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An automated system is a collection of devices working together to accomplish tasks or produce a product or family of products. EXAMPLE 1: Automatic door lock/unlock system. There is a biometric sensor to match the fingerprint which is connected to the control box as an input. Control box receives the signal and acts accordingly. EXAMPLE 2: Home burglar alarm system. Control box receives signal (image, switch input) and activates the alarm.
Production Systems
A production system is a collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company Two categories: Facilities the factory, the equipment in the factory and the way the equipment is organized (plant layout) Manufacturing support systems the set of procedures used by a company to manage production and to solve technical and logistics problems in ordering materials, moving work through the factory, and ensuring that products meet quality standards
Manufacturing Systems
Three categories in terms of the human participation in the processes performed by the manufacturing system: 1. Manual work systems - a worker performing one or more tasks without the aid of powered tools, but sometimes using hand tools 2. Worker-machine systems - a worker operating powered equipment 3. Automated systems - a process performed by a machine without direct participation of a human
Worker-Machine System
Automated System
Fixed Automation
A manufacturing system in which the sequence of processing (or assembly) operations is fixed by the equipment configuration Typical features: Suited to high production quantities High initial investment for custom-engineered equipment High production rates Relatively inflexible in accommodating product variety
Programmable Automation
A manufacturing system designed with the capability to change the sequence of operations to accommodate different product configurations Typical features: High investment in general purpose equipment Lower production rates than fixed automation Flexibility to deal with variations and changes in product configuration Most suitable for batch production Physical setup and part program must be changed between jobs (batches)
Flexible Automation
An extension of programmable automation in which the system is capable of changing over from one job to the next with no lost time between jobs Typical features: High investment for custom-engineered system Continuous production of variable mixes of products Medium production rates Flexibility to deal with soft product variety
Increased throughput or productivity. Improved quality. i.e accuracy Improved robustness (consistency), of processes or product. i.e Precision Reduce excess labour cost
Components of automation
Robots CNC Machines
Conveyers, palletizers [hard automation devices with little flexibilities] Control Devices [ PLCs, Microcontroller based]
Feedback Devices [Sensors, Vision systems]
It knows which place is empty and which place is occupied through sensor feedback.
1. Analog e.g capacitive pressure sensor, temperature sensor, force sensor etc. 2. Digital sensors e.g limit switches, optical switches, counters etc. 3. Contact sensors e.g Limit switch (mechanical) 4. Non-contact or proximity sensor e.g Limit switch (optical)
Sensor is 8 by 8 pixels No of Pixels (covered by the image) in X Px=3 No of Pixels in (covered by the image) in Y Py= 4.5
Diameter of the part is d= 5mm. What is the resolution is X and Y direction? Resolution in X direction Rx= d/Px = 5/3 = 1.67 mm Resolution in Y direction Ry = d/Py = 5/4.5 = 1.11 mm
Automation Principle
1. Understand the existing process Input/output analysis Value chain analysis /supply chain analysis Charting techniques and mathematical modeling 2. Simplify the process Reduce unnecessary steps and moves 3. Automate the process Ten strategies for automation and production systems Automation migration strategy
Automation Strategies
1. Specialization of operations 2. Combined operations 3. Simultaneous operations 4. Integration of operations 5. Increased flexibility 6. Improved material handling and storage 7. On-line inspection 8. Process control and optimization 9. Plant operations control 10. Computer-integrated manufacturing
Cost Justification
Automation system is installed when it saves money for the company Before installing any new automation system company must calculate the payback period
P = Payback period in years C = Total cost of the system including installations W = Annual wages of labour and fringe benefits for the workers who are replaced
Cost Justification
I = Savings in terms of productivity, quality, materials D = Depreciation allowance M = System maintenance cost. S = Additional staffing for maintenance, programming.
System Design
Start Key in no of shafts to be machined Robot load another part
Pass?
NO
System Design
Operator inputs no of shafts to be machined Robotic arm load the part on a CNC lathe machine Robot unload the part after machining and load it in a QC station (Vision system) The shaft diameter is measured and if it is outside the tolerance limit the part is scrapped. If it is within tolerance limit the finished part is counted. Robot loads the next part until it reaches the desired value.