Rajarambapu Institute of Technology, Rajaramnagar

Department of Mechanical Engineering

Advanced Industrial Automation & Robotics

UNIT I

Course Prerequisites

In order to understand this course, students

should posses the knowledge of:

1. Manufacturing process

2. Plant layout

3. Types of production

4. Basics of robotics such as anatomy, drive

systems, end effectors.

Course Outcomes (COs)

After successful completion of the course, the

students should be able to:

1. Analyze workstation breakdown of transfer lines

2. Determine the efficiency of transfer lines with and without buffer

storages.

3. Determine efficiency of automated assembly machines.

4. Analyze forward and reverse kinematics of robot.

5. Analyze image processing of robot

6. Do economic analysis of robot

AUTOMATION IN PRODUCTION SYSTEMS

(1) Automation of the manufacturing systems in the factory and (2) Computerization of the manufacturing support systems

AUTOMATION IN PRODUCTION SYSTEMS

(1) Automation of the manufacturing systems in the factory and

(2) Computerization of the manufacturing support systems

Automated Manufacturing Systems

• Automated machine tools that process parts

• Transfer lines that perform a series of machining

operations

• Automated assembly systems

• Manufacturing systems that use industrial robots to

perform processing or assembly operations

• Automatic material handling and storage systems to

integrate manufacturing operations

• Automatic inspection systems for quality control

Automated Manufacturing Systems

Classification:

• Fixed automation.• Programmable automation, and• Flexible automation.

Manufacturing automation is defined as making use of mechanical /

electronics / computer based systems to operate and control production

processes.

Fixed Automation

• High initial investment for custom-engineered

equipment

• High production rates

• Relatively inflexible in accommodating product

variety

Programmable Automation

• High investment in general purpose equipment

• Lower production rates than fixed automation

• Flexibility to deal with variations and changes in

product configuration

• Most suitable for batch production

Flexible Automation

• High investment for a custom-engineered system

• Continuous production of variable mixtures of

products

• Medium production rate,

• Flexibility to deal with product design variations

Reasons for Automating

1. To increase labor productivity2. To reduce labor cost3. To mitigate the effects of labor shortages4. To reduce or eliminate routine manual and

clerical tasks5. To improve worker safety6. To improve product quality7. To reduce manufacturing lead lime8. To accomplish. processes that cannot be done

manually9. To avoid the high cast of not automating

Basic Elements of an Automated System

• Power to Accomplish the Automated Process• Program of Instructions• Control System

Elements of an automated system: (1) power, (2) program of instructions, and (3) control systems.

Automation Principles and Strategies

1. USA Principle

2. Ten strategies for automation and production

systems

3. Automation migration strategy

USA Principle

The USA Principle is a common sense approach

to automation projects.

USA stands for:

1. Understand the existing process

2. Simplify the process

3. Automate the process.

Ten Strategies for Automation and Production Systems

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 operations control

10. Computer-integrated manufacturing (CIM).

Automation Migration Strategy

Phase 1: Manual production

Phase 2· Automated production

Phase 3: Automated integrated production

Basic Elements of an Automated System

• Power to Accomplish the Automated Process• Program of Instructions• Control System

Elements of an automated system: (1) power, (2) program of instructions, and (3) control systems.

Power to Accomplish the Automated Process

• Power for the Process.

• Loading and unloading the work unit

• Material transport between operations

•Power for Automation

• Controller unit

• Power to actuate the control signals

• Data acquisition and information processing

Program of Instructions

• Single step work cycle

• Multi step work cycle

• Decision-Making in the Programmed Work Cycle

• Operator interaction

• Different part or product styles processed by the

System

• Variations in the starting work units

Control System

The control element of the automated system executes

the program of instructions. The control system causes

the process to accomplish its defined function. which for

our purpose is to carry out some manufacturing

operation.

Types:• Closed loop (feedback)• Open loop

Control Systems

• Closed Loop Control System

• Open Loop Control System

Control Systems

• Closed Loop Control System

Control Systems

Open loop systems are usually appropriate when the following conditions apply:

1. The actions performed by the control system are simple,

2. The actuating function is very reliable, and

3. Any reaction forces opposing the actuation are small

enough to have no effect on the actuation.

In addition to executing work cycle programs, an automated system may be capable of executing advanced functions that are not specific to a particular work unit. In general these functions are concerned with enhancing the performance and safety of the equipment.

Advanced automation functions include the following:• Safety monitoring• Maintenance and repair diagnostics and• Error detection and recovery

ADVANCED AUTOMATION FUNCTIONS

Functions of safety monitoring

• To protect human workers in the vicinity of the

system and

• To protect the equipment associated with

system.

Safety Monitoring

Possible responses to various hazards might include one or more of the following:

• Complete stoppage of the automated system.• Sounding an alarm• Reducing the operation speed of the process• Taking corrective actions to recover from the

safety violation

Safety Monitoring

The following list suggests some of the possible sensors and their application for the safety monitoring:

• Limit switches. • Photoelectric sensors• Temperature sensors• Heat or smoke detectors• Pressure sensitive floor pads• Machine vision system

Safety Monitoring

Maintenance and Repair Diagnostics refers to the capabilities of an automated system to assist in the identification of the source of potential or actual malfunctions and failures of the system. Three modes of the operation are typical of a modern maintenance and repair diagnostics subsystems:

• Status monitoring• Failure diagnostics• Recommendation of repair procedure

Maintenance and Repair Diagnostics

Status monitoring serves two important functions in machine diagnostics:

• Providing information for diagnosing a current failure and

• Providing data to predict a future malfunction or failure

Status monitoring

Error Detection: As indicated by the term, error detection and recovery consists of two steps:

• Error detection and• Error recovery.

In analyzing a given production operation, the possible errors can be classified into one of three general categories

• Random errors• Systematic errors and• Aberrations

Error Detection and Recovery

Error recovery is concerned with applying necessary corrective action to overcome the error and bring the system back to normal operation.

1. Make adjustments at the end of current cycle

2. Make adjustments during the current cycle

3. Stop the process to invoke corrective action

4. Stop the process and call for help

Error Recovery

1. Device level

2. Machine level

3. Cell or system level

4. Plant level

5. Enterprise level

LEVELS OF AUTOMATION

Manufacturing Systems

1. One worker tending one machine, which operates on semi-automatic cycle2. A cluster of semi-automatic machines, attended by one worker3. A fully automated assembly machine, periodically attended by a human

worker4. A group of automated machines working on automatic cycles to produce a

family of similar parts. 5. A team of workers performing assembly operations on a production line.

Production Machines

1. Manually operated,

2. Semi-automated, or

3. Fully automated.

Material Handling System

1. Loading and unloading work units and

2. Positioning the work units at each station.

In manufacturing systems composed of multiple workstations, a means of

3. Transporting work units between stations is also required.

Most material handling systems used in production also provide

4. A temporary storage function.

Material Handling System

General issues relating to the material handling system.

1. Loading, Positioning and Unloading

2. Work Transport Between Stations

i. Variable routing and

ii. Fixed routing.

3. Pallet Fixtures and Work Carriers in Transport Systems

Material Handling System

Types of routing in multiple station manufacturing systems: (a) variable routing

and (b) fixed routing.

Material Handling System

Common Material Transport Equipment Used for Variable and Fixed Routing in

Multiple Station Manufacturing Systems

Type of Part

Routing

Material Handling Equipment

Variable routing Automated guided vehicle system Power-and-free

overhead conveyor Monorail system, Cert-on-track

conveyor

Fixed routing Powered roller conveyor, Belt conveyor,

Drag chain conveyor, Overhead trolley conveyor,

Rotary indexing mechanisms, Walking beam

transfer equipment

Material Handling System

Pallet Fixtures and Work Carriers in Transport Systems

1. Pallet fixtures

2. Modular Pallet Fixtures

3. Work Carriers

4. Direct Transport

Computer Control System

Pallet Fixtures and Work Carriers in Transport Systems

1. Communicate instructions to workers

2. Download part programs to computer-controlled

machines

3. Material handling system control

4. Schedule production

5. Failure Diagnosis

6. Safety monitoring

7. Quality control

8. Operations management

Human Resources

1. Direct Labour

2. Indirect Labour

CLASSIFICATION OF MANUFACTURING SYSTEMS

Factor Alternatives

Types of operations

performed

Processing operations versus assembly operations

Type of processing or assembly operation

Number of workstations

and system layout

One station versus more than one station

For more than one station, variable routing versus fixed

routing

Level of automation Manual or semi-automated workstations that require

full-time operator attention versus fully automated that

require only periodic worker attention

Part or product variety All work units identical versus variations in work units

that require differences in processing

Level of Automation

1. Manually operated

2. Semi-automated

3. Automated

Manning Level Mi

Automation in the Classification Scheme

1. Type I M Single-station manned cell

2. Type I A Single station automated cell

3. Type II M Multi-station manual system with variable routing

4. Type II A Multi-station automated system with variable

routing

5. Type II H Multi-station hybrid system with variable routing

6. Type III M Multi-station manual system with fixed routing

7. Type III A Multi-station automated system with fixed routing

8. Type III H Multi-station hybrid system with fixed routing