SRI KRISHNA COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHATRONICS ENGINEERING

MODULE 2
Session: Manufacturing Automation

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SESSION OBJECTIVES

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

able to understand,
▪ What is automation?

▪ Automation types

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Topics

❑ Automation introduction

❑ Types of Automation Systems

❑ Pneumatic

❑ Hydraulic

❑ Automation using PLC’s

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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

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Introduction
❑ Examples of automated manufacturing systems:

Automated machine Automated transfer Automated

tools lines assembly systems

Automated Automated material

inspection handling and storage
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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
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Categories of automation

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

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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
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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

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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

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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

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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

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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

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Automation migration strategy
P3

Automated
Transfer lines
I/P O/P

Automated Automated Automated

Workstation Workstation Workstation

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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

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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

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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

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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

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Advanced automation functions
Advanced automation

Safety Maintenance & Error detection and

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

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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

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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

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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

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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
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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

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 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

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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

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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

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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

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 END

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