AUTOMATION:

A Technology by which a process is performed without human assistance is

called Automation. Sometimes, human may present as observers or even
participant. But the process itself operates under its own self direction. It is
implemented by means of a control system that executes a program of
instruction.

To automate a process, power is required both to drive the process itself & to
operate the program & control system.

Three Components or elements of an automated system:-

1) Power:
Electric power is used in most automated system.
Advantages of electric power system are:-
a) Electric power is widely available.
b) Readily converted to other form of power such as mechanical, thermal
etc.
c) It can be stored in long life batteries.
Other power sources are solar energy, wind, water, fossil fuels etc.
(sometimes, electric power & alternative power are used together in
 automation). E.g- Laser beam machining (Light & thermal energy are
used as power sources) - A high coherent light beam is used to
remove the material by melting & vaporization.

2) Program of Instruction:
The activities in an automated process are defined by a program of
instructions.

3) Control system:
The program of Instructions is executed by a control system.
Two types of control system can be distinguished as
a) Closed Loop (Feedback control system)
b) Open loop control system.

Closed loop:-
Closed loop control system is also known as feedback control system is
one in which the process variable of interest (output of process) is
compared with the corresponding process parameter(Input of the
process) & any differences between them is used to drive the output
value into agreement with input.
 Open loop:-
It executes the program of instructions without a feedback loop. No
measurement of the output variable is made, so there is no comparison
between output & input in this control system.

ADVANTAGES:

1) Improve productivity.
2) Improve accuracy & precision of the products, less human error.
3) Improve quality of product.
4) Reduce direct human labor costs.
5) Replace human in works done in dangerous environment.
6) Reduce operation time or increase safety.

DISADVANTAGES:

1) An automated system may have a limited level of intelligence or less

versatile.
2) Initial cost is high.
3) Unpredictable costs.

TYPES OF AUTOMATION:

1. Fixed or Rigid automation

 It is also called hard automation which refers to the use of special
purpose equipment to automate a fixed sequence of processing or
assembly operations. each of the operation in the sequence is usually
simple, involving perhaps a plain linear or rotational motion or an
uncomplicated combination of two. it is relatively difficult to
accommodate changes in the product design. this is called hard
automation.
Advantages:-
 Low unit cost
 Automated material handling
 High production rate

Disadvantages:-

 High initial investment

 Relatively inflexible in accommodating product changes.

2. Programmable automation
In this automation the product equipment is designed with the capability
to change the sequence of operations to accommodate different product
configurations. The operation sequence is controlled by a program, which
is a set of instructions coded. So, that they can be read and interpreted
by the system. New program can be prepared & entered into the
equipment to produce new product.
Advantages:-
 Flexible to deal with design variations.
 Suitable for batch production.

Disadvantages:-

 High initial investment & general purpose equipment

  Lower production rate than fixed or rigid automation.

3. Flexible or Soft Automation

It is an extension of programmable automation. It provides the automatic
control equipment with the flexibility to change the product design.
These changes can be performed quickly through the commands given in
the form of codes to various machines by technicians. It lets
manufacturers turn out several product on the same production line.
Some example of this type automation equipment includes automatic
guided vehicles & multipurpose CNC Machines.
Advantages:-
 Continuous production of variable mixtures of product.
 Flexible to deal with product design variation.

Disadvantages:-

 Medium production rate

 High investment.
 High initial cost relative to fixed automation.
Reasons for automation (WHY AUTOMATION?):

 Shortage of labour.
 High cost of labour.
 Increase productivity- higher production output per hour of labour input
is possible with automation.
 Competition- ultimate goal of company is to increase profits. Automation
may result in lower prices, superior products, beta labour relations and a
better Company image.
 Safety- welding, spray painting and other operations can be health
hazards.
 Lower costs- it may increase the scrap rate and reduce the cost of raw
materials.