety in working conditions

It is the technologyassociated with the use of electrical, mechanical and computer

based systems to operate and control production in order to increase reliability andefficiency. This is usually accomplished through programmed commands combined

with automatic feedback controlto ensure proper execution of the instructions.

The resulting system is capable of operating without human intervention.


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Automation is encompassing virtually every walk of life

Automation solutions are required right from agriculture tospace technology

Plant automation is the necessity for the manufacturing

industry to survive in todays globally competitive market


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In 1970 with the coming of microprocessor and associated

peripheral chips, the whole processes of control and

automation underwent a radical change.

Companies dealing with automations like Fanuc and Festo and

other major company's made these changes at very faster

rate and advanced methods in the recent years.

And CAD related companies are also made flexible and realisticautomation design facility in software's.


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Increases productivity

Reduces labor cost

Alleviates the effects of labor shortages

Reduces or eliminates the routine manual and clerical tasks

Improves worker safety

Improves product quality

Reduces manufacturing lead time

Accomplishes processes that cannot be done manually

Reduces unit cost Performs repetitive tasks consistently

Multiple tasks can be performed at the same time

High forces and power can be applied

Performs computations quickly


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Worker displacement

High costs of designing, fabricating, and installing

equipments/machines

A higher level of maintenance needed than with a manually

operated machine

Requires relatively extensive labor training in order to make

labor capable of operating automated machines


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Manual control Automatic control

1) All the actions related to process control are taken by the

operator .

1) All the actions related to process control are taken automatically.

2) Likely human errors, consequently quality of the final product will

be low.

2) Errors are very low , consequently quality of product will be high

and accurate.

3) The production safety, energy consumption and usage of raw

material are all subjected to correctness and accuracy of human

actions.

3) The production safety, energy consumption and usage of raw

material is low as compared to manual control.

4) Manually you need to make documentations. Like counting,

production reports & inspection reports etc.

4) Generates documentations automatically with the help of software.

5) Space required is more 5) Less space required.

6) Maintenance will be difficult 6) Ease of maintenance

7) High labour cost 7) Reduced labor cost

8) No flexibility in design. 8) Tremendous flexibility in design.

9) Generates high man power. 9) Less man power required.


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Ergonomics is the science of designing the job, equipment, and workplace to fit the worker.

Proper ergonomic design is necessary to prevent repetitive strain injuries, which can

develop over time and can lead to long-term disability

Derived from two Greek words:

Nomoi meaning natural laws

Ergon meaning work Hence, ergonomists study human capabilities in relationship to work

demands.


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Time management refers to a range of skills, tools, and techniques used

to manage time when accomplishing specific tasks, projects and goals.

This set encompasses a wide scope of activities, and these

include planning, allocating, setting goals, delegation, analysis of time

spent, monitoring, organizing, scheduling, and prioritizing. Initially time

management referred to just business or work activities, but eventually

the term broadened to include personal activities as well. A time

management system is a designed combination of processes, tools andtechniques.

FIRST GENERATION: reminders based on clocks and watches, but with

computer implementation possible; can be used to alert a person when

a task is to be done.

SECOND GENERATION: planning and preparation based on calendarand appointment books; includes setting goals.

THIRD GENERATION: planning, prioritizing, controlling (using a

personal organizer, other paper-based objects, or computer or PDA-

based systems) activities on a daily basis. This approach implies

spending some time in clarifying values and priorities.

Fourth generation: being efficient and proactive using any of the above

tools; places goals and roles as the controlling element of the systemand favors importance over urgency.


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AN INDUSTRIAL ROBOT is officially defined by ISO

as an automatically controlled, reprogrammable,

multipurpose manipulator programmable in three or

more axes. The field of robotics may be more

practically defined as the study,

design and use of robot systems for manufacturing (a

top-level definition relying on the prior definition ofrobot).

Typical applications of robots include welding,

painting, assembly, pick and place, packaging and

palletizing, product inspection, and testing, all

accomplished with high endurance, speed, and

precision.


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Pneumatics

Pneumatics is a branch of technology, which deals with the study and

application of use of pressurized gas to affect mechanical motion.

Pneumatic systems are extensively used in industry, where factories are

commonly plumbed with compressed air or other compressed inert

gases. This is because a centrally-located and electrically-powered

compressor that powers cylinders and other pneumatic devices through

solenoid valves is often able to provide motive power in a cheaper,

safer, more flexible, and more reliable way than a large number of

electric motors and actuators.

Hydraulics

Hydraulics is the science of transmitting force and/or motion through

the medium of a confined liquid. In a hydraulic device, power is

transmitted by pushing on a confined liquid. The transfer of energy

takes place because a quantity of liquid is subject to pressure. To

operate liquid-powered systems, the operator should have a

knowledge of the basic nature of liquids. This chapter covers the

properties of liquids and how they act under different conditions.


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Kaizen (Japanese for "improvement" or "change for the better") refers to a philosophy or practices that focus

upon continuous improvement of processes in manufacturing, engineering, supporting business processes, and

management. It has been applied in healthcare, government, banking, and many other industries. When used in

the business sense and applied to the workplace, kaizen refers to activities that continually improve all functions,

and involves all employees from the CEO to the assembly line workers. It also applies to processes, such as

purchasing and logistics, that cross organizational boundaries into the supply chain. By improving standardized

activities and processes, kaizen aims to eliminate waste

Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and

minimizing variability in manufacturing and business processes. It uses a set of quality management methods, including

statistical methods, and creates a special infrastructure of people within the organization ("Black Belts", "Green Belts", etc.)

who are experts in these methods. Each Six Sigma project carried out within an organization follows a defined sequence of

steps and has quantified targets. These targets can be financial (cost reduction or profit increase) or whatever is critical to

the customer of that process (cycle time, safety, delivery, etc.).

TOTAL PROJECT MANAGEMENT AND TOTAL QUALITIY MANAGEMENT


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Automations application s in tooling now is huge. Automations are used in moulds for actuations of

side core and internal side cores , in press tools for strip feeders and slug removing units, in jigs and

fixtures for clamping, tool guiding units.

And majorly used in molding machines for taking out the component after completion of cycle time

automatically.


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Hydraulic actuation is used to move side cores in

moulds & Die casting tools

Injection Moulding machines are built with

Hydraulics systems


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Press machines are built with Hydraulics

systems

Automatic strip feeding is done by Pneumatic

automations

Finished component separation systems


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Work holding devices Indexing unit

Inspection/ Testing fixture

SPM

Etc.


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Digital manufacturing helps companies to achieve the highest levels of innovation, quality,

and cost control that are transforming the way they do business.

Now a days cad software's are providing real-time modeling and process simulation and

animations of whole process.

Major software in the field of automation design are


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LIST OF MAJOR COMPANIES INVOLVED IN AUTOMATIONS DESIGN SALES AND SERVICE


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THANK YOU

PRESENTED BY

MARUTHI BHAJANTRI

GOVT. TOOL ROOM AND TRAINING CENTREHUBLI-30

9902101010

Automations in Toolings

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