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Introduction and Basic concept of automation
- 1. Chapter 1 INTRODUCTION ANDBASIC CONCEPT OF INDUSTRIAL AUTOMATION Slide prepare by : Hajar Ismail
- 2. At the endof the class, student should be able to:- 1.0 INTRODUCTION AND BASIC CONCEPT OF AUTOMATION 1.1 Describe the concept of industrial automation. 1.1.1 Definition of industrial automation. 1.1.2 State the advantages and disadvantages. 1.1.3 Identify types of automation. 1.1.4 Describe the Automation in production system. 1.2 Explain the basic concept of robot terminology. 1.2.1 Describe the basic concept following: a. Link and Joint b. Degree of Freedom (dof) c. Orientation Axes d. Position Axes e. Tool Centre Point (TCP) f. Work envelope/workspace g. Speed h. Payload i. Repeatability j. Accuracy k. Settling Time l. Control Resolution m. Coordinates
- 3. What is IndustrialAutomation ( Video)
- 4. • Definition Industry: SystematicEconomic Activity that could be related to Manufacture/Service/ Trade. • Definition Industrial Automation: Automation is a set of technologies that results in operation of machines and systems without significant human intervention and achieves performance superior to manual operation
- 5. Advantages for Automation 1.To increase labor productivity. Automating a manufacturing operation usually increases production rate and labor productivity. This means greater output per hour of labor input. 2. To reduce labor cost. Ever-increasing tabor cost has been and continues to be the trend in the world's industrialized societies. Consequently, higher investment in automation has become economically justifiable to replace manual operations. Machines are increasingly being substituted for human lahar to reduce unit product cost. 3. To migrate the effects of labor shortages. There is a general shortage of labor in many advanced nations and this has stimulated the development of automated operations as a substitute tor labor.
- 6. Advantages for Automation 4.To reduce or eliminate routine manual and clerical tasks. An argument can be put forth that there is social value in automating operations that are routine, boring, fatiguing, and possibly irksome. Automating such tasks serves a purpose of improving the general level of working conditions. 5. To improve worker safety. By automating a given operation and transferring the worker from active participation in the process to a supervisory role, the work is made safer. The safety and physical well-being of the worker has become a national objective with the' enactment of the Occupational Safety and Health Act (OSHA) in 1970. This has provided an impetus for automation.
- 7. Advantages for Automation 6.To improve product quality. Automation not only results in higher production rates than manual operations; it also performs the manufacturing process with greater uniform and conformity to quality specifications. Reduction attraction defect rate is one of the chief benefits of automation. 7. To reduce manufacturing lead time. Automation helps to reduce the elapsed time between customer order and product delivery, providing a competitive advantage 10 the manufacturer for future orders. By reducing manufacturing lead time, the manufacturer also reduces work-in-process inventory.
- 8. Advantages for Automation 8.To accomplish processes that cannot be done manually. Certain operations cannot be accomplished without the aid of a machine. These processes have requirements for precision, miniaturization or complexity of geometry that cannot be achieved manually. Examples include certain integrated circuit fabrication operations, rapid prototyping processes based on computer graphics (CAD) models, and the machining of complex, mathematically defined surfaces using computer numerical control. These processes can only be realized by computer controlled systems. 9. To avoid the high cost of not automating. There is a significant competitive advantage gained in automating a manufacturing plant. The advantage cannot easily be demonstrated on a company's project authorization form. The benefits of automation often show up in unexpected and intangible ways, such as in 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 the general public
- 9. Disadvantages of Automation 1.Higher Start-up cost and the cost of operation. Automated equipment includes the high capital expenditure required to invest in automation. An automated system can cost millions of dollars to design, fabricate, and install. 2. Higher Cost of Maintenance. A higher level of maintenance needed than with a manually operated machine. These include buying electromechanical devices such as electromechanically valve, sensory devices, and smart devices. Cost of spare parts for automation system may consider higher compare to the manual operate.
- 10. Disadvantages of Automation •Obsolescence/Depreciation Cost. Obsolescence and depreciation is a gradual reduction in the value of physical assets. This phenomenon is characteristic of all physical assets in the form of equipment and machinery. It was something that was inevitable due to technology development. Obsolescence or depreciation can be classified into two parts, namely: - i. Physical Depreciation - occurred as a result of physical damage of equipment or robots. It describes a form that can be seen clearly as damage, wear and corrosion. ii. Depreciation of the functions - it existed from changes in demand for services may be provided. Depreciation caused by changes in the need for an equipment service discovery of new equipment or a robot system inability to meet demand
- 11. Disadvantages of Automation 4.Unemployment. A disadvantage often associated with automation, is worker displacement. Due to the fact that manual laborers are being replaced by robots or other automated machineries, this results to mass lay-off. A lot of people are losing their jobs especially those who work in the manufacturing industry such as a car factory. 5. Not economically justifiable for small scale production.
- 12. Types of Automation System Automatedmanufacturing systems can be classified into three basic types: i. Fixed automation. ii. Programmable automation, and iii. Flexible automation.
- 13. Fixed Automation Fixed/hard automationis designed for large volume production of a single product or task. The machine layout is designed to the fixed sequence of operations. Pros— • Typically, lower build costs compared to programmable and flexible options. • Improved product consistency • Operates at high speed for a high production rate • Lower unit cost for each piece sold Cons— • Machine layout inflexible, so alterations to design are costly and time-consuming
- 14. Hard automation • Examples offixed automation include machining transfer lines found in the automotive industry, automatic assembly machines, and certain chemical processes. • This is relatively useful for many companies who use automation to create food products of one type and variant. It allows them to effectively produce that item and package it in bulk. • Foods that require chemical processes, for example, may use this to ensure the consistency of the chemical processes.
- 15. Programma ble Automation • Programmable automationallows the production equipment and automation to be altered to changing needs. This is done by controlling the automation through a program, which can be coded in certain ways for the automation to change the sequence of automation. • It’s used more commonly in low to medium levels of production, often being most suitable for batch production. • Programmable automation will often be used by factories who make different variants of foods. This allows them to make batches, from a few dozen to potentially thousands at a time, of one product. If the product needs changing, it simply needs to be reprogrammed. • Advantages include: Flexibility to change products if needed Suitable if batch production is required Disadvantages include: Expensive for equipment Lower production levels Often time-consuming to change products This type of automation is well suited for: Low/Medium demand and occasional changes in products.
- 16. Programmable automation iffor the manufacturer that needs flexibility in production for batch runs. Programmable machinery allows for the reprogramming of sequences which will allow for different product configurations. Pros— • Flexible system • Suitable for batch runs from 50 to 1000 unit Cons— • Re-configuring the system can still be time-consuming. • This system requires an upfront substantial investment for general purpose programmable equipment.
- 17. Flexible Automation Flexible/soft automation isan extension of programmable automation, but with less time lost for reprogramming or tool changes. This automation is for the manufacturer that needs to run a variety of products with no downtime between batches. Pros— • Continuous production includes in sequence product variables • Medium production Cons— • Higher initial investment than fixed or programmable • Components that allow for quick changes, such as a robot arm, will need logic controllers, sensors and lasers. • Skilled labor for part changes, maintenance, and other supervisory duties.
- 18. Three types ofautomation relative to production quantity and product variety.
- 19. Describe the Automationin Production System Production System consists of facilities and manufacturing support systems A production system is a collection of people, equipment, and procedures organized to perform the manufacturing operations of an organization. A production system consists of facilities and manufacturing support systems (Figure 1.5): i. Facilities—the factory, the equipment in the factory, and the way the equipment is organized around the shop floor. ii. Manufacturing support systems—the set of procedures used to manage production and to solve technical and logistics problems met in manufacturing processes. These systems include product design, planning and control, logistics and other business functions.
- 22. Basic Concept ofAutomation Terminology • Links and Joints • Links are the solid structural members of a robot, and joints are the movable couplings between them. Joints or axes found in the manipulator (robotic arm). A joint of an industrial robot (Figure 1.10) is similar to a joint in the human body. It provides relative motion between two parts of the body. Joints consists of two types, major axis comprising the base, shoulder and elbow and minor axis comprising wrist pitch, wrist roll and wrist yaw.
- 25. Degree of freedom(DOF) • Each joint on the robot introduces a degree of freedom. Each dof can be a slider, rotary, or other type of actuator. • Robots typically have 5 or 6 degrees of freedom. 3 of the degrees of freedom allow positioning in 3D space, while the other 2or 3 are used for orientation of the end effector. • 6 degrees of freedom are enough to allow the robot to reach all positions and orientations in 3D space. • 5 dof requires a restriction to 2D space, or else it limits orientations. • 5 dof robots are commonly used for handling tools such as arc welders.
- 26. Each joint representsa degree of freedom; there are 22 joints and thus 22 degree of freedom in the human hand
- 28. • From theFigure 1.13 we can see that the robot has five degrees of freedom. That means we can have it move in five independent ways. The five different movements are created in five different joints as described below. 1. Base Joint: This joint allows movement of 350° rotational motion. 2. Shoulder Joint: This joint allows movement of 120° rotational motion. 3. Elbow Joint: This joint allows movement of 135° rotational motion. 4. Wrist Joint: This joint allows movement of 340° rotational motion. 5. Gripper: This joint allows movement of 2 linear motions (open and close actions).
- 29. Orientation Axes • ifthe tool is held at a fixed position, the orientation determines which direction it can be pointed in. • Roll, pitch and yaw are the common orientation axes used. Looking at the figure below it will be obvious that the tool can be positioned at any orientation in space. • (Imagine sitting in a plane. If the plane rolls you will turn upside down. The pitch changes for takeoff and landing and when flying in a crosswind the plane will yaw.)
- 31. Position Axes • Thetool, regardless of orientation, can be moved to a number of positions in space. • Various robot geometries are suited to different work geometries. (more later) The definition of an object's location in 3-D space, usually defined by a 3-D coordinate system using X, Y, and Z coordinates. • Part of a robot can move to a spot within its work envelope, using devices that tell it exactly where it is. Translatory degrees of freedom.
- 32. Tool Centre Point(TCP) • The tool center point is located either on the robot, or the tool. Typically the TCP is used when referring to the robots position, as well as the focal point of the tool. (e.g. the TCP could be at the tip of a welding torch) The TCP can be specified in Cartesian, cylindrical, spherical, etc. coordinates depending on the robot. • As tools are changed we will often reprogram the robot for the TCP. • Tool midpoint is the reference point of tools controlled by the robot.
- 34. Work envelope/workspace • Workenvelope is the volume/area where the robotic arm can perform task/work . • The space in which a robot can operate is its work envelope, which encloses its workspace. • While the workspace of the robot defines positions and orientations that it can achieve to accomplish a task, the work envelope also includes the volume of space the robot itself occupies as it moves.
- 36. Speed • Speed isthe rate of movement from point to point done by robots under the control of the program. • It is a measure of the speed of the device.
- 37. Payload • The payloadindicates the maximum mass the robot can lift before either failure of the robots, or dramatic loss of accuracy.
- 38. Repeatability • The degreeability of a robotic arm to detect targets has been set correctly and then returns to its original point in the work cell. • The robot has a high repeatability will be able to repeat the task with the right repeatedly without error.
- 39. Accuracy • The degreeof ability that can be made by a robotic arm to move to a certain point in the work cell as we enter the coordinates in the off- line programming station (off-line programming).
- 40. Settling Time • Thesettling time is the time required for the robot to be within a given distance from the final position. • During a movement, the robot moves fast, but as the robot approaches the final position is slows down, and slowly approaches. • The time-instant when the actual output converges to the desired output is known as the settling time.
- 41. Control Resolution • Capabilityof robot's positioning system to divide the motion range of each joint into closely spaced points. • This is the smallest change that can be measured by the feedback sensors, or caused by the actuators, whichever is larger. If a rotary joint has an encoder that measures every 0.01 degree of rotation, and a direct drive servo motor is used to drive the joint, with a resolution of 0.5 degrees, then the control resolution is about 0.5 degrees (the worst case can be 0.5+0.01).
- 42. Coordinates • combination ofboth the position of the origin and orientation of the axes. • Points are programmed in the cells identified job position by using the values of the coordinates x, y and z of the tools midpoint and extension angles at the wrist axis robot arm is pitch, roll and yaw.