INTRODUCTION TO AUTOMATION

Automation system is the system effectiveness or devices to operate wisely, without or under minimal human

monitoring level. Automation including 3 steps that is input ( sensor, keyboard, cd drive, tape) processing (PLC, CPU,

software, relay, valve ) and output (actuator, monitor, AC/DC motor, servo, solenoid and valve)

HISTORY

1. MANUAL ULANG ALIK 2.PENJENTERAAN 3. AUTOMATION

3 INTELIGENT CONVEYOR SYSTEM (AUTOMATION)

INPUT PROCESSING OUTPUT

MANUAL

REPETATIVE MECHANIZATION AUTOMATION

MANUAL REPETATIVE Kerja yang sama diulangi dengan

menggunakan kekuatan fizikal dengan sdikit alat atau

tanpa alat.

PENJENTERAAN Mesin digunakan tapi tenaga manusia

masih diperlukan utk menyiapkan kerja cth mesin

pengisi memuatkan beras kedalam guni, tali sawat bg

memudahkan kerja

AUTOMASI : sistem kawalan, mesin, proses, minimum 1 org pekerja

KAWALAN AUTOMASI : plc, microcontroller, relay, pid (depend on cost, kesesuaian)

Why we needs automation

1. to improve quality of the product and keeping quality consistency

2. to improve the quantity of the production line.

3. To reducing the manpower support.

Which area that needs the automation system;

1. Assembly Line (Talian pemasangan)

2. Pengujian dan Pengemasan Bungkusan (Packaging)

3. Hazard and Dangerous Zone

4. High speed and precision process, computer integrated machine (CIM)

THE ADVANTAGES OF AUTOMATION

i) Reducing the labour cost

ii) Improving the eff. In term of quality and quantity

iii) Flexibility in market demand in term of product changes and rearrangement of the manuf. Process

iv) Reliability : Duration of the process could be constantly operated by keeping the product quality.

v) Repeatability : the output can be scheduled and controlled

vi) Safe : To minimize and avoiding the human from contact with high risk / hazard area

vii) Labor shortage problem solving

AUTOMASI : tenaga manusia digantikan dgn mesin yg

dikawal oleh pengawal utk menghasilkan sesuatu

produk. Manusia hnya mengawal pada sistem kawalan

dn akan mengurangkn buruh di pasaran.

ADVANTAGES IN PROCESS FROM GRAPHICAL GIVE US; Automatically rice packaging, constant in amount for 1 packet of rice. Intelligent distribute system using in make whether to accept or reject the rice quality Robot Arm is using in goods handling and placing.

Definition of Industrial Automation

Automation is basically the delegation of human control function to technical equipments for

1) Increasing Productivity

2) Increasing Quality

3) Reducing Cost

4) Increasing Safety in working conditions.

Industrial automation is the use of robotic devices to complete manufacturing tasks. In this day and age of

computers, industrial automation is becoming increasingly important in the manufacturing process because

computerized or robotic machines are capable of handling repetitive tasks quickly and efficiently. Machines used

in industrial automation are also capable of completing tasks that are not desirable to workers. In addition, the

company can save money because it does not need to pay for expensive benefits for this specialized machinery. There

are both pros and cons for a company when it comes to industrial automation. On the plus side, with soaring

healthcare costs, paid days off, vacation time, and other costly employee benefits, companies can save money

with industrial automation. While robotic machinery can initially be extremely expensive, the loss of monthly wages

for production workers leads to incredible savings for the company. While machinery used

for industrial automation can break down, it does not happen often. If it does, only a handful of maintenance or

computer engineers are needed to handle repairs and get lines running smoothly again.

Advantages and disadvantages of Automation

Advantage of automation Disadvantages of automation

Replacing human operators in tasks that

involve hard physical or monotonous

work.

Technology limits. Current technology is unable to automate all

the desired tasks.

Replacing humans in tasks that should

be done in dangerous environments (i.e.

fire, space, volcanoes, nuclear facilities,

underwater, etc)

Unpredictable development costs. The research and

development cost of automating a process is difficult to predict

accurately beforehand. Since this cost can have a large impact

on profitability, it's possible to finish automating a process only

to discover that there's no economic advantage in doing so.

Making tasks that are beyond the

human capabilities such as handling

too heavy loads, too large objects, too

Initial costs are relatively high. The automation of a new

product required a huge initial investment in comparison with

the unit cost of the product, although the cost of automation

hot or too cold substances or the

requirement to make things too fast or

too slow

is spread in many product batches. The automation of a plant

required a great initial investment too, although this cost is

spread in the products to be produced.

AUTOMATION IN PRODUCTION SYSTEMS

Some elements of the production systems are likely to be automated,where as the others will be operated manually

or clerically. For ourpurposes here, automation can be defined as a technology concernedwith the application of

mechanical, electronic and computer basedsystems to operate and control production.In modern production systems,

the two categories overlap to someextent, because the automated manufacturing systems operating on thefactory

floor are themselves often implemented by computer systems andconnected to the computerized manufacturing

support systems andmanagement information system operating at the plant and enterpriselevels. The term computer

integrated manufacturing is used to indicatethis extensive use of computers in production systems

ARM ROBOTS

Joint action

Joint action any productive way in which multiple active resources participate in accomplishing a single function,

including coordination, collaboration, cooperation, unwitting assistance, witting non-interference, and even

competition. The critical factor is that the interaction among the resources acting jointly involves some

communication on the part of each participating actor, and the joint action accomplishes some part of a function of

the larger system.

Reliability

The reliability concern is: What are the business requirements for the system to be up and running, and can the

integrated system meet those requirements? The requirements for the system to be up and running relate to the

requirements for support of the business process, typically in terms of availability, timeliness, continuity, and

maintenance of state.

Degree Of Fredom

Degree of freedom (DOF) of a mechanical system is the number of independent parameters that define its

configuration. It is the number of parameters that determine the state of a physical system and is important to the

analysis of systems of bodies in mechanical engineering, aeronautical engineering, robotics, and structural

engineering.

The position of a single car (engine) moving along a track has one degree of freedom, because the position of the car is

defined by the distance along the track. A train of rigid cars connected by hinges to an engine still has only one degree

of freedom because the positions of the cars behind the engine are constrained by the shape of the track.

An automobile with highly stiff suspension can be considered to be a rigid body traveling on a plane (a flat, two-

dimensional space). This body has three independent degrees of freedom consisting of two components of translation

and one angle of rotation. Skidding or drifting is a good example of an automobile's three independent degrees of

freedom.

Link And Joint

Arotational joint (R) is identified by its motion, rotation about an exis perpendicular to the adjoint links. Here the

length of adjoint links to do not change but the relative position of the link with respect to one another changes as the

rotation takes places

Links and Joints

In a robot, the connection of different manipulator joints is known as Robot Links, and the integration of two or more

link is called as Robot Joints. A robot link will be in the form of solid material, and it can be classified into two key types

– input link and output link. The movement of the input link allows the output link to move at various motions. An

input link will be located nearer to the base.

There are five major types of joints such as:

Rotational Joint:

Rotational joint can also be represented as R – Joint. This type will allow the joints to move in arotary motion along the

axis, which is vertical to the arm axes.

Linear Joint:

Linear joint can be indicated by the letter L – Joint. This type of joints can perform both translational and sliding

movements. These motions will be attained by several ways such as telescoping mechanism and piston. The two links

should be in parallel axes for achieving the linear movement.

Twisting Joint:

Twisting joint will be referred as V – Joint. This joint makes twisting motion among the output and input link. During

this process, the output link axis will be vertical to the rotational axis. The output link rotates in relation to the input

link.

Orthogonal Joint:The O – joint is a symbol that is denoted for the orthogonal joint. This joint is somewhat similar to

the linear joint. The only difference is that the output and input links will be moving at the right angles.

Revolving Joint:

Revolving joint is generally known as V – Joint. Here, the output link axis is perpendicular to the rotational axis, and the

input link is parallel to the rotational axes. As like twisting joint, the output link spins about the input link.

GRIPPERS

Grippers are not only required for use with industrial robots: they are a universal component in automation. Grippers

operate with:

Industrial robots (handling and manipulation of objects).

-assembling, machining, and packaging).

-guided manipulators (remote prehension, medical, aerospace, nautical)

-carrying equipment).

Possibilities for prehension of a spherical object. (1) pure enclosing without clamping, (2) partial form fit combine with

clamping force, (3) pure force closure, (4) holding with vacuum air (pneumatic force closure), (5) retention using

magnetic field (force field), (6) retention using adhensive media.

Types of grippers used in industrial robot applications include the following:

• mechanical grippers, consisting of two or more fingers that can be actuated by the robot controller to open and dose

to grasp the workpart; Figure 3.63 shows a two finger gripper

• vacuum grippers, in which suction cups are used to hold flat objects

• magnetized devices, for holding ferrous parts

• adhesive devices, where an adhesive substance is used to hold a flexible material such as a fabric

• simple mechanical devices such as hooks and scoops.

SENSOR

General Characteristics of sensor

Sensor is a device that when exposed to a physical phenomenon (temperature, displacement, force, etc.) produces a

proportional output signal (electrical, mechanical, magnetic, etc.). The term transducer is often used synonymously

with sensors. However, ideally, a sensor is a device that responds to a change in the physical phenomenon.

Sensors are transducers when they sense one form of energy input and output in a different form of energy. For

example, a thermocouple responds to a temperature change (thermal energy) and outputs a proportional change in

electromotive force (electrical energy). Therefore, a thermocouple can be called a sensor and or transducer.

Figurer 5.1: A typical control system

Furthermore, sensors are classified as analog or digital based on the type of output signal. Analog sensors produce

continuous signals that are proportional to the sensed parameter and typically require analog-to-digital conversion

before feeding to the digital controller. Digital sensors on the other hand produce digital outputs that can be directly

interfaced with the digital controller. Often, the digital outputs are produced by adding an analog-to-digital converter

to the sensing unit. If many sensors are required, it is more economical to choose simple analog sensors and interface

them to the digital controller equipped with a multi-channel analog-to-digital converter.

STEPPER MOTOR

DESCRIBE THE THEORY:

Stepper motors consist of a permanent magnetic rotating shaft, called the rotor, and electromagnets on the stationary

portion that surrounds the motor, called the stator. Figure 1 illustrates one complete rotation of a stepper motor. At

position 1, we can see that the rotor is beginning at the upper electromagnet, which is currently active (has voltage

applied to it). To move the rotor clockwise (CW), the upper electromagnet is deactivated and the right electromagnet

is activated, causing the rotor to move 90 degrees CW, aligning itself with the active magnet. This process is repeated

in the same manner at the south and west electromagnets until we once again reach the starting position

Figure 1

In the above example, we used a motor with a resolution of 90 degrees or demonstration purposes. In reality, this

would not be a very practical motor for most applications. The average stepper motor's resolution -- the amount of

degrees rotated per pulse -- is much higher than this. For example, a motor with a resolution of 5 degrees would move

its rotor 5 degrees per step, thereby requiring 72 pulses (steps) to complete a full 360 degree rotation.

Figure 2

We may double the resolution of some motors by a process known as "half-stepping". Instead of switching the next

electromagnet in the rotation on one at a time, with half stepping you turn on both electromagnets, causing an equal

attraction between, thereby doubling the resolution. As you can see in Figure 2, in the first position only the upper

electromagnet is active, and the rotor is drawn completely to it. In position 2, both the top and right electromagnets

are active, causing the rotor to position itself between the two active poles. Finally, in position 3, the top magnet is

deactivated and the rotor is drawn all the way right. This process can then be repeated for the entire rotation.

THEORY :

Stepper motors have smooth armatures and include a permanent magnet core that is magnetized widthwise or

perpendicular to its rotation axis. These motors usually have two independent windings, with or without center taps.

The most common step angles for PM motors are 45° and 90°, but motors with step angles as fine as 1.8°per step as

well as 7.5, 15, and 30° per step are generally available. Armature rotation occurs when the stator poles are

alternately energized and de-energized to create torque. A 90° stepper has four poles and a 45° stepper has eight

poles, and these poles must be energized in sequence. Permanent -magnet steppers step at relatively low rates, but

they can produce high torques and they offer very good damping characteristics.

Stepper motors are controlled directly. The primary command and control variable is the step position. This is in

contrast to d.c motors where the control variable is the motor voltage and the command variable may be either

position or velocity. A d.c motor requires a feedback control system and controls the position indirectly. A stepper

motor system is normally operated “open loop”.

REFER TO THE PICTURE BELOW AND BY USING ALL YOUR KNOWLEDGE AND SOURCE, GIVE AN EXPLANATION TO

DESCRIBE THE THEORY AND ITS FUNCTION IN OUR INDUSTRY TODAY..

Penjelasan kepada huraikan teori

Motor stepper menyediakan satu cara untuk kedudukan terperinci dan kawalan kelajuan tanpa menggunakan sensor

maklum balas. Operasi asas motor stepper membolehkan aci bergerak jumlah yang tepat dari darjah setiap kali satu

denyutan elektrik dihantar kepada motor. Oleh kerana aci motor bergerak hanya beberapa darjah yang ia direka untuk

apabila setiap nadi dihantar, anda boleh mengawal denyutan yang dihantar dan mengawal kedudukan dan kelajuan.

Pemutar motor menghasilkan tork daripada interaksi antara medan magnet di pemegun dan pemutar. Kekuatan

medan magnet adalah berkadar dengan jumlah arus dihantar ke pemegun dan bilangan lilitan pada belitan. Motor

pelangkah menggunakan teori beroperasi magnet untuk membuat aci motor bertukar jarak yang terperinci apabila

satu denyutan elektrik disediakan. Rajah 1 menunjukkan pandangan tipikal keratan rentas pemutar dan pemegun

motor stepper. Daripada rajah ini anda dapat melihat bahawa pemegun (pegun penggulungan) mempunyai lapan

tiang, dan pemutar mempunyai enam tiang (tiga magnet lengkap). Pemutar akan memerlukan 24 denyutan elektrik

untuk menggerakkan 24 langkah-langkah untuk membuat satu putaran lengkap. Satu lagi cara untuk mengatakan ini

adalah bahawa pemutar akan bergerak tepat 15 ° untuk setiap nadi elektrik motor menerima. Bilangan darjah

pemutar akan bertukar apabila satu denyutan elektrik dihantar ke motor boleh dikira dengan membahagikan bilangan

darjah dalam satu putaran aci (360 °) dengan jumlah kutub (utara dan selatan) di pemutar . Dalam motor stepper ini

360 ° dibahagikan dengan 24 untuk mendapatkan 15 °.

Apabila tiada kuasa dibekalkan kepada motor, baki kemagnetan dalam magnet pemutar akan menyebabkan pemutar

untuk menahan atau menyelaraskan satu set kutub magnet dengan kutub magnet salah satu magnet pemegun. Ini

bermakna bahawa pemutar akan mempunyai 24 kedudukan penahan. Apabila pemutar adalah dalam kedudukan

Penahan, ia akan mempunyai cukup tenaga magnet untuk menjaga aci daripada bergerak ke kedudukan seterusnya.

Inilah yang membuat pemutar merasa seperti ia menekan dari satu kedudukan ke depan kerana anda memutar

pemutar dengan tangan tanpa kuasa digunakan.

Fungsi dalam industri hari ini

Motor stepper telah menjadi komponen penting untuk aplikasi dalam pelbagai industri yang berbeza. Yang berikut

adalah senarai industri menggunakan motor stepper:

Pesawat - Dalam industri pesawat, motor pelangkah digunakan dalam instrumentasi pesawat, antena dan

penderiaan aplikasi dan peralatan pengimbasan

Automotif - Industri automotif melaksanakan motor pelangkah untuk aplikasi berkaitan kawalan pelayaran,

peranti penderiaan, dan kamera. Pihak tentera juga menggunakan motor stepper dalam pemakaiannya

antena kedudukan

Kimia - Industri kimia menggunakan motor stepper untuk dicampur dan persampelan bahan. Mereka juga

menggunakan pengawal motor stepper dengan motor stepper tunggal dan multi-paksi untuk ujian peralatan

Elektronik Pengguna dan Peralatan Pejabat - Di dalam industri elektronik pengguna, motor pelangkah

digunakan secara meluas dalam kamera digital untuk fokus dan fungsi zoom ciri. Dalam peralatan pejabat,

motor pelangkah dilaksanakan dalam peralatan imbasan berasaskan PC, pemacu storan data, pemacu cakera

optik memandu mekanisme, pencetak, pengimbas dan

Permainan - Dalam industri permainan, motor pelangkah digunakan secara meluas dalam aplikasi seperti slot

dan mesin loteri, pemintal roda, dan walaupun shufflers kad

Industri - Di dalam industri perindustrian, motor pelangkah digunakan dalam tolok automotif, mesin alat

dengan tunggal dan multi-paksi stepper motor pengawal, dan kit retrofit yang menggunakan pengawal motor

pelangkah juga. Motor stepper juga boleh didapati dalam kawalan mesin CNC

Perubatan - Dalam industri perubatan, motor pelangkah digunakan dalam pengimbas perubatan, kawalan

gerakan mikroskopik atau nanoscopic peranti automatik, pendispensan pam, dan alat kromatografi automatik

penyuntik. Motor stepper juga ditemui di dalam fotografi digital pergigian (X-RAY), pam cecair, alat

pernafasan, dan analisis jentera darah, centrifuge

Peralatan Saintifik Instrumen -Scientific melaksanakan motor stepper dalam kedudukan sebuah balai cerap

teleskop, spectrographs, dan centrifuge

Sistem Pengawasan - motor stepper digunakan dalam pengawasan kamera

FUNCTION IN INDUSTRY :

Used in automotive applications for electronic throttle control, dashboard indicators, and climate control

systems.

Also found in industrial equipment such as robotics, electronic component handlers, testers, dispensers and

other manufacturing equipment.

Stepper motors are often controlled using special function ICs that provide limited control functionally.

FUNCTION:

Motors convert electrical energy into mechanical energy. A stepper motor converts electrical pulses into specific

rotational movements. The movement created by each pulse is precise and repeatable, which is why stepper motors

are so effective for positioning applications.