Chapter 1

Introduction to Automation

ESE616 - Industrial Automation and

Robotics

Definition

Automation - greek word Auto (self), Matos (moving)

The technique, method, or system of operating or

controlling a process by highly automatic means, as by

electronic devices, reducing human intervention to a

minimum.

In industrial context, automation can be defined as a

technology that is concerned with the use of mechanical,

electrical/electronic, and computer-based systems to control

production process.

Example

Manual PCB Insertion :

Example

Automatic PCB Insertion :

History of Automation

Automation has been introduced very early in the history of

human civilization, in the form of mechanization of tasks

with mechanical tools such as wheel, lever and pulley,

which amplify the physical capabilities of human and

animal.

Mostly applied for construction, agriculture and textile.

History of Automation

Later, natural power sources such as water, wind, and

gravity were utilized to power up machines, namely the

water wheel and windmill that can run without any

involvement of human or animal strength.

History of Automation

Thomas Newcomen invented the first commercially

successful steam engine in 1712, to pump water out of

coal mines, but not very efficient and wasted a lot of fuel.

Later in 1770s, James Watt made significant

improvements to the steam engine and became much

more efficient that helped stepped-up the pace of the

industrial revolution (1780s).

History of Automation

Industrial revolution accelerated automation. Later,

Michael Faraday, 1831 design the electric motors and

Barsanti and Matteucci, 1854 introduced internal

combustion engines.

Manufacturing became more productive with these new

automated machines.

History of Automation

Triode (vacuum tube) was invented in 1906, as the key

component for radio, telephone, radar, and television. It is

also helped in development of early computer systems.

Transistor (invented in 1947) had replaced triode as the

main electronic device, less power and a lot more smaller

in size.

History of Automation

Integrated circuits (invented in 1958), combines large

number of tiny transistors into a small chip, that

consequently increased electronic circuit performance and

reduced cost enormously.

Technology of IC has laid the path for the introduction of

the first microprocessor (Intel 4004, in 1971), which

integrates all the functions of a central processing unit

(CPU) of a computer.

History of Automation

The new technologies have allowed the introduction of

advance automatic control systems, with complicated

control functions and faster execution of calculations.

In general, automation has becomes part of our life.

Throughout the history, automation has changed the way

we are doing our work.

Purpose of Automation System

Improvement of Quality

Quality of work/service

Quality of product

Improvement of Quantity

Quantity of work/service

Quantity of product

Application and Implementation Automation system can be found everywhere..????

Banking system

-Auto teller Machine, cash deposit etc..

-Internet banking

Retailing

Fast food outlets Ordering and payment

Food serving robot, conveyor system

Online shopping ordering and payment

Tourism

Hotel booking, flight booking, car rental etc

Transportation

- Auto cruise system

- Navigation system

Application and ImplementationTraffic control

-Air traffic

-Ground traffic Traffic light, AES etc..

Home automation

- Electrical appliances

- Smart home

Military

- Radar system

- Missile control

- UAV, UUV

Agriculture

- Plant irrigation

- Animal feeder

- Fruit plucking

Industrial automation

- Raw material /unfinished product to finished product

Automation System

Element of Automation System

Power

Program of Instruction Control System Process

Automation System consist of three basic elements: Power to accomplish

the process and operate the system, a program of instruction to direct the

process, and a control system to actuate the instruction

Automation System

Power Element

An automated system is used to operate some process, and

power is required to drive the process as well as the

controls.

Main power source is electrical where it can be obtained

with reasonable cost.

The electrical power also is readily converted to alternative

power energy such as mechanical, thermal, light, acoustic,

hydraulic and pneumatic.

Can be used to power up low power equipments, e.g

computer, data transmission system..etc.

Easy to store and available at any locations (long-life

batteries).

Automation System Power for the process

Process in automation system refers to manufacturing operation.

The power form that is applied directly to the process normally

converted from electrical form.

Example of action in the process that required power

Loading and unloading the product,

Product transport between operations

Example:

Automated

bottle making

process

Automation System Power for Automation

Other than the basic power requirements for the process.

Use to power up the sensors, control unit, actuate the control signals,

data acquisition and processing.

Automation System

Program of Instruction

The action performed by automated process are defined by a program

of instructions.

Each part or product made in the operation requires one or more

processing steps that are unique to that particular part or product.

The particular processing steps for the work cycle are specified in a

work cycle program.

The work cycle can be a single process or combination of multiple

process.

Automation System

Program of Instruction

Example (process),

Consider an automated turning operation in which a cone-shaped

geometry is generated. Assume the system is automated and that a robot

is used to load and unload the work unit. The work cycle consists of the

following steps: (1) Load starting workpiece, (2) position cutting tool

prior to turning, (3) turn, (4) reposition tool to a safe location at end of

turning, and (5) unload finished workpiece. Identify the activity (ies)

and process parameter(s) in each step of the operation.

Automation System

Program of Instruction

Example (Solution),

Step (1): The robot manipulator reaching for the raw workpart, lifting and positioning the part

into the chuck jaws of the lathe, then removing the manipulator to a safe position to await

unloading. The process parameters are the axis values of the robot manipulator (which is

change continuously), the gripper value (open or close), and the chuck jaw value (open or

close).

Step (2): Movement of the cutting tool to a ready position. The process parameters are the x-

and z- axis position of the tool.

Step (3) Requires the simultaneous control of three process parameters: rotational speed of the

workpiece (rev/min), feed (mm/rev), radial distance of the cutting tool from the axis of rotation.

To cut the conical shape, radial distance must be changed continuously at a constant rate for

each revolution of the workpiece. For a consistent finish on the surface, the rotation speed must

be continuously adjusted to maintain a constant surface speed (m/min); and for equal feed

marks in the surface, the feed must be set at a constant value. Depending on the angle of the

cone, multiple turning passes may be required to gradually generate the desired contour. Each

pass represents an additional step in the sequence.

Step (4) & (5) involve the reverse activities as steps (2) and (1), respectively, and the process

parameters are the same.

Automation System

Program of Instruction

At the early version of operations, the work cycles were

controlled by hardware components, such as limit switches,

timers, cams, and electromechanical relays.

There are advantages using these hardware components:

(1) Required considerable time to design and fabricate, thus

forcing the production equipment to be used for batch

production only (2) Making even minor changes in the

program was difficult and time consuming; and (3) the

program was in a physical form that is not readily

compatible with computer data processing and

communication.

Automation System

Program of Instruction

Modern controllers used in automated systems are based on

digital computers. The programs for computer controlled

equipment are contained in magnetic tape, diskettes,

compact disks (CD-ROMs), computer memory and other

modern storage devices.

Thus, the work cycle may include manual steps, where the

operator performs certain activities and the automated

system performs the rest.

Automation System

Program of Instruction

Decision making in the Programmed Work Cycle

Many automated manufacturing operations require decisions to be made during

the programmed work cycle to cope with variations in the cycle. In many cases,

the variations are routine elements of the cycle that include:

Operator interaction.

Different part or product styles processed by the system.

Variation in the starting work unit.

The program can be designed to respond to sensor or operator inputs by

executing the appropriate subroutine corresponding to the input.

In other cases, the variations in the work cycle are nor routine at all such as

failure of an equipment. Thus, the program must include contingency

procedures or modifications in the sequence to cope with conditions that lie

outside the normal routine.

Automation System

Control System

The control element of the automated system executes the program

instructions. The control system causes the process to accomplish its defined

function, which for our purpose is to carry out some manufacturing operation.

The controls can be either closed loop or open loop. A closed loop control

system, also known as a feedback control system, is one in which the output

variable is compared with an input parameter, and any difference between the

two is used to drive the output into agreement with the input.

Controller

Feedback

Actuator Processinput Output

Closed loop control system

Automation System

Control System

Open loop control system operates without the feedback loop, so no

comparison is made between the actual value of the output variable and the

desired input parameter. The controller relies on an accurate model of the effect

of its actuator on the process variable.

Controller Actuator Processinput Output

Open loop control system

Automation System

Control System

A (one axis) positioning system consisting of a lead

screw driven by a dc servo

A (one axis) positioning system consisting of a lead

screw driven by a stepper motor

Example

Reason for automating

Increase labor productivity

Reduce labor cost

Mitigate the effects of labor shortages

Reduce or eliminate routine manual and clerical tasks

Improve worker safety

Improve product quality

Reduce manufacturing lead time

Accomplish processes that cannot be done manually

Reduce unit cost

Source: encyclopedia britanica

Advantages and Disadvantages

Advantages and Disadvantages

Reason for not automating

Task is too technologically difficult to automate

Short product life cycle

Customized product one-of-a-kind

Flexibility in coping with changing demand

Source: encyclopedia britanica