Chapter1-Introduction To Automation PDF
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Abdul RazziChapter1-Introduction To Automation PDF
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Abdul RazziCommon questions
Powered by AIOpen-loop and closed-loop control systems differ primarily in feedback mechanisms. An open-loop control system operates without feedback; it relies on pre-set instructions and assumes the actuator will produce the desired effect. In contrast, a closed-loop (or feedback) control system continuously compares the output with the desired input parameter, using any discrepancies to adjust the process for alignment. This makes closed-loop systems more accurate and adaptable than open-loop systems, which cannot correct deviations during operation .
The development of the steam engine significantly contributed to automation during the Industrial Revolution by providing a new and more efficient source of power. The original steam engine, invented by Thomas Newcomen in 1712, although not efficient, laid the groundwork for future improvements. In the 1770s, James Watt made critical advancements to the steam engine, enhancing its efficiency and making it a more viable and powerful energy source. This breakthrough accelerated the pace of industrialization by mechanizing processes that were previously manual or animal-powered, facilitating the rise of factories and automated manufacturing systems .
Automation improves product and service quality by embedding precision, consistency, and controlled environmental conditions in the production process, minimizing human error and variation. Automated systems perform tasks with high accuracy and repeatability, ensuring products meet predefined quality standards. Additionally, automation can refine processes through real-time monitoring and adjustments, adhering to strict quality control protocols, and quickly responding to defects or anomalies .
An automation system consists of three basic components: power, a program of instruction, and a control system. The power component is necessary to drive the process as well as the controls, and is primarily electrical, though it can be converted to other forms such as mechanical or thermal. The program of instruction defines the actions performed by the automation according to specific steps and sequences. Lastly, the control system executes the program instructions, ensuring that the process carries out its intended function .
Factors that might lead a company to avoid automating a process include the technological difficulty of automation, a short product life cycle, the need for customized or unique products, and the necessity for flexibility in meeting changing demand. These factors can render the benefits of automation less significant than its costs, especially when the process requirements are highly variable or when rapid product adaptation is crucial .
Automation is commonly applied in banking, retailing, fast food, online shopping, tourism, transportation, traffic control, home management, military, agriculture, and industrial sectors. It benefits these industries by enhancing efficiency, accuracy, and speed. For instance, in banking, ATMs and internet banking streamline services. In retail and fast food, automation speeds up ordering and payments. In industrial applications, it improves productivity by transforming raw materials into finished goods with minimal manual intervention. These implementations help reduce time, labor costs, and errors while improving safety and quality .
Program instructions are crucial in automating manufacturing processes as they define specific actions and sequences needed to complete a work cycle. Instructions determine the steps for part manipulations, shaping operations, tool positioning, and handling workflows. Traditionally, instructions were executed by hardware, such as switches and relays, which were less flexible. Modern systems utilize digital storage for program instructions, allowing greater complexity, flexibility, and integration of contingency operations for adaptive responses to cycle variations .
The primary reasons for implementing automation in manufacturing include increasing labor productivity, reducing labor costs, addressing labor shortages, eliminating routine manual tasks, improving worker safety, enhancing product quality, reducing manufacturing lead times, accomplishing tasks impossible manually, and reducing unit costs. Automation allows industries to operate more efficiently and economically while maintaining high quality and safety standards .
Integrated circuits have advanced automation by combining a large number of tiny transistors into a single chip, significantly increasing electronic circuit performance while reducing costs. This advancement paved the way for the development of the microprocessor, which integrates all functions of a CPU into a compact format, thereby enabling more sophisticated and efficient control systems in automation. These technological improvements allowed for more complex, faster, and cost-effective automatic control systems, impacting numerous industries by improving productivity and enabling new applications .
Decision-making is critical in automated systems to handle variations and exceptions in the operational cycle, ensuring the system can adapt to real-time changes without human intervention. This is implemented through programmed decision structures that respond to inputs from sensors or operators. The system can execute corresponding subroutines based on these inputs. For non-routine variations like equipment failure, contingency procedures must be included in the programs to adjust the process sequence dynamically. This capability enhances system robustness and flexibility in real-world applications .
