INTRODUCTION TO

AUTOMATION
AUTOMATION DEFINED

• Automation is a set of technologies that results in operation of

machines and systems without significant human intervention.

• It achieves performance superior to manual operation

AUTOMATION DEFINED-2
• Automation can be defined as the technology by
which a process or procedure is accomplished without
human assistance.
• It is implemented using a program of instructions
combined with a control system that executes the
instructions.
• To automate a process, power is required, both to
drive the process itself and to operate the program
and control system.
BASIC ELEMENTS OF AN
AUTOMATED SYSTEM
• An automated system consists of three basic elements:
1. Power to accomplish process and operate the system.
2. A program of instructions to direct the process, and
3. A control system to actuate the instructions.

4. The relationship among these elements is illustrated in

Fig. 1
FIG 1. ELEMENTS OF AN AUTOMATED
SYSTEM
•
POWER FOR AUTOMATION
• Beyond the basic power requirements for
manufacturing operations, additional power is
required for automation. The additional power is used
for the following functions.
1. Controller unit which are based on a digital
computer.
2. Power to actuate the electromechanical devices
such as switches, and motors etc. after receiving
signal from the controller unit.
3. Data acquisition and information processing
COMMON MANUFACTURING PROCESSES AND THEIR POWER REQUIREMENTS

S/N Process Power Form

1 Casting Thermal
2 Electric Discharge Machining Electrical

3 Forging Mechanical
4 Heat- treating Thermal
5 Injection Molding Thermal and Mechanical

6 Laser beam cutting Light and thermal

7 Machining Mechanical
8 Sheet metal punching and blanking Mechanical

9 Welding Thermal (maybe mechanical)

 DEFINITION OF FULL
AUTOMATION

• The technique, method, or system of operating or controlling a

process by highly automatic means, as by electronic devices,
reducing human intervention to a minimum.
• A mechanical device, operated electronically, that functions
automatically, without continuous input from an operator.
• Act or process of automating.
WHAT A FULLY AUTOMATED
SYSTEM CONSISTS OF
a. an inter-disciplinary Computer Integrated Manufacturing (iCIM)
which implies automation of production planning, control,
modification, optimization and visualization.
b. a Flexible Manufacturing System (FMS) which involves automation
of material and signal flow within a networked flexible production
system.
WHAT A FULLY AUTOMATED
SYSTEM CONSISTS OF-2
Fully Automated System represents the interaction of single
production steps to an entire production process. It involves
 Installation and Commissioning
· Programming
· Communication
 Maintenance and Trouble Shooting
FULLY AUTOMATED SYSTEM-3
FULLY AUTOMATED SYSTEM-
(FMS, iCIM DIAGRAM)
CLASSIFICATION OF
AUTOMATION PRODUCTION
SYSTEM
Automated production systems can be classified into three basic
types:
• Fixed automation,
• Programmable automation, and.
• Flexible automation.
TYPES OF AUTOMATION
SYSTEMS

a. Fixed Automation: It is used in high volume production with

dedicated equipment, which has a fixed set of operation and designed
to be efficient for this set. e.g. Distillation Process, Conveyors, Paint
Shops, Transfer lines, mechanized machinery system to perform fixed
and repetitive operations in order to produce a high volume of similar
parts.
TYPES OF AUTOMATION-2

b. Programmable Automation:
It is used for a changeable sequence of operation and configuration of
the machines using electronic or computer controls. e.g. in Steel
Rolling Mills, Paper Mills etc.
TYPES OF AUTOMATION-3

c. Flexible Automation: It is used in Flexible

Manufacturing Systems (FMS) which is invariably
computer controlled. Human operators give high-
level commands in the form of codes entered
into computer identifying product and its location
in the sequence and the lower level changes are
done automatically. Such systems typically use
Multi purpose Computer Numerical Control (CNC)
machines, Automated Guided Vehicles (AGV) etc.
TYPES OF AUTOMATION-4

d. Integrated Automation: It denotes complete automation of a

manufacturing plant, with all processes functioning under different
computer control and under coordination through digital information
processing.
It includes technologies such as computer-aided design and
manufacturing, computer-aided process planning, computer numerical
control machine tools, flexible machining systems, automated storage
and retrieval systems, automated material handling systems such as
robots and automated cranes and conveyors, computerized scheduling
and production control.
Why Automation?
Why manual?
ANOTHER LOOK AT LEVELS OF INDUSTRIAL AUTOMATION PROCESS

There are several ways to describe the levels of an

Industrial Automation Process, but the simplest of all is
the following hierarchical triangle of three level
representation of a typical Industrial Automation
Application.
SUPERVISORY LEVEL
Supervisor Level
• Sitting at the top of hierarchy, the supervisor level
usually consists of an Industrial PC, which is usually
available as a desktop PC or a Panel PC or a Rack-
mounted PC. These PCs run on standard operating
systems with a special software, usually provided by
the supplier for industrial process control.
• The main purpose of the software is process
visualization and assignment of parameters. A special
industrial ethernet is used for communication, which
can be Gigabit LAN or any wireless topology (WLAN).
CONTROL LEVEL
Control Level
• The Control Level is the mid-level in the hierarchy and
this is the level where all the automation related
programs are executed. For this purpose, generally,
Programmable Logic Controllers or PLCs are used,
which provide real-time computing capability.
• PLCs are usually implemented using 16-bit or 32-bit
microcontrollers and run on a proprietary operating
system to meet the real-time requirements. PLCs are
also capable of being interfaced with several I/O
devices and can communicate through various
communication protocols.
FIELD LEVEL
Field Level
• The terminal equipment like Sensors and Actuators are
categorized into Field Level in the hierarchy. The sensors like
temperature, optical, pressure etc. and actuators like motors,
valves, switches etc. are interfaced to a PLC through a field
bus and the communication between a Field Level device and
its corresponding PLC is usually based on a point-to-point
connection.

• Both wired and wireless networks are used for

communication and using this communication, the PLC can
also diagnose and parameterize various components.
MOTIVATIONS FOR INDUSTRIAL AUTOMATION

The fundamental motivations for implementing industrial

automation are:
• Increase production
• Reducing cost, especially, human-related cost
• Improving the quality of the product
• Efficient use of raw materials
• Reduce energy consumption
• Increase business profits
• There are a few secondary motivations for using automation
in industrial production process like providing a safe
environment for the operator, reducing the environmental
pollution, etc.
 ADVANTAGES AND DISADVANTAGES OF
INDUSTRIAL AUTOMATION
• Advantages
• The task performed by human operators involving tedious physical work can
be easily replaced.
• Human operators can avoid working in dangerous production environments
with extreme temperatures, pollution, intoxicating elements or radio-active
substances.
• The tasks that are difficult for a typical human operator can be easily done.
These tasks include lifting heavy and large loads, working with extremely
tiny objects etc.
• Production is always faster and the cost of the product is significantly less
(when compared to the same product that is produced with manual
operation).
• Several quality control checks can be integrated into the production process
to provide consistency and uniformity.
• The economy of the industry can be significantly improved, which has a
direct impact on the standard of the living.
 ADVANTAGES AND DISADVANTAGES OF
INDUSTRIAL AUTOMATION-2
• Disdvantages
• Loss of jobs. Since, majority of the work is done by machines,
the requirement for manual labor is very less.
• All the desired tasks cannot be automated using the current
technology. For example, products with irregular shapes and
sizes are best left for manual assembly. (This trend seems to be
changing with advanced computers and algorithms).
• It is feasible to use automation for certain process i.e. high-
volume production, repeatable and consistent products.
• The initial cost of implementing an automation system is very
high.
• A set of skilled personnel is always a requirement for
maintenance and service
 THE AUTOMATION CONTROL
SYSTEM
• The controls in an automated system can be either closed
loop or open loop. A closed loop system is also called a
feedback control system in which the output variable is
compared with an input parameter. A closed loop control
system consists of six basic elements namely:
(1) Input parameter, (2) Process, (3) Output variable, (4)
Feedback sensor, (5) Controller, and (6) Actuator
These are shown in Fig. 2
FIG. 2 CLOSED LOOPCONTROL SYSTEM

A (one-axis) positioning system consisting of a leadscrew by a dc servomotor

 WORK CYCLES
• The actions performed by an automated process are
defined by the program of instructions. Each part or
product requires one or more processing steps that are
unique to that part or process. These processing steps are
performed during what is called a “WORK CYCLE”.
Homework
• Consider an automated turning operation that generates a
cone-shaped product. The system is automated and a robot
loads and unloads the work units. Determine the possible
steps in its work cycle.
 MORE ADVANCED
AUTOMATION FUNCTION
• 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,
the functions are concerned with enhancing the safety and
performance of the equipment. Advanced automation
functions include the following:
(1) Safety monitoring-e.g. with limit switches, photoelectric,
temperature heat, smoke, pressure, machine vision
(2) Maintenance and repair diagnostics-e.g. Status
monitoring, Failure diagnostics,Recommendation for
repair procedure
(3) Error detection and recovery
HOMEWORK 1
• Consider an automated cell consisting of a CNC machine tool, a parts storage
unit, and a robot for loading and unloading the parts between the machine and
the storage unit. List possible errors in each category. (2nd one is given).
S/N
Category Possible Errors

1 Machine and Process

2 Cutting Tools Tool breakage, tool wear out,
vibration, tool not present, wrong
tool

3 Workholding Fixtures
4 Part storage unit
5 Load/Unload Robot
EXAMPLE 1. ERROR RECOVERY IN AN
AUTOMATED MACHINING CELL
For the automated cell of Homework 1, develop a list of
possible corrective action that might be taken by the system
to address some of the errors.
 EXAMPLE 1

S/N Error Detected Possible Corrective Action to Recover

1 Part dimensions deviating due to
thermal deflection of machine tool

2 Part dropped by robot during pickup

3 Starting work part is oversized
4 Tool vibration (Chatter)
5 Cutting temperature too high
6 Cutting tool failed
7 No more parts in parts storage unit
8 Chips fouling machine operation