Industrial Automation - Elements - Industrial Engineering 4.0 - IoT CIM

Ralph M. Barnes: Few people advocate using human labor to do work that can be done better and cheaper by machines.

Ralph M. Barnes: It is suggested that the best manual method and the best combination of manual and machine method (mechanized) be developed and used as a basis for evaluating a proposed automated process.

Ralph M. Barnes: If a large-volume fairly complex job is to be considered, a comparison would be of the estimated cost to do each element of each suboperation manually, or in machanized way, or automatically.

Ralph Barnes is the first PhD in Industrial Engineering. He wrote the popular text, Motion and Time Study.

Industrial engineers have to learn mechanization and automation that is engineering very well and use it in industrial engineering to provide increased support of machines to people to increase their productivity and standard of living.

Automation in Manufacturing - The Role - Industrial Engineering 4.0 - IoT - CIM

Increasing standard of living of people through implementing more and more productive machines and tools in engineering systems is the purpose of industrial engineering.

Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System

Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.

https://nraoiekc.blogspot.com/2021/04/jidoka-automation-and-mechanization.html

Industrial Automation - Elements - Industrial Engineering 4.0 - IoT CIM 

IoT and Computer Integrated Manufacturing

Introduction to Automation (Groover)

Sections:

Basic Elements of an Automated System

Advanced Automation Functions

Levels of Automation

Automation Defined

“Automation is the technology by which a process or procedure is accomplished without human assistance”

Basic elements of an automated system:

1. Power - to accomplish the process and operate the automated system

2. Program of instructions – to direct the process

3. Control system – to actuate the instructions

Automation  is implemented using a Program of Instructions combined with a Control System that executes the instructions. Power is required to operate the components of the system.

Power to Accomplish the Automated Process

Power for the complete process of manufacturing

To drive the manufacturing process itself power is required.

To load and unload the work unit (into proper position and orientation for the process to be performed)

Transport between operations

Power is required for the components of the automation system, Controller unit, actuators,  Data acquisition and information processing system.

Electricity is the Principal Power Source

Program of Instructions

“Set of commands that specify the sequence of steps in the work cycle and the details of each step”

Example: CNC part program

During each step, there are one or more activities involving changes in one or more process parameters

Examples: Temperature setting of a furnace

Axis position in a positioning system

Motor on or off

Work cycle.

A new part or parts are completed during each work cycle.

The actions performed by an automated process are defined by a “Program of Instructions”.

A new part or parts are completed during each work cycle.

The particular processing steps for the work cycle are specified in a “Work Cycle Program” (part programs).

The program of instructions is repeated each work cycle without deviation.

In many cases, the corresponding instructions for dealing with variations are incorporated into the regular program.

Decision-Making in a Programmed Work Cycle

The following are examples of automated work cycles in which decision making is required:

Operator input to machine

Automated teller machine - How much to disburse. Based on the request of the customer of the bank.

Different part or product styles processed by the system - Which one to be processed now?

Variations in the starting work units

Additional machining pass for oversized sand casting (nonstandard/unidentical parts)

Features of a Work Cycle Program

Number of steps in the work cycle

Manual participation in the work cycle (e.g., loading and unloading workparts)

Process parameters - how many must be controlled?

Operator interaction – is operator required to enter processing data?

Variations in part or product styles

Variations in starting work units - some adjustments in process parameters may be required to compensate for differences in starting units

Control System

The Control element of the automated system executes the program of instructions. The control system causes the process to accomplish its defined function, to carry out some manufacturing operation.

Control System – Two Types

Closed-loop (feedback) control system – a system in which the output variable is compared with an input parameter, and any difference between the two is used to drive the output into agreement with the input

Open-loop control system – operates without the feedback loop. It is simpler and less expensive. But there is risk that the actuator will not have the intended effect.

Input Parameter (set point) represents the desired value of the output of the process. The process is the operation or function being controlled (output value).

A sensor is used to measure the output variable and close the loop between input and output.

The controller compares the output with the input and makes the required adjustment in the process to reduce the difference between them.

The adjustment is accomplished using one or more actuators which are the hardware devices that physically carry out the control actions.

(a) Feedback Control System 

Positioning System Using Feedback Control

A one-axis position control system consisting of a leadscrew driven by a dc servomotor and using an optical encoder as the feedback sensor

When an Open-Loop Control System can be used?

Actions performed by the control system are simple

Actuating function is very reliable

Any reaction forces opposing the actuation are small enough as to have no effect on the actuation

If these conditions do not apply, then a closed-loop control system should be used.

Controller Unit (digital computer)

Read program of instructions - Make the control calculations - Execute instructions by transmitting the proper commands to the actuating devices

Actuators are electromechanical devices such as switches and motors.

Advanced Automation Functions

In addition to executing work cycle programs, an automated system may be capable of executing advanced functions that are not specific to a particular work unit. In general, advanced functions are concerned with enhancing the safety and performance of the equipment.

Advanced automation functions are made possible by special subroutines included in the program of instructions.

Safety monitoring

Maintenance and repair diagnostics

Error detection and recovery

Safety Monitoring

“Use of sensors to track the system's operation and identify conditions that are unsafe or potentially unsafe”

Possible responses to hazards:

Complete stoppage of the system

Sounding an alarm

Reducing operating speed of process

Taking corrective action to recover from the safety violation

Safety monitoring is done through: 

Temperature sensors

Heat or smoke detectors

Pressure sensitive floor pads

Vision systems

Maintenance and Repair Diagnostics

Maintenance and Repair Diagnostics refer to the capabilities of an automated system to assist in identifying the source of potential or actual malfunctions and failures of the system.

Status monitoring

Monitors and records status of key sensors and parameters during system operation

Provide information for diagnosing a current failure

Provide data to predict a future malfunction or failure

Failure diagnostics

Invoked when a malfunction occurs

Purpose: analyze recorded values so the cause of the malfunction can be identified

Recommendation of repair procedure

Provides recommended procedure for the repair crew to effect repairs

Errors

Random errors occur as a result of the normal stochastic nature of the process

Systematic errors are those that result from some assignable cause such as a change in raw material properties

Aberrrations (disorders) result from either an equipment failure or a human mistake

Error Detection and Recovery

Error detection – functions:

Use the system’s available sensors to determine when a deviation or malfunction has occurred

Correctly interpret the sensor signal

Classify the error

Error recovery – possible strategies:

Make adjustments at end of work cycle

Make adjustments during current work cycle

Stop the process to invoke corrective action

Stop the process and call for help

Levels of Automation

Device level – actuators, sensors, and other hardware components to form individual control loops for the next level (lowest level in the hierarchy)

Machine level – CNC machine tools and similar production equipment, industrial robots, material handling equipment

Cell or system level – a manufacturing cell or system is a group of machines or workstations connected and supported by a material handling system, computer and other equipment appropriate to the manufacturing process

Part dispatching and machine loading

Coordination among machines and material handling system

Collecting and evaluating inspection data

Automation Plant level – factory or production systems level

Order processing

Process planning

Inventory control

Purchasing

Material Requirements Planning

Shop floor control

Quality control

Automation Enterprise level – corporate information system

Marketing/Sales

Accounting

Design

Research

Aggregate planning

Master Production Scheduling

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What is Industrial Automation?

Industrial automation is a set of technologies that uses control systems and devices, such as computer software and robotics, to enable automatic operation of industrial processes and machinery without the need for human operators.

https://www.unitronicsplc.com/what-is-industrial-automation/

https://www.surecontrols.com/what-is-industrial-automation/#:~:text=Industrial%20automation%20is%20the%20use,in%20the%20scope%20of%20industrialization.

Servomotor

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Magazine  https://www.industrialautomationindia.in/

Servo amplifier troubleshooting

https://staging-diy.haascnc.com/reference-docs/servo-amplifier-how-it-works-and-troubleshooting-guide

Ready to Run Linear Motion System - Yaskawa

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https://www.youtube.com/watch?v=JmOYAz1CgYs

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Encoder for Feedback

Servomotors need feedback. Provided by encoder.

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https://www.youtube.com/watch?v=k2GQVJ4z0kM

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PLC controls number of devices. It has to be programmed first so that it follows the program and forwards appropriate instructions to the device actuators for starting and stopping various activities.

PLC Programming tutorial on simatic.

Environment is prepared in the first part of the video.

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https://www.youtube.com/watch?v=y2eWdLk0-Ho

Actual program in the second part

https://www.youtube.com/watch?v=nYr8Q21nG0k

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What is a PLC? PLC Basics Part 1 - It is a detailed lecture. Number of pictures are shown.

5 Nov 2012

plcprofessor  https://www.youtube.com/channel/UCRLC9X8d_iDqUzhA_aCnTgA More videos

https://www.youtube.com/watch?v=PLYosK87D8E

Part 2

https://www.youtube.com/watch?v=-8DVa3SBu38

What is a PID Controller?

10 Dec 2018

RealPars  https://www.youtube.com/channel/UCUKKQwBQZczpYzETkZNxi-w

530K subscribers

https://www.youtube.com/watch?v=sFqFrmMJ-sg

What is the Difference Between PLC and DCS?

23 Jul 2018

RealPars

https://www.youtube.com/watch?v=iF99iKlDpxA

What is SCADA?

3 Jun 2019

https://www.youtube.com/watch?v=nlFM1q9QPJw

Typical application of SCADA system in smart factory

2021-12-15 06:28 HKT

https://inf.news/en/tech/47259c1d0850bb199b2fe077d068055f.html