Automation

What is Automation?

- Automation Is the technology by which a process or procedure is accomplished without human assistance.

Automation-ITC

Robotics

Basic Elements of automated system

Power to operate the process.

Instruction program.

Control system to actuate the instructions.

Power to Accomplish the automated process

The Principal source of automation power is electricity, that is due to:

Availability.
Moderate cost.
Ease of conversion to other forms of energy, such as mechanical, thermal, and hydraulic.
Ability of data storage and transmission.
Ability of storage in batteries to be used anywhere.

Program of Instructions

It defines the actions performed by an automated process.

Work Cycle Programs:

the simplest example is the control of a furnace temperature(process parameter) at a specified value(one step).
More complicated example:

Load the part into the
production machine.
Perform the process(such as cutting, stamping,....)
Unload the part.

Possible Cases of variation in work cycle are:

Operator interaction with the program of instructions, such as ATM machine.

Different part or product styles processed by the system; such as a welding robot dealing with more than one car model at the same assembly line (batch production or flexible automation).

Variations in the starting work units: (They are not consistent); such as sand castings prior to machining, adjustments might be needed for individual pieces.

Safety Monitoring

Automation enhances workplace safety by design. Safety monitoring capabilities protect both human workers and equipment.

Safety Monitoring Responses:

Stopping the alarm

Sounding an alarm

Reducing opperation speed

Taking corrective actions

Maintenance and Repair Diagnostics

Three modes of operation:

Status monitoring

Current system parameters.

Failure diagnostics

Detects malfunctions and identifies the causes of the failure.

Recommendation of repair procedure

Using artificial intelligence to suggest repair steps

Error Detection and recovery

In case of a malfunction, the control computer automatically takes corrective action.

Production System Errors:

Random Errors

Due to the stochastic nature of the process.

Systematic Errors

Result from some assignable cause, such as change in raw material properties.

Aberrations

Deviations resulting from either equipment failure or human mistake.

Error Recovery Strategies:

Make adjustments at the end of the current work cycle.
Make adjustments during the current cycle.
Stop the process for automatic corrective action.
Stop the process, call for help, and initiate manual action if automation is unable to fix the issue.

Levels of Automation (Hierarchy):

5. Enterprise Level:

The highest level, the enterprise level, encompasses broader business functions such as marketing, sales, accounting, design, and research. Automation at this level often involves the integration of information systems to optimize business processes and decision-making across the organization.

4. Plant Level:

The plant level manages entire production systems, including aspects like shop floor control, quality control, order processing, and inventory management. It oversees the overall operation of the manufacturing facility.

3. Cell or System Level:

Groups of machines working together form the cell or system level. This level involves the integration and coordination of multiple machines to perform specific tasks or processes, often seen in manufacturing cells or production lines.

2. Machine Level:

Individual machines, including PLCs, CNC machines, and robots, constitute the machine level. These machines operate autonomously and may be coordinated within a system.

1. Device Level:

At the lowest level, individual components such as sensors and actuators form the device level. These elements are fundamental building blocks that directly interact with the physical aspects of the system.

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