Automation

Automation

Needs for Automation
1. Higher quality and efficiency
2. Economical
3. Reduce labour costs and required skill
4. Allow modular design
5. Improve production cycle
Type of Automation
1. Hard
  1. Standard Product
  2. High volume
  3. Expensive machines
  4. Inflexible
2. Soft
  1. Computer control
  2. Non-standard
  3. complex parts
  4. F.M.S.
  5. flexible
Numerical Control
1. C.N.C.
  1. Closed Loop
  2. Open Loop
  3. Positioning
    1. Indirect
    2. Direct
    3. Control
      1. Point-to-Point
      2. Contouring
      3. Interpolations
        Linear
        Circular
        Parabolic
  4. Adaptive Control
    1. Dynamic Feedback system
      1. Adjust parameters based on sensor data
    2. Optimse Production rate
    3. Optimise Quality
    4. Minimise cost and prevent tool failure
Industrial Robots
1. Configurations
  1. SCARA
    1. Limited D.O.F
    2. Highly accurate
  2. Linear/Cartesian
    1. 3 axis
    2. Highly accurate
    3. No Rotation
  3. Parallel Kinematic
    1. Very accurate
    2. Low force
  4. Parallel link
    1. Low accuracy
    2. Very fast
  5. Anatomy
    1. Joints
      1. translational
        Linear
        Orthagonal
      2. Rotary
        Rotational
        Revolving
        Twisting
      3. Drives
        Electric
        Pneumatic
        Hydraulic
    2. Links
  6. Jointed arm
  7. Wrist
    1. End effector
      1. Grippers
        Basic Jaw/finger
        Centric/Noncentric
        springback/double action
        Adaptive Gripping
        Compensating units
      2. Compliant: fragile processes
      3. Force-Torque sensors
        Positional feedback
2. Summary
  1. General Purpose
  2. Programmable machines
  3. Super-human consistency and accuracy
  4. Computer controller and interfaced
3. Control systems
  1. Limted sequence
    1. Mechanical stops
  2. Playback with Point-point
    1. work cycle=sequence of points
  3. Playback with continuous
    1. interpolation to execute paths
  4. Intellligent control
    1. sensor input response
    2. decision making
    3. communication
  5. Programming
    1. Lead-Through
      1. no programming knowledge
      2. limited logic capability
    2. Offline
      1. greater complexity
      2. use of simulation
4. Sensors
  1. Sensor fusion
    1. Combine sensors - higher level of data
  2. Types
    1. Mechanical
    2. Thermal
    3. Electrical
    4. Magnetic
    5. Optical
  3. Tactile Sensing
    1. Continuous sensing of variable contact forces
      1. Closed loop feedback
      2. Touch sensing
      3. Slip sensing
  4. Photo-electric
    1. Transmitter and reciever
      1. IR or visible light
  5. Colour
    1. ID objects by colour
      1. RGB lights
        Part detection or orientation
  6. Laser Scanning
    1. Time of flight
      1. Distance of surface
        times light pulse round trip
        Long distance/Low accuracy
    2. Triangulation
      1. Laser line/dots
        Camera records position
        Short distance/high accuracy
  7. Visual sensing
    1. Linear array
      1. One dimensional
        object presence
    2. Matrix array
      1. multiple features
        feature measurement/component detection
    3. Machine vison
      1. Camera
        Acquire image
        Lighting
        Lens
      2. Microprocessor
        Image processing
        Extract information
        Decision
      3. Applications
        In-line inspection
        Part identification and sorting
        Positional input for robot
        Vision guided Robots
        Robotic system
        Vision system
        Part handling
Automated material handling
1. Selection factors
  1. Part shape/weight
  2. distances
  3. Path condition
  4. Level of automation
2. Flexible material handling
  1. Self Guided Vehicles
    1. calculate own paths
  2. Automated Guided Vehicles
    1. follow pre-set paths
  3. Material transfer systems
  4. Part Tracking
    1. Bar code
    2. Magnetic Strips
    3. R.F. tags
  5. End effectors
    1. allow robot-part interaction
Learning from humans
1. Learning algorithms
2. Targeted skills
  1. Trajectory
  2. Grasping
3. Direct Learning
  1. Humans Perform
    1. robot follows
      1. Joysticks/manipulators
  2. Raw sensor data
4. Indirect Learning
  1. Robot observes and learns
    1. Vision sensing
    2. Reasoning logic
    3. Decision making
  2. Learns concept
    1. high level learning methods
      1. e.g. grasping hot coffee mug to filll
Human Robot collaboration
1. Semi-automation requires humans
  1. safety
    1. Dynamic safety system
      1. Progressive light screens
      2. Vision systems
      3. Dynamic speed settings
    2. Robot aware of human activity
  2. Human factors
    1. Time study
    2. MODAPTS
      1. work action code
      2. Establish time for job
      3. Establish best method and layout
      4. Balance flow of work
      5. Develop S.O.P and WI
      6. Uses MOD to describe unit of human work
Virtual Engineering
1. Current
  1. Requirements
    1. Mechanical
      1. Electrical
        Commisioning
  2. Finds problems too late
  3. Validation done on real system
    1. Long and expensive commissioning
  4. Unknown production rate until running
2. Reduces on-site commissioning
  1. Digital validation
  2. PLC program validation (against virtual Equip)
3. reuse components from digital library
Virtual Commissioning
1. Emulation environment to validate control logic and test systems
  1. Reduce design cost
    1. testing and decision making
  2. Emulation
    1. validate PLC and user interface
  3. Virtual Production System Analysis
    1. Production rate
    2. resource working rate etc
  4. Support for human operations
    1. Anthropomorphic settings
    2. MODAPTS code
2. User benefits
  1. Faster delivery of systems
  2. Reduced startup time and ramp up
    1. shorter time to market
  3. Reduced overall project cost
  4. system validated BEFORE its built
  5. Avoid costly prototypes
  6. Increase process effectiveness
Business
1. challenges
  1. Awareness
  2. Risk
  3. Skills
  4. Training
2. Steps to automate
  1. Phase 1
    1. Manual production
      1. single independant workstations
  2. Phase 2
    1. Automated production stations
      1. Manual handling
  3. Phase 3
    1. Automated Production
      1. Automated handling
3. Benefits of automation
  1. Improve quality and consistency
  2. More staff utilization
  3. reduces operating costs and waste
  4. Increases output and yield
  5. reduces labour turnover
  6. increased flexibility
  7. saves floor space
  8. reduces long term capital costs
  9. unmanned operations
4. Understanding costs
  1. True cost of manual Ops
  2. Reliability
  3. Eliminating variability
  4. Costs of reworks and waste
  5. running costs
  6. Maintenance costs
  7. cost of floor space
  8. Added productivity
  9. Training
  10. Cost of H&S compliance
5. Economical aspects
  1. Type and cost of equipment
  2. Cost of running and maintenance
  3. Skill level and labour required
  4. Production quantity
  5. APPROPRIATE LEVEL OF AUTOMATION
    1. selective automation

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