automation project report

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RAYAT BAHRA A

INSTITUTE OF ENGINEERING AND NANOTECHNOLOGY

TRAINING REPORT

ON

AUTOMATION ENGINEERING


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ACKNOWLEDGEMENT

I have taken efforts in this project. However, it would not have been

possible without the kind support and help of many individuals andorganizations. I would like to extend my sincere thanks to all of them.

I am highly indebted to Er. Navin Kumar Jha for their guidance andconstant supervision as well as for providing necessary informationregarding the project & also for their support in completing theproject.I would like to express my gratitude towards my parents & memberof Wind Tech. Pvt. Ltd.for their kind co-operation andencouragement which help me in completion of this project.I would like to express my special gratitude and thanks to industrypersons for giving me such attention and time.My thanks and appreciations also go to my colleague in developingthe project and people who have willingly helped me out with theirabilities.


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INDEX

1. Acklowledgement2. Introduction3. methods of automation


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AutomationAutomation is the use of machines, control systems and informationtechnologies to optimize productivity in the production of goods anddelivery of services. The correct incentive for applying automation is

to increase productivity, and/or quality beyond that possible withcurrent human labor levels so as to realize economies of scale, and/orrealize predictable quality levels. In the scope of industrialization,automation is a step beyond mechanization. Whereas mechanizationprovides human operators with machinery to assist them with themuscular requirements of work, automation greatly decreases theneed for human sensory and mental requirements while increasingload capacity, speed, and repeatability. Automation plays anincreasingly important role in the world economy and in dailyexperience.


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http://en.wikipedia.org/wiki/File:Factory_Automation_Robotics_Palettizing_Bread.jpg


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Robots being used at a bakery for food production

Automation has had a notable impact in a wide range of industriesbeyond manufacturing (where it began). Once-ubiquitous telephone

operators have been replaced largely by automated telephoneswitchboards and answering machines. Medical processes such asprimary screening in electrocardiography or radiography andlaboratory analysis of human genes, sera, cells, and tissues are carriedout at much greater speed and accuracy by automated systems.Automated teller machines have reduced the need for bank visits toobtain cash and carry out transactions.

In general, automation has been responsible for the shift in the worldeconomy from industrial jobs to service jobs in the 20th and 21stcenturies.
http://en.wikipedia.org/wiki/File:KUKA_robot_for_flat_glas_handling.jpghttp://en.wikipedia.org/wiki/File:Factory_Automation_Robotics_Palettizing_Bread.jpghttp://en.wikipedia.org/wiki/File:KUKA_robot_for_flat_glas_handling.jpghttp://en.wikipedia.org/wiki/File:Factory_Automation_Robotics_Palettizing_Bread.jpg


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The term automation, inspired by the earlier word automatic (comingfrom automaton), was not widely used before 1947, when GeneralMotors established the automation department. At that time

automation technologies were electrical, mechanical, hydraulic andpneumatic. Between 1957 and 1964 factory output nearly doubledwhile the number of blue collar workers started to decline, due toautomation technology.

Automation is done by using following methods..

PLC (programmable logic control)system SCADA (supervisory control & data acquisition) HMI (human machine interface) DCS (distributed control system) CNC (computer numeric control)system DRIVE (variable frequency drive )system

Advantages and disadvantages


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The main advantages of automation are:

Increased throughput or productivity. Improved quality or increased predictability of quality. Improved robustness (consistency), of processes or product. Increased consistency of output. Reduced direct human labor costs and expenses.

The following methods are often employed to improve productivity, quality, or robustness.

Install automation in operations to reduce cycle time. Install automation where a high degree of accuracy is required. Replacing human operators in tasks that involve hard physical or monotonous work.[3] Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities,

underwater, etc.)

Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc. Economic improvement: Automation may improve in economy of enterprises, society or most of

humanity. For example, when an enterprise invests in automation, technology recovers its investment;

or when a state or country increases its income due to automation likeGermanyorJapanin the 20th

Century.

Reduces operation time and work handling time significantly. Frees up workers to take on other roles. Provides higher level jobs in the development, deployment, maintenance and running of the automated

processes.

The main disadvantages of automation are:

Security Threats/Vulnerability: An automated system may have a limited level of intelligence, and istherefore more susceptible to committing errors outside of its immediate scope of knowledge (e.g., it istypically unable to apply the rules of simple logic to general propositions).

Unpredictable/excessive development costs: Theresearch and developmentcost of automating aprocess may exceed the cost saved by the automation itself.

High initial cost: The automation of a newproductorplanttypically requires a very large initialinvestment in comparison with the unit cost of the product, although the cost of automation may be

spread among many products and over time.

In manufacturing, the purpose of automation has shifted to issues broader than productivity, cost, andtime.

Reliability and precision

The old focus on using automation simply to increase productivity and reduce costs was seen to beshort-sighted, because it is also necessary to provide a skilled workforce who can make repairs andmanage the machinery. Moreover, the initial costs of automation were high and often could not berecovered by the time entirely new manufacturing processes replaced the old. (Japan's "robot junkyards"were once world famous in the manufacturing industry.)
http://en.wikipedia.org/wiki/Automation#cite_note-3http://en.wikipedia.org/wiki/Automation#cite_note-3http://en.wikipedia.org/wiki/Automation#cite_note-3http://en.wikipedia.org/wiki/Germanyhttp://en.wikipedia.org/wiki/Germanyhttp://en.wikipedia.org/wiki/Germanyhttp://en.wikipedia.org/wiki/Japanhttp://en.wikipedia.org/wiki/Japanhttp://en.wikipedia.org/wiki/Japanhttp://en.wikipedia.org/wiki/Research_and_developmenthttp://en.wikipedia.org/wiki/Research_and_developmenthttp://en.wikipedia.org/wiki/Research_and_developmenthttp://en.wikipedia.org/wiki/Product_%28business%29http://en.wikipedia.org/wiki/Product_%28business%29http://en.wikipedia.org/wiki/Product_%28business%29http://en.wikipedia.org/wiki/Planthttp://en.wikipedia.org/wiki/Planthttp://en.wikipedia.org/wiki/Planthttp://en.wikipedia.org/wiki/Planthttp://en.wikipedia.org/wiki/Product_%28business%29http://en.wikipedia.org/wiki/Research_and_developmenthttp://en.wikipedia.org/wiki/Japanhttp://en.wikipedia.org/wiki/Germanyhttp://en.wikipedia.org/wiki/Automation#cite_note-3


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Automation is now often applied primarily to increase quality in the manufacturing process, whereautomation can increase quality substantially. For example,internal combustion enginepistonsused tobe installed manually. This is rapidly being transitioned to automated machine installation, because theerror rate for manual installment was around 1-1.5%, but has been reduced to 0.00001% withautomation.[citation needed]

Lights out manufacturing

Main article:Lights out (manufacturing)

Lights out manufacturing is when a production system is 100% or near to 100% automated (not hiringany workers). In order to eliminate the need for labor costs all together.

Health and environment

The costs of automation to the environment are different depending on the technology, product or engineautomated. There are automated engines that consume more energy resources from the Earth in

comparison with previous engines and those that do the opposite too. Hazardous operations, such asoilrefining, the manufacturing ofindustrial chemicals, and all forms ofmetal working, were always earlycontenders for automation.

Convertibility and turnaround time

Another major shift in automation is the increased demand for flexibility and convertibility inmanufacturing processes. Manufacturers are increasingly demanding the ability to easily switch frommanufacturing Product A to manufacturing Product B without having to completely rebuild theproduction lines. Flexibility and distributed processes have led to the introduction ofAutomated GuidedVehicleswith Natural Features Navigation.

Digital electronics helped too. Former analogue-based instrumentation was replaced by digitalequivalents which can be more accurate and flexible, and offer greater scope for more sophisticatedconfiguration, parametrization and operation. This was accompanied by thefieldbusrevolution whichprovided a networked (i.e. a single cable) means of communicating between control systems and fieldlevel instrumentation, eliminating hard-wiring.

Discrete manufacturing plants adopted these technologies fast. The more conservative process industrieswith their longer plant life cycles have been slower to adopt and analogue-based measurement andcontrol still dominates. The growing use ofIndustrial Etherneton the factory floor is pushing thesetrends still further, enabling manufacturing plants to be integrated more tightly within the enterprise, viathe internet if necessary. Global competition has also increased demand forReconfigurableManufacturing Systems.

Automation tools

Engineers can now havenumerical controlover automated devices. The result has been a rapidlyexpanding range of applications and human activities.Computer-aided technologies(or CAx) now serve
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the basis for mathematical and organizational tools used to create complex systems. Notable examplesof CAx includeComputer-aided design(CAD software) andComputer-aided manufacturing(CAMsoftware). The improved design, analysis, and manufacture of products enabled by CAx has beenbeneficial for industry.[4]

Information technology, together withindustrialmachineryandprocesses, can assist in the design,implementation, and monitoring of control systems. One example of anindustrial control systemis aprogrammable logic controller(PLC). PLCs are specialized hardened computers which are frequentlyused to synchronize the flow of inputs from (physical)sensorsand events with the flow of outputs toactuators and events.[5]

Anautomated online assistanton a website, with anavatarfor enhancedhumancomputer interaction.

Human-machine interfaces(HMI) orcomputer human interfaces(CHI), formerly known as man-machine interfaces, are usually employed to communicate with PLCs and other computers. Servicepersonnel who monitor and control through HMIs can be called by different names. In industrial processand manufacturing environments, they are called operators or something similar. In boiler houses andcentral utilities departments they are called stationary engineers.[6]

Different types of automation tools exist:

ANN -Artificial neural network BPM -Bonita Open Solution DCS -Distributed Control System HMI -Human Machine Interface SCADA -Supervisory Control and Data Acquisition PLC -Programmable Logic Controller PAC -Programmable automation controller Instrumentation
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Motion control Robotics

Limitations to automation

Current technology is unable to automate all the desired tasks.

As a process becomes increasingly automated, there is less and less labor to be saved or qualityimprovement to be gained. This is an example of bothdiminishing returnsand thelogistic function.

Similar to the above, as more and more processes become automated, there are fewer remaining non-automated processes. This is an example of exhaustion of opportunities. New technological paradigms

may however set new limits that surpass the previous limits.

Current limitations

Many roles for humans in industrial processes presently lie beyond the scope of automation. Human-levelpattern recognition,language comprehension, and language production ability are well beyond the

capabilities of modern mechanical and computer systems. Tasks requiring subjective assessment orsynthesis of complex sensory data, such as scents and sounds, as well as high-level tasks such asstrategic planning, currently require human expertise. In many cases, the use of humans is more cost-effective than mechanical approaches even where automation of industrial tasks is possible. Overcomingthese obstacles is a theorized path topost-scarcityeconomics.

Applications

This section requiresexpansion.(April 2011)

Automated retail

Food and drink

Main article:Automated restaurant

The food retail industry has started to apply automation to the ordering process,McDonald'shasintroduced touch screen ordering and payment systems in many of its restaurants, reducing the need foras many cashier employees.[7]University of Texashas introduced fully automated cafe retail locations.[8]

Some Cafes and restaurants have utilized mobile and tablet "apps" to make the ordering process moreefficient by customers ordering and paying on their device.[9][10]Some restaurants have automated fooddelivery to customers tables using aConveyor belt system. The use ofrobotsis sometimes employed to

replacewaiting staff.[11]

Stores

Main article:Automated retail
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ManySupermarketsand even smaller stores are rapidly introducingSelf checkoutsystems reducing theneed for employing checkout workers.

Online shoppingcould be considered a form of automated retail as the payment and checkout arethrough an automatedOnline transaction processingsystem. Other forms of automation can also be an

integral part of online shopping, for example the deployment of automated warehouse robotics such asthat applied byAmazonusingKiva Systems.

Automated mining

Main article:Automated mining

involves the removal of human labor from theminingprocess.[12]Themining industryis currently in thetransition towards Automation. Currently it can still require a large amount ofhuman capital,particularly in thethird worldwhere labor costs are low so there is less incentive for increasingefficiency through automation.

Automated video surveillance

Main article:Surveillance

The Defense Advanced Research Projects Agency (DARPA) started the research and development ofautomated visual surveillance and monitoring (VSAM) program, between 1997 and 1999, and airbornevideo surveillance (AVS) programs, from 1998 to 2002. Currently, there is a major effort underway inthe vision community to develop a fully automatedtracking surveillancesystem. Automated videosurveillance monitors people and vehicles in real time within a busy environment. Existing automatedsurveillance systems are based on the environment they are primarily designed to observe, i.e., indoor,

outdoor or airborne, the amount of sensors that the automated system can handle and the mobility ofsensor, i.e., stationary camera vs. mobile camera. The purpose of a surveillance system is to recordproperties and trajectories of objects in a given area, generate warnings or notify designated authority incase of occurrence of particular events.[13]

Automated highway systems

Main article:Automated highway systems

As demands for safety and mobility have grown and technological possibilities have multiplied, interestin automation has grown. Seeking to accelerate the development and introduction of fully automated

vehicles and highways, theUnited States Congressauthorized more than $650 million over six years forintelligent transport systems(ITS) and demonstration projects in the 1991Intermodal SurfaceTransportation Efficiency Act(ISTEA). Congress legislated in ISTEA that theSecretary ofTransportationshall develop an automated highway and vehicle prototype from which future fullyautomated intelligent vehicle-highway systems can be developed. Such development shall includeresearch in human factors to ensure the success of the man-machine relationship. The goal of thisprogram is to have the first fully automated highway roadway or an automated test track in operation by
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1997. This system shall accommodate installation of equipment in new and existing motor vehicles."[ISTEA 1991, part B, Section 6054(b)].

Full automation commonly defined as requiring no control or very limited control by the driver; suchautomation would be accomplished through a combination of sensor, computer, and communications

systems in vehicles and along the roadway. Fully automated driving would, in theory, allow closervehicle spacing and higher speeds, which could enhance traffic capacity in places where additional roadbuilding is physically impossible, politically unacceptable, or prohibitively expensive. Automatedcontrols also might enhance road safety by reducing the opportunity for driver error, which causes alarge share of motor vehicle crashes. Other potential benefits include improved air quality (as a result ofmore-efficient traffic flows), increased fuel economy, and spin-off technologies generated duringresearch and development related to automated highway systems.[14]

Automated waste management

Automated waste collection trucks prevent the need for as many workers as well as easing the level of

Labor required to provide the service.[15]

Automated manufacturing

Main article:Numerical control

Automated manufacturing refers to the application of automation to produce things in the factory way.Most of the advantages of the automation technology has its influence in the manufacture processes.

The main advantages of automatedmanufacturingare higher consistency and quality, reduced leadtimes, simplified production, reduced handling, improved work flow, and increased worker morale when

a good implementation of the automation is made.

Lights outfactories are factories that require no workers in order to run.

Home automation

Main article:Home automation

Home automation (also calleddomotics) designates an emerging practice of increased automation ofhousehold appliances and features in residential dwellings, particularly through electronic means thatallow for things impracticable, overly expensive or simply not possible in recent past decades.

Industrial automation

Industrial automation deals with the optimization of energy-efficient drive systems by precisemeasurement and control technologies. Nowadays energy efficiency in industrial processes arebecoming more and more relevant. Semiconductor companies likeInfineon Technologiesare offering 8-bit micro-controller applications for example found inmotor controls, general purpose pumps, fans, and
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ebikes to reduce energy consumption and thus increase efficiency. One of Infineon's 8-bit product linefound in industrial automation is theXC800 family.

Agriculture: Now that were moving towards automated orange-sorting[1]and autonomous tractors[2],the next step in automated agriculture is robotic strawberry pickers[3].

See also:Building automationandLaboratory automation

Agent-assisted Automation

Main article:Agent-assisted Automation

Agent-assisted Automation refers to automation used by call center agents to handle customer inquiries.There are two basic types: desktop automation and automated voice solutions. Desktop automationrefers to software programming that makes it easier for the call center agent to work across multipledesktop tools. The automation would take the information entered into one tool and populate it acrossthe others so it did not have to be entered more than once, for example. Automated voice solutions allowthe agents to remain on the line while disclosures and other important information is provided tocustomers in the form of pre-recorded audio files. Specialized applications of these automated voicesolutions enable the agents to process credit cards without ever seeing or hearing the credit card numbersor CVV codes[16]

The key benefit of agent-assisted automation is compliance and error-proofing. Agents are sometimesnot fully trained or they forget or ignore key steps in the process. The use of automation ensures thatwhat is supposed to happen on the call actually does, every time.

vs
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automation project report

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