History of Automation

Sai AnjaneyaHistory of Automation

Applications of AutomationHome Automation Air Conditioner, Geyser, Washing Machine, Cleaning RobotBuilding Automation Elevators, Automatic door opening, fire alarms, automatic parkingOffice Automation Fax, Printer, MS Word, Smart Phones, PCMobility Automation Aircraft, Boats, ships, bikes, cars, railsIndustrial Automation Robots, Design and Manufacturing Software, Whole plant

Industrial Automation

Automation Video

YearCasting Deformation Joining Machining Ceramics Plastics 4000 B.C. Stone, clay molds Bending, forging (Au, Ag, Cu) Riveting Stone, emery, corundum, garnet, flint Earthenware Wood, natural fiber 2500 BCLost wax (bronze) Shearing, sheet forming Soldering, brazing Drilling, sawing Glass beads, potter's wheel 1000 BCHot forging (iron), wire- drawing (?) Forge welding, gluingIron sawsGlass pressing, glazing 0. A.D.Coining (brass), forging (steel) Turning (wood), filing Glass blowing 1000 Wire drawing Stoneware, porcelain (China) 1400 Sand casting, cast iron Water hammer Sandpaper Majolica, crystal glass 1600 Permanent mold Tinplate can, rolling (Pb) Wheel lathe (wood) 1800 Flasks Deep drawing, rolling, (steel), extrusion (Pb) Boring, turning, screw cuttingPlate glass; porcelain (Germany) 1850 Centrifugal, molding machine Steam hammer, tinplate rolling Shaping, milling, copying lathe Window glass from slit cylinder Vulcanization

History of material processing technologies

YearCasting Deformation Joining Machining Ceramics Plastics 1875 Rail rolling, continuous rolling Turret lathe, universal mill, vitrified wheel Celluloid, rubber extrusion, molding 1900 Tube rolling, extrusion (Cu) Oxyacetylene, arc welding, electrical resistance weldingGeared lathe, automatic screw machine, hobbing, high-speed steel, synthetic SiC, Al2O3 Automatic bottle making 1920 Die casting W wire (from powder) Coated electrode Bakelite, PVC casting, cold molding, injection molding1940 Lost wax for engineering parts, resin-bonded sandExtrusion (steel) Submerged arc Acrylics, PMMA, P.E., nylon, synthetic rubber, transfer molding, foaming 1950 Ceramic mold, modular iron, semi-conductors Cold extrusion (steel) TIG welding, MIG welding, electroslag EDM ABS, silicones, fluorocarbons, polyurethane 1960 Plasma arc Manufactured diamond Float-glass Acetals, polycarbonate, polypropylene

History of material processing technologies

Selected Events in the History of Automation Organized automation, mechanization: Industrial revolution, 1770-, England, Europe, US

Hard automation and transfer lines: Henry Ford, 1900-, USA

Numerically Controlled (NC) machine tools, 1952 (US Air Force, MIT)

Microchip computers: late 1960-, USA

CNC (computer numerical controlled) machine tools, 1970-, USA

Industrial Robots, USA, Japan, 1970-

Computer networks, DARPA USA, 1970-

Flexible Manufacturing Systems (FMS), Japan, 1980-.

Functions of Industry

Types of Automation9

Programmable automationFlexibleautomationFixed automation

Manual

LowMediumHigh Parts per year

LowMedium HighNumber of different partsProduction Volume

ProductionVariety

Examples of Automation Automatic rice cookerPut the rice and water in it in the morning, set it to start cooking at 6pm.It turns on automatically. When the rice is cooked, it switches to keep warm mode.Q1. How does it control when to turn on?Q2. What type of sensor(s) and actuators are inside this machine?Q5. The cooker can be set to cook different food types (rice, congee, fish). How is the logic for so many functions controlled?Q4. How can the rice be kept warm for up to 12 hours?Q3. How would you sense when the rice is cooked?

Examples of Automation Park and ShopThe sales clerk swipes item across a glass sheet on top of the counter.The price (and name) of the item are automatically printed on the receipt.The receipt also calculates the total price of all items you have bought.Q1. Identify the sensors and actuators in this example.Q5. How can the information of which item is purchased be used to improve customer service?Q4. How does the system know the price and name of the item?Q3. How does the system know what item was swiped?Q2. Is this an example of digital or analog control?

Open Loop, Closed Loop SystemsActuatorDeviceSignalActuatorDeviceSignal-Sensorfeedback

Basic Structure of Automatic Control System

ComputersCommunication network

A/DconverterAnalog SignalsDigital Signals

Sensors and Actuators

Network InterfacePhysical Process

Analog controls

D/Aconverter

Microprocessor

PLC

Technologies14

CNC Milling Machine 4-Feb-1715

3D Printing18

What are levels of automationVideo

Levels of AutomationLevelsDescriptionAttributesLevel 0LaborMechanizationLevel 1ScriptsAutomationLevel 2OrchestrationLevel 1 + AdaptabilityLevel 3AutonomicsLevel 2 + AwarenessLevel 4Pre-cognitiveLevel 3 + AnalyticsLevel 5CognitiveLevel 4 + Alive

REASONS FOR AUTOMATING

21Increased productivity. High cost of labor. Labor shortages. Trend of labor towards service sector. Safety. High cost of raw materials. Improved product quality. Reduced manufacturing lead-time. Reduction of in process inventory. High cost of not automating.

21Increased productivity. Automation of manufacturing operations hold the promise of increasing the productivity of labor. This means greater output per hour of labor input. Higher production rates (output per hour) are achieved with automation than with the corresponding manual operations. High cost of labor. The trend in the industrialized societies of the world has been towards ever increasing labor costs as a result higher investments in automated equipment has become economically justifiable to replace manual operations. The high cost of labor is forcing business leaders to substitute machines for human labor because machines can produce at higher rates of output the use of automation results in lower costs per unit of product. Labor shortages. In many advanced nations there has been a general shortage of labor. West Germany for example has been forced to import labor to augment its own supply. Labor shortages also stimulate the development of automation as a substitute for labor.Trend of labor towards service sector. This trend has been especially prevalent in the USA. In 1986 the proportion of the work force employed in manufacturing stands at about 20%. In 1947 this percentage was 30%. By the year 2000 some estimates put the figure as low as 2%. Certainly automation of production jobs has caused some of this shift. However there are also social and institutional forces that are responsible for the trend. The growth of government employment at the federal, state and local levels has consumed a certain share of the labor market which might have otherwise have gone into manufacturing. Also there has been a tendency for people to view factory work as tedious, demeaning and dirty. This view has caused them to see employment in the service sector of the economy. Safety. By automating the operations and transferring the operator from active participation to a supervisory role work is made safer. The safety and physical well being of the worker has become a national objective. High cost of raw materials. The high cost of raw materials in manufacturing results in the need for greater efficiency in using these materials. The reduction of scrap is one of the benefits of automation. Improved product quality. Automated operations not only produce parts at faster rates than do their manual counterparts but they produce parts with greater consistency and conformity to quality specifications.Reduced manufacturing lead-time. Automation allows the manufacturer to reduce the time between customer order and product delivery. This gives the manufacturer a competitive advantage in promoting good customer service. Reduction of in process inventory. Holding large inventories of work in process represents a significant cost to the manufacturer because it ties up capital. In process inventory is of no value. It serves none of the purposes of raw materials stocked or finished product inventory. Accordingly it is to the manufacturers advantage to reduce work in progress to a minimum. Automation tends to accomplish this goal by reducing the time a work part spends in the factory.High cost of not automating. A significant competitive advantage is gained by automating the manufacturing plant. The advantage cannot easily be demonstrated on a companies project authorization form. The benefits of automation often show up in intangible and unexpected ways such as improved quality higher sales, better labor relations and better company image. Companies that do not automate are likely to find themselves at a competitive disadvantage with their customers, their employees and general public. All these factors make production automation attractive alternative to manual methods of production.

ARGUMENTS AGAINST AUTOMATION22Automation will result in the subjugation of the human being via machine. There will be a reduction in the labor force with resulting unemployment. Automation will reduce purchasing power.

22Automation will result in the subjugation of the human being via machine. This is really an argument whether workers job will be down graded or upgraded by automation. on the one hand automation tends to transfer the skills required to perform work from human operators to machines. In doing so it reduces the need for skilled labor. The manual work left by automation requires lower skill levels and tends to involve rather menial tasks. Example loading and unloading workparts, changing tools etc. in this sense automation tends to downgrade factory work. On the other hand the routine monotonous tasks are the easiest to automate and are therefore the first jobs to be automated. Few workers are thus needed in these jobs. Tasks requiring judgement and skill are more difficult to automate. the net result id that the overall level of manufacturing labor will be upgraded and not downgraded.There will be a reduction in the labor force with resulting unemployment. It is logical to argue that the immediate effect of automation will be to reduce the need for human labor thus displacing workers because automation will increase productivity by a substantial margin. The creation of new jobs will not occur fast enough to take up the slack of displaced workers as a consequence unemployment rates will accelerate.Automation will reduce purchasing power. As machines replace workers and these workers join the unemployment ranks they will not receive the wages necessary to buy the products bought by automation. markets will become saturated with products that people cannot afford to purchase. Inventories will grow, production will stop, unemployment will reach epidemic proportions. And the result will be massive economic depression.

ARGUMENTS IN FAVOUR OF AUTOMATION23Automation is the key to the shorter work week. Automation brings safer working conditions for the workers. Automated production results in lower prices and better products. The growth of automation industries will itself provide employment opportunities. Automation is the only means of increasing our standard of living.

23Automation is the key to the shorter work week. There has been and is a trend towards fewer working hours and more leisure time. The arguments hold that automation will allow the average number of working hours per week to continue to decline thereby allowing greater leisure time.Automation brings safer working conditions for the workers. Since there is lesser physical participation of the worker in the production process, there is less chance of personal injury to the worker.Automated production results in lower prices and better products. It has been estimated that the cost to machine one unit of product by conventional general purpose machine tool requiring human operators may be 100 times the cost of manufacturing the same unit using automated mass production techniques. The growth of automation industries will itself provide employment opportunities. This will specially be true in computer industry. As the companies in this industry have grown new jobs have been created. These new jobs include not only workers directly employed by the company but also computer programmers, system engineers, and others needed to use and operate computers. Automation is the only means of increasing our standard of living. Only through productivity increases brought about by the new automated methods of production will we be able to advance our standard of living. Granting wages increases without a commensurate increase in productivity will result in inflation. In effect this will reduce our standard of living. To afford a better society we must increase productivity faster than we can increase wages and salaries.

the Near Future

Industry 4.0

Internet of Things

Source: IAC

Wearable technologies

Autonomous Car