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Department of mechanical Engineering,PVPIT
Automation &Simulation
By-Bhushan Chhatre (T.E. Mech)
Sai Motling (T.E. Mech)
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Email ID:- [email protected] [email protected]
Abstract
Automation is the word inspired from word automatic
Nowadays; industries are adapting over to automation to increase their
productivity as well as quality to maintain their position in market.
Automation is next step forward from mechanization enabling more
precise and reliable outputs. Automation has become a key to success
for fastest growing industries. Along with automation, simulation
plays vital role in manufacturing giving an in detail information of
product even before it is going to manufacture.
In this paper we have emphasized on types of automation
which can be used as per manufacturers requirement. The merits of
automation with respect to demerits have been studied. It also focuses
on modern trends in automation that are being used in industries. The
exact purpose of simulation in manufacturing has been also defined.
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INDEX
1. Introduction
2. History
3. Essence of Automation
4. Revolutionizing In Industries:
Types of Automation
5. Application
Automatic Sorting Machines
Automated Inspection for Quality Control
Industrial Robots
AGV
6. Advantages of Automation
7. Disadvantages of Automation
8. Simulation
Sheet metal forming simulation
Metal casting simulation
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Automation & Simulation
1. Introduction:
Automation is the use of machines, control systems and information
technologies to optimize productivity in the production of goods and
delivery of services. In the scope of industrialization, automation is a step
beyond mechanization. Whereas mechanization provides human operators
with machinery to assist them with the muscular requirements of work,
automation greatly decreases the need for human operators while increasing
load capacity, speed, and repeatability.
2. History:
The term automation, inspired by the earlier word automatic was
not widely used before 1947, when General Motors established the
automation department. At that time automation technologies were
electrical, mechanical, hydraulic and pneumatic. Between 1957 and 1964
factory output nearly doubled while the number of blue collar workersstarted to decline.
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3. Essence of Automation:
Control Systems: It is a device, or set of devices to manage,
command, direct or regulate the behavior of other devices or system.
Industrial control system (ICS):It contains several
types of control systems used in industrial production,
including supervisory control and data acquisition (SCADA)
systems, distributed control systems (DCS), and other smaller
control system configurations such as skid-mounted
programmable logic controllers (PLC) often found in the
industrial sectors and critical infrastructures.
Numerical control (NC): It refers to the automation of
machine tools that are operated by abstractly programmed
commands encoded on a storage medium, as opposed to
controlled manually via hand wheels or levers, or mechanically
automated via cams alone.
Robotics:It isthe branch of technology that deals with the
design, construction, operation, manufacture and application of
robots and computer systems for their control, feedback, and
information processing.
4. Revolutionizing In Industries:
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Industrial Automation is a discipline that includes
knowledge and expertise from various branches of engineering
including electrical, electronics, chemical, mechanical,
communications and more recently computer and software
engineering. Automation & Control by its very nature demands a cross
fertilization of these faculties.
Types in Automation:-
Fixed Automation:-
In this type, sequence of process is fixed in equipment
configuration.
Advantages:
1. Maximum efficiency.
2. Low unit cost.
3. High production rates.
Disadvantages:
1. High initial investments.
2. Inflexible to accommodate change in product design.
Programmable Automation-
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It includes equipment designed to accommodate a
specific class. It has capabilities to change sequence of operations by
reprogramming to accommodate different product configuration.
Advantages:-
1. Flexibility to do changes in product design.
2. Low unit cost for large batches.
3. Most suitable for batch production.
Disadvantages:-
1. New product needs long set up time.
2. High investments for costumed engineering systems.
Flexible Automation:
It includes system capable of changing over from one
job to another job to another job in least possible time.
Advantages
1. Flexibility to deal with new product design.
2. Useful in manufacturing of customized products.
Disadvantages:
1. High initial investments.
2. Medium production rates.
3. High unit cost.
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5. Applications:
1. Automatic Sorting Machines:
The Autosort is a multifunctional sorting system to
recover a wide range of pieces of material from different
waste streams, single stream, packaging, paper, household
waste and other sorting tasks looking for enhanced material
information and color in combination.
The Autosort uses the new DUOLINE scanning
technology which conducts a double scan on every pass.
Extremely fast and extremely reliable sensors take between
the scanner unit and the conveyer belt while maintaining
the high resolution. In order to sort different material grain
sizes, machines are available in a number of resolution
stages. The highest resolution is about 2.5 mm. alongside
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its superior sorting quality;it provides a high degree of
input material, built-in maintenance and control functions
of the valve units and the option of controlling and
monitoring the sorting unit from a control room.
Benefits:
1. Extremely fast process.
2. Low operating costs.
3. High quality sorting regarding purity, thought.
4. Switch able between wide ranges of sorting tasks.
5. Easily adaptable to your process.
2. Automated Inspection for Quality Control:
In present scenario, manual inspection is largely
replaced by automated inspection as errors are reduced to
great extent by automation of the process. Economic
justification of an automated inspection system depends on
whether the savings in labor cost & improvement in
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accuracy will be more than the investment and/or
development costs of the system. Automated inspection is
defined as the automation of one or more steps involved in
the inspection procedure. Automated or semi-automated
inspection can be implemented in the number of alternative
ways.Machine vision (MV) is the technology and methods
used to provide imaging-based automatic inspection and
analysis for such applications as automatic inspection,
process control, and robot guidance in industry.
Machine vision is the technology to replace or complement
manual inspections and measurements with digital cameras
and image processing. The technology is used in a variety
of different industries to automate the production, increase
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production speed and yield, and to improve product
quality. Machine vision in operation can be described by a
four-step flow:
1.Imaging: Take an image.
2. Processing and analysis: Analyze the image.
3. Communication: Send the result to the system in
control of the process.
4. Action: Take action depending on the vision system's
result.
In inspection applications the purpose of the visionsystem is to validate certain features, for example presence
or absence of a correct label on a bottle, screws in an
assembly, chocolates in a box, or defects. In the example to
the right, a camera inspects brake pads for defects.
3. Industrial Robots:-
Robots can substitute for humans in hazardous
work environments. Consistency and accuracy achieved by
robots not attainable by humans. They can be
reprogrammed. Most robots are controlled by computers
and can therefore be interfaced to other computer systems.
Robot manipulator consists of two sections:
1. Body-and-arm They are used for positioning of
objects in the robots work volume.
2. Wrist assembly It is required for orientation of
objects.
The two main types of robots are as follows:
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1. Grippers They grasp and manipulate objects (e.g.,
parts) during work cycle.
2. Tools They are used to perform a process, e.g., spot
welding, spray painting.
Applications:
1. Material handling applications
Material transfer pick-and-place, palletizing
Machine loading and/or unloading
2. Processing operations
Spot welding and continuous arc welding
Spray coating waterjet cutting, laser cutting, grinding.
3. AGV (Automated Guided Vehicles):
An automated guided vehicle or automatic guided
vehicle (AGV) is a mobile robot that follows markers or
wires in the floor, or uses vision or lasers. They are most
often used in industrial applications to move materials
around a manufacturing facility or a warehouse.
Advantages:
Clear floor space.
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Simple installation
High availability/reliability
Flexible performance increments.
Short installation times.
Tracking Methods
Optical Tracks contrasting color
Wire Embedded in floor
Inertial Gyro with magnets in floor.
Laser Triangulation from reflective target
Charging Method
Standard Charging (Battery swap)
In-Vehicle (Opportunity) Charging
Inductive Charging
6. Advantages of Automation
1.Increased throughput or productivity.
2. Improved quality or increased predictability.
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3. Improved consistency, of processes or product.
4. Reduce Production Cost
5. Better Floor Space Utilization
6. Reduce Waste
7. Disadvantages of automation
1. Security Threats/Vulnerability: An automated system may
have a limited level of intelligence, and is therefore more
susceptible to committing errors outside of its immediate scope
of knowledge.
2. Unpredictable/excessive development costs: Theresearch
and developmentcost of automating a process may exceed the
cost saved by the automation itself.
3. High initial cost: The automation of a newproduct orplant
typically requires a very large initial investment in comparison
with the unit cost of the product, although the cost of automation
may be spread among many products and over time.
4. Current technology is unable to automate all the desired tasks.
5. Lower skill levels of workers.
6. Not economically justifiable for small scale production.
5. Simulation:
In a traditional workflow, engineers frequently
could nottest and validate their control system designs
until late in the development cycle, when motors, sensors,
actuators, and other system hardware finally became
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available. This approach was sufficient when expected
system behavior was predictable. Simulation software is
based on the process of modeling a real phenomenon with
a set of mathematical formulas. It is, essentially, a program
that allows the user to observe an operation through
simulation without actually performing that operation.
Simulation software is used widely to design equipment so
that the final product will be as close to design specs as
possible without expensive in process modification.
Simulations are also used to test new theories. Aftercreating a theory of causal relationships, the theorist can
codify the relationships in the form of a computer program.
If the program then behaves in the same way as the real
process, there is a good chance that the proposed
relationships are correct.
Sheet metal forming simulation
Sheet metal forming simulation software utilizes
mathematical models to replicate the behavior of an actual
metal sheet manufacturing process.Essentially, it is a
computer program that converts a computer into a fully
functioning metal manufacturing prediction unit. efficiency
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in the metal forming.
Metal Casting Simulation
Metal castingsimulation is currently performed by
Finite Element Method simulation software designed as a
defect-prediction tool for the foundry engineer, in order to
correct and/or improve his/hercasting process, even before
prototype trials are produced. The idea is to use information to
analyze and predict results in a simple and effective manner to
simulate different processes such as:
1. Gravity sand casting.
http://en.wikipedia.org/wiki/Metal_castinghttp://en.wikipedia.org/wiki/Simulationhttp://en.wikipedia.org/wiki/Finite_Element_Methodhttp://en.wikipedia.org/wiki/Foundryhttp://en.wikipedia.org/wiki/Casting_processhttp://en.wikipedia.org/wiki/Casting_processhttp://en.wikipedia.org/wiki/Metal_castinghttp://en.wikipedia.org/wiki/Simulationhttp://en.wikipedia.org/wiki/Finite_Element_Methodhttp://en.wikipedia.org/wiki/Foundryhttp://en.wikipedia.org/wiki/Casting_process -
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2. Gravity die casting.
3. Gravity tilt pouring.
4. Low pressure die casting.
5. High pressure
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