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8/2/2019 IEPM Automation
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8/2/2019 IEPM Automation
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Coined at Ford Motor Company in 1945 to describe
a logical development in technical progress whereautomatic handling between machines is combined withcontinuous processing at machines
It is the technology concerned with the application of
complex mechanical, electronic and computer basedsystems in the operation and control of production.
Examples are -
Automatic Materials Handling System
Feedback Control Systems
Computer Process Control Systems
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1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating
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Functional Group Technology
Processing, Fabrication
and Assembly
Numerically Controlled (N/C) MachinesCNC
DNC
Robotics
Flexible manufacturing systems (FMS)
Automated Material
Handling
Automated storage and Retrieval system(AS/RS)
Automated Guided Vehicle (AGV)
Design and Engineering
Computer-Aided Design/Manufacturing
(CAD/CAM)
Computer Integrated Manufacturing (CIM)
Inspection and
CommunicationsAutomatic Identification Systems (AIS)
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Numerical control (NC) refers tothe automation of machine tools
that are operated by abstractly
programmed commands encoded
on a storage medium, as opposed
to manually controlled via handwheels or levers, or mechanically
automated via cams alone.
Form of flexible (programmable)
automation in which the process
is controlled by numbers, letters,and symbols.
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The EIA definition ofcomputer numericalcontrol (CNC). A numerical control system
wherein a dedicated, storedprogram computer is used toperform some or all of thebasic numerical controlfunctions in accordance withcontrol programs stored in the
read-write memory of thecomputer.
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The first benefit offered by all forms of CNC machine tools is improved
automation The second major benefit of CNC technology is consistent and accurate
workpieces
A third benefit offered by most forms of CNC machine tools is flexibility-just a change of variable is required.
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In DNC, several NC machinesare directly controlled by acomputer, eliminatingsubstantial hardware from theindividual controller of eachmachine tool.
If the computer is connected to
a number of machines it candistribute programs to differentmachines as required. Usually,the manufacturer of the controlprovides suitable DNCsoftware.
The part-program isdownloaded to the machinesdirectly (thus omitting the tapereader) from the computermemory.
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It consists of a variety of computer-controlled methods for automaticallyplacing and retrieving loads from specific storage locations
It is used in manufacturing, distribution, retail, wholesale and institutions
It is typically used in applications where:
there is a very high volume of loads being moved into and out of storage
storage density is important because ofspace constraints
accuracy is critical because of potential expensive damages to the load
The traditional vending machine is the most common and familiar AS/RSsystem
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AS/RS
Fixed AisleSingle masted
Double masted
Man-aboardCarousels/VerticalLift Modules (VLMs)
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Increased inventory control and tracking
Savings in inventory storage costs
Improved warehouse space utilization, both vertically and
horizontally
Creates greater storage density
Reduced labor costs
Increasing workplace safety
Removing personnel from difficult working conditionsEg : Cold food storage environments
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It is a mobile robot that follows markers or wires in the
floor, or uses vision or lasers
They are most often used in industrial applications to move
materials around a manufacturing facility or a warehouse
They increase efficiency and reduce costs by helping to
automate a manufacturing facility or warehouse
In an automated process, AGVs are programmed to
communicate (via an offboard server) with other robots to
ensure the product is moved smoothly through the warehouse,whether it is being stored for future use or sent directly to
shipping areas
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It is the manufacturing approach of using computers tocontrol the entire production process
This integration allows individual processes to exchange
information with each other and initiate actions
Through the integration of computers, manufacturing canbe faster and less error-prone
CIM implies that there are at least two computersexchanging information, e.g. the controller of an arm robotand a micro-controller of a CNC machine
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As with all systems, CIM too has its challenges to be solved
Integration of components from different suppliers:
When different machines, such as CNC, conveyors and robots, are using
different communications protocols
Data integrity:
The higher the degree of automation, the more critical is the integrity of the
data used to control the machines
Process control: Computers may be used to assistthe human operators of the manufacturing
facility, but there must always be a competent engineer on hand to handle
circumstances which could not be foreseen by the designers of the control
software
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Use of computer systems to assist in
the creation, modification, analysis,
and optimization of a design
Typical tools: Tolerance analysis
Mass property calculations
Finite-element modeling and visualization
Defines the geometry of the design
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Use of computer systems to plan,
manage, and control
manufacturing operations
Direct or indirect computerinterface with the plants
production resources
Numerical control of machine
tools
Programming of robots
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Major component is hardwareand software allowing shapemanipulation
Hardware includes graphicdevices and their peripherals forinput and output operations
Software includes packages thatmanipulate or analyze shapesaccording to user interaction
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Sense and input data into computers
Use bar codes, radio frequencies, magnetic stripes, optical
character recognition, machine vision
Data read from products, documents, parts, and containers
Used in warehouses, factory floors, retailing, wholesaling
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Better Inventory Management
Increased Throughput and Productivity
Shorter Order Cycles
Faster Shipping Reduced Labor cost
Increased Revenue
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Robotics:Robotics is the science and technology of
Robots, their design, manufacture, and
application.
An Industrial robot is a general-purpose,programmable machine possessing certain
anthropomorphic characteristics.
A robot can be programmed to perform of a
sequence of repetitive tasks, which will beperformed until the robot is reprogrammed
to perform some other motion cycle.
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Parts handling
Pick and Place jobs
Machine loading and unloading
Production equipment
Metal-cutting machine tools
Spray Painting
Spray paint nozzle attached to the robots arm
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Welding
Spot Welding
Continuous welding
Assembly
Extension of pick-and-place motions
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