SRI KRISHNA COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHATRONICS ENGINEERING

MODULE 2
Session: Manufacturing Automation

1/5/2020 17MT320 Computer Integrated Manufacturing 1

SESSION OBJECTIVES

❑ On the completion of this session, the students might be

able to understand,
▪ What is automation?

▪ Automation types

1/5/2020 17MT320 Computer Integrated Manufacturing 2

Topics

❑ Automation introduction

❑ Types of Automation Systems

❑ Pneumatic

❑ Hydraulic

❑ Automation using PLC’s

1/5/2020 17MT320 Computer Integrated Manufacturing 3

Introduction
❑ Major developments that led to CIM was the introduction of computer
control of manufacturing equipment and operations
❑ Manufacturing automation was mainly through the so-called hard
automation through hydraulic, pneumatic or electric methods
❑ Automation involves not only carrying out the manufacturing process
without human intervention but also many connected operations like
stock feeding, proper sequencing, etc.

Manufacturing
Mechanization
automation

Providing human Complete automation of

operators with machines the process
to assist them

1/5/2020 17MT320 Computer Integrated Manufacturing 4

Introduction
❑ Examples of automated manufacturing systems:

Automated machine Automated transfer Automated

tools lines assembly systems

Automated Automated material

inspection handling and storage
1/5/2020 17MT320 Computer Integrated Manufacturing 5
Reasons for automation
Increase productivity
Labor
Reduce cost
Mitigate effects of shortages

Eliminate routine and clerical tasks

Task
Processes that cannot be done manually

Product Improve quality

and
Reduce lead time
Process
Reduce cost

Improve worker safety

Safety
Product and process safety
1/5/2020 17MT320 Computer Integrated Manufacturing 6
Categories of automation

Manufacturing Potential
support computerization
systems applications
Production
CIM
System
Potential
Facilities:
automation
Equipments
applications

1/5/2020 17MT320 Computer Integrated Manufacturing 7

Types of automation based on variety and quantity

Programmable
• Capability to change
• High investment
• Flexibility
• Lower production rates
•
Product Variety

High suitability for batch Flexible

production • High cost for custom FMS for various
NC machines, systems processes
industrial robots and • Variable products
PLC’s • Medium production
rates Fixed
• Flexibility to deal with
• Fixed by equipment
variations
• High initial
investment
• High production
Assembly lines and
rates
transfer lines
• Inflexibility
100 10000 1000000
Production Quantity
1/5/2020 17MT320 Computer Integrated Manufacturing 8
Principle of automation – USA principle
❑ Article by American Production and Inventory Control Society

nderstand the existing process

❖Inputs
❖Outputs
❖Raw materials implify the process

❖Machines ❖Processes

❖Process times ❖Purpose

❖Simplify or eliminate utomate the process
or combine ❖Ten strategies of

❖Manual or automation

simultaneous

1/5/2020 17MT320 Computer Integrated Manufacturing 9

Strategies of Automation

Specialization of
1 operations
Use of special purpose machines

Combined Reduce the number of distinct

2 operations production machines or workstations

Simultaneous Two or more operations performed

3 operations simultaneously in one machine

Linking several workstations

Integration of
4 together in a single integrated
operations
mechanism

1/5/2020 17MT320 Computer Integrated Manufacturing 10

Strategies of Automation
Maximum utilization of equipment for job shop and
Increased
5 flexibility medium volume stations by using same equipment

Improved material Reduce non productive time by use of

6 handling and storage
automated material handling system

On line Integrating inspection inside the

7 inspection
manufacturing process

Control schemes intended to

Process control
8 and optimization operate the individual processes
and associated equipment

1/5/2020 17MT320 Computer Integrated Manufacturing 11

Strategies of Automation

Plant operations
9 control Control schemes at the plant level

Integration of factory operations with

10 CIM engineering design and management
functions

1/5/2020 17MT320 Computer Integrated Manufacturing 12

Automation migration strategy
P1 Manual Manual Manual
Workstation handling Inspection

I/P O/P

P2
Automated Manual Manual Automated
Workstation handling handling inspection

I/P O/P

1/5/2020 17MT320 Computer Integrated Manufacturing 13

Automation migration strategy
P3

Automated
Transfer lines
I/P O/P

Automated Automated Automated

Workstation Workstation Workstation

1/5/2020 17MT320 Computer Integrated Manufacturing 14

Elements of automation
❑ Three basic elements:
❑ Power to accomplish the process
❑ Program of instructions to direct the process
❑ Control system to actuate the instructions

Power

Program of Control
Process
instructions system

1/5/2020 17MT320 Computer Integrated Manufacturing 15

Power to accomplish the process
❑ Electrical power, fossil fuels, solar energy, water and wind

Power

For the process For automation

❑ Also for loading and unloading work unit ❑ Controller unit
❑ Material transport ❑ Power to actuate the control
signals
❑ Data acquisition and information
processing

1/5/2020 17MT320 Computer Integrated Manufacturing 16

Program of instructions
❑ Actions performed by an automated process are defined by instructions
❑ Process specific steps are called as work cycle program (part program
in NC) Program

Work cycle Decision making

❑ Single or multiple steps ❑ Automated process requires
❑ Typical sequence : load–perform- decision to be made
unload ❑ Features: No of steps, manual
❑ Process parameters as inputs participation and interaction,
❑ Process variables are outputs process parameters, variations
❑ Features: no and sequence of in part or starting work units
operations, process parameter changes

1/5/2020 17MT320 Computer Integrated Manufacturing 17

Control system
❑ Control system executes the program of instructions
❑ Closed loop or open loop

Input Output
Controller Actuator Process
parameter variable
Feedback
sensor

Input Output
Controller Actuator Process
parameter variable

1/5/2020 17MT320 Computer Integrated Manufacturing 18

Advanced automation functions
Advanced automation

Safety Maintenance & Error detection and

monitoring Repair diagnostics recovery
❑ Design to operate safely ❑ Status monitoring – ❑ Deviation or malfunction
❑ Use of sensors information about current detection
❑ Complete stop, alarm, failure and data to predict ❑ Random errors,
reducing speed or future failure systematic errors and
corrective action ❑ Failure diagnostics aberrations
❑ Limit switches, photelectric ❑ Recommendation of repair ❑ Anticipate all the
sensors, heat or smoke procedure possible errors and
detectors, machine vision ❑ Identify signs of failure specify the appropriate
systems, etc., sensor systems

1/5/2020 17MT320 Computer Integrated Manufacturing 19

Levels of automation

Enterprise Corporate
⑤
level information system

④ Plant level Production system

Manufacturing
Cell or
③ system – groups of
system level
machines

Machine
② Individual machines
level

① Device level Sensors, actuators

1/5/2020 17MT320 Computer Integrated Manufacturing 20

Automation systems and Equipment
Automation systems can be classified into three major types:
i. Pneumatic automation
ii. Hydraulic automation
iii. Automation systems using programmable logic controllers

Pneumatics Hydraulic
▪ Handle higher loads and torques
▪ Low cost
▪ Pressure range from 35MPa to
▪ For clamping, cleaning, etc.
200MPa
▪ Air motors and cylinders
▪ Require a power pack
▪ DCV’s to control direction
▪ Cylinders, rotatory actuators,
pumps and valves

1/5/2020 17MT320 Computer Integrated Manufacturing 21

Automation using PLC
Industrial control circuits are designed to serve below functions:

Switching Sequencing Process control

▪ ON/OFF ▪ Operations ▪ A PLC may be used

▪ Basic actuators like performed in a to control a process
cylinders, electric particular order on the basis of
motors, pneumatic ▪ Eg: Cylinder signals received
valves, etc. sequencing ABB-A- from a process.
▪ Eg: Hydraulic ▪ The signals may be
cylinder to actuate analog or digital.
the door of a CNC

1/5/2020 17MT320 Computer Integrated Manufacturing 22

Applications and advantages of PLC
Applications Advantages
(a) Switching functions in a CNC ▪ Flexibility
machine tool like spindle motor ▪ Low cost
on/off, coolant motor on/off, etc. ▪ Speed of operation
(b) Operation of lifts in buildings. ▪ Security
(c) Control of electric motors in ▪ Reprogramming
industrial drives. ▪ Modularity
(d) Transfer machine control. ▪ Analog and digital inputs
(e) Heating control in process ▪ Correction of errors
industries. ▪ Reliability
(f) Control of traffic signals. ▪ Maintainability
(g) Robot control ▪ Offline and Boolean programming
1/5/2020 17MT320 Computer Integrated Manufacturing 23
Parts of a PLC

Programming
Device
ALU, Memory,
Timers and
Counters, Flags
Limit switch
Proximity switch Microproces Coils
Pressure switch I/P O/P Relays
sor Memory
Temperature Actuators
switch, etc.

Power
Supply

1/5/2020 17MT320 Computer Integrated Manufacturing 24

 Operation of PLC
▪ The PLC system software executes the
Field user program.
signals
▪ The usual method of operation of a
I/P Process
Module Image I/P PLC is to scan all the inputs, process
the user program and then scan all
outputs. This is called a scan cycle.
User
Program

Process O/P Field

Image O/P Module controls

1/5/2020 17MT320 Computer Integrated Manufacturing 25

Programming of PLC

Off-line On-line
▪ Programs designed prior to ▪ With direct connection to
operation PLC
▪ Check and detect any ▪ Changes made when the
errors easily PLC is in running mode
▪ Preferred method
Limit Push Relay
ON/OFF Button coil
switch

Supply Neutral
Circuit Diagram

1/5/2020 17MT320 Computer Integrated Manufacturing 26

Factory Level Automation
• Services embedded in integrated architecture Factory Talk

• Simplifies data production, movement and use

• Provides a tag once and it is reused throughout
the system

• Operator interface and supervisory View

Visualization
monitoring
• Faster development and implementation
• Flexibility and lower cost

1/5/2020 17MT320 Computer Integrated Manufacturing 27

Factory Level Automation

• Network infrastructure flow

NetLinx • Seamless flow of information from shop floor to the
enterprise system
• Reduced programming, increased flexibility,
reduction in installation cost and increased
productivity

Logix
• Most effective controller
• Programming through single package

1/5/2020 17MT320 Computer Integrated Manufacturing 28

 END

1/5/2020 17MT320 Computer Integrated Manufacturing 29