AN INTRODUCTION OF INDUSTRIAL AUTOMATION:

FROM INDUSTRY 1.0 TO 4.0

MG1024
Dr. Xi Vincent Wang
Associate Professor
KTH Royal Institute of Technology, Sweden
About Vincent
• Associate Professor at the IIP Department of Production Engineering，
KTH
• Born in China, PhD in New Zealand, Join KTH in 2013
• Mechanical and Automation Engineering
• Researcher and Project Manager for Multiple EU and National
Research Projects,
• Research Area: Manufacturing Systems, Cyber-Physical Systems,
Robotics, Cloud Manufacturing
Reference Books
• Wang, L. and Wang, X.V., (2018) Cloud-Based Cyber-Physical Systems in
Manufacturing.

• Groover, Mikell (2014). Fundamentals of Modern Manufacturing:

Materials, Processes, and Systems.

• TESTO (2008). Fundamentals of automation technology Technical

book.
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What is automation?
• Greek words ‘Auto’ (self) and ‘Matos’ (moving).

• The use or introduction of automatic equipment, (a device or process

working by itself with little or no direct human control) in a
manufacturing or other process or facility.
• Oxford Dictionary
• The technique of making an apparatus, a process, or a system
operate automatically (having a self-acting or self-regulating
mechanism)
• Merriam-Webster dictionary
• The technology by which a process or procedure is performed
without human assistance.
• Groover, Mikell (2014). Fundamentals of Modern Manufacturing: Materials, Processes, and Systems.

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Why Automation?
ü Higher Productivity
ü Higher Quality
ü Higher Safety in working conditions
ü Shorter Time
ü Lower Cost

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Industrial Automation

Plant Field Instrument Control System

input output
Hardware Software
Control Control

Technical System

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A journey of 4 Industrial Revolutions

Complexity

Time
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Manual automation - Industry 1.0

• All actions are taken by the
operators

WANGXI@KTH.SE Source: https://pixabay.com 8

 What is the enabler of the intelligence in automation?

Plant Field Instrument Control System

input output
Hardware Software
Control Control

Technical System
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Industrial Automation

Plant Field Instrument Control System

input output
Hardware
Control Software Control - Human
-Mechanics
Technical System

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Manual Automation
• Advantage:
• Flexibility of Human

• Drawbacks:
• Likely human errors and consequently its effect on the quality of
final project
• Production, safety, energy consumption, and the usage of raw
material

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Four Industrial Revolutions: Industry 2.0

Complexity

Time
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Hardwired logic control - Industry 2.0

The contactor and relays together with hardware timers and
counters for the desired level of automation

Source: https://wikimedia.org
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 What is the enabler of the intelligence in automation?

Plant Field Instrument Control System

input output
Hardware Software
Control Control

Technical System
2020-11-23

Industrial Automation

Plant Field Instrument Control System

input output
Hardware Control
Software
-Hardwires,
Control
timers, counters
Technical System

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Hardwired logic control

• The contactor and relays together with hardware timers and counters
for the desired level of automation

• Drawbacks:
• Bulky panels,
• Complex wiring
• Longer project time
• Difficult to change
• Difficult maintenance and trouble shooting

Source: https://pixabay.com
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Industry 3.0: PLC

Complexity

Time
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Programmable Logic Controller (PLC) - Industry 3.0

Source: https://wikimedia.org
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 What is the enabler of the intelligence in automation?

Plant Field Instrument Control System

input output
Hardware Software
Control Control

Technical System
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Industrial Automation

Plant Field Instrument Control System

input Hardware output

Control Software Control –
-Micro- program
processors
Technical System

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Programmable Logic Controller (PLC)

• Advantages
• Reduced space
• Energy saving
• Easy maintenance
• Economical
• Good system life and reliability
• High flexibility
• Shorter project time
• Easier storage, archiving and documentation

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Programmable Logic Controller (PLC)

• Disadvantage
• Proprietary PLC devices
• Initial costs are high
• Too much work requires in connecting wires
• Unemployment rate increases?

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The first Robot in the world

• Unimate
• Conceived from a design for a mechanical arm patented in 1954
(granted in 1961) by American inventor George Devol
• Unimate was developed as a result of the foresight and business acumen
of Joseph Engelberger - the Father of Robotics
• By 1961, the Unimate 1900 series became the first mass produced
robotic arm for factory automation

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Unimate 1900 series

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Unimate 1900 series

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Industrial robot in Industry 3.0

• 1973: ABB Robotics (formerly ASEA) introduced
IRB 6, among the world's first commercially
available all electric micro-processor
controlled robot.
• The first two IRB 6 robots were sold to
Magnusson in Sweden for grinding and
polishing pipe bends and were installed in
production in January 1974.

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Industrial robot in Industry 3.0

• In 1973 KUKA Robotics built its first
robot, known as FAMULUS.
• One of the first articulated robots
to have six electromechanically
driven axes.

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Important Parameters of a Robot

• Number of axes – two axes are required to reach any point in a plane;
three axes are required to reach any point in 3D space
• Degrees of freedom –usually the same as the number of axe
• Working envelope – the region of space a robot can reach.

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Important Parameters of a Robot

• Kinematics – the actual arrangement of rigid members and joints in
the robot, which determines the robot's possible motions. Classes of
robot kinematics include articulated, cartesian, parallel and SCARA

Articulated Cartesian Parallel SCARA

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Important Parameters of a Robot

• Carrying capacity or payload – how much weight a robot can lift.
• Speed – how fast the robot can position the end of its arm.
• Acceleration – how quickly an axis can accelerate - changes of
direction.
• Accuracy – how closely a robot can reach a commanded position.
• Repeatability – how well the robot will return to a programmed
position.

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Robot Programing
• Robot Programing
• Tutorial: online Robot programming

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ABB Rapid
• MoveL p10, v1000, fine, tool0;
• MoveL is an instruction that moves the robot linearly (in a straight
line) from its current position to the specified position. • p10
specifies the position that the robot shall move to.
• v1000 specifies that the speed of the robot shall be 1000 mm/s.
• fine specifies that the robot shall go exactly to the specified position
and not cut any corners on its way to the next position.
• tool0 specifies that it is the mounting flange at the tip of the robot
that should move to the specified position.

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ABB Rapid
• MoveC - Moves the robot circularly
MoveC p1, p2, v500, z30, tool2;

• MoveJ - Moves the robot by joint movement

MoveJ p1, vmax, z30, tool2;

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KUKA Robot Language

• LIN POINT1
• LIN POINT2
• LIN: Linear motion.
• CIRC: Circular motion.
• PTP: Point--to--point motion.

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Robot Programing
In English VAL (Unimate robots)
PROGRAM PICKPLACE
Move to P1 (a general safe position) 1. MOVE P1
Move to P2 (an approach to P3) 2. MOVE P2
Move to P3 (a position to pick the object) 3. MOVE P3
Close gripper 4. CLOSEI 0.00
Move to P4 (an approach to P5) 5. MOVE P4
Move to P5 (a position to place the object) 6. MOVE P5
Open gripper 7. OPENI 0.00
Move to P1 and finish 8. MOVE P1
.END

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Robot Programing
In English
Move to P1 (a general safe position)
Move to P2 (an approach to P3)
Move to P3 (a position to pick the object)
Close gripper
Move to P4 (an approach to P5)
Move to P5 (a position to place the object)
Open gripper
Move to P1 and finish
Stäubli VAL3
begin
movej(p1,tGripper,mNomSpeed)
movej(appro(p3,trAppro),tGripper,mNomSpeed)
movel(p3,tGripper,mNomSpeed)
close(tGripper)
movej(appro(p5,trAppro),tGripper,mNomSpeed)
movel(p5,tGripper,mNomSpeed)
open(tGripper)
movej(p1,tGripper,mNomSpeed)
end

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Robot Programing
In English trAppro - Epson RC+
Function PickPlace
Move to P1 (a general safe position) Jump P1
Move to P2 (an approach to P3) Jump P2
Move to P3 (a position to pick the object) Jump P3
Close gripper On vacuum
Wait .1
Move to P4 (an approach to P5) Jump P4
Move to P5 (a position to place the object) Jump P5
Open gripper Off vacuum
Wait .1
Move to P1 and finish Jump P1
Fend

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Robot Programing
In English ROBOFORTH (a language based on FORTH).
: PICKPLACE
Move to P1 (a general safe position) P1
Move to P2 (an approach to P3) (Approach positions P2 specified before)
Move to P3 (a position to pick the object) P3 GRIP WITHDRAW
Close gripper

Move to P4 (an approach to P5) (Approach positions P4 specified before)

Move to P5 (a position to place the object) P5 UNGRIP WITHDRAW
Open gripper P1
;
Move to P1 and finish

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Robot Programing
• Robot Programing
• Tutorial: online Robot programming

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robotbenchmark
• https://robotbenchmark.net/
• Co-Funded by EU Human Brain Project
• Lead by Cyberbotics Ltd, Switzerland
• Free online programing and simulation tool

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Tutorial 1: Viewpoint Control

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Tutorial 1: Viewpoint Control

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Tutorial 2: Robot Programming

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Tutorial 2: Robot Programming

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Tutorial 3: Inverted Pendulum

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Tutorial 3: Inverted Pendulum

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AN INTRODUCTION OF INDUSTRIAL AUTOMATION:
FROM INDUSTRY 1.0 TO 4.0
MG1024
Dr. Xi Vincent Wang
Associate Professor
KTH Royal Institute of Technology, Sweden