History of Automation

Sai Anjaneya
Applications of Automation
 Home Automation –
 Air Conditioner, Geyser, Washing Machine,
Cleaning Robot
 Building Automation –
 Elevators, Automatic door opening, fire alarms,
automatic parking
 Office Automation –
 Fax, Printer, MS Word, Smart Phones, PC
 Mobility Automation –
 Aircraft, Boats, ships, bikes, cars, rails
 Industrial Automation –
 Robots, Design and Manufacturing Software, Whole
plant
Industrial Automation
Automation Video
 History of material processing technologies
Year Casting Deformation Joining Machining Ceramics Plastics

4000 B.C. Stone, clay Bending, forging Riveting Stone, emery, Earthenware Wood, natural
molds (Au, Ag, Cu) corundum, fiber
garnet, flint
2500 BC Lost wax Shearing, sheet Soldering, Drilling, sawing Glass beads,
(bronze) forming brazing potter's wheel
1000 BC Hot forging Forge welding, Iron saws Glass pressing,
(iron), wire- gluing glazing
drawing (?)
0. A.D. Coining (brass), Turning (wood), Glass blowing
forging (steel) filing

1000 Wire drawing Stoneware,

porcelain
(China)
1400 Sand casting, Water hammer Sandpaper Majolica, crystal
cast iron glass
1600 Permanent mold Tinplate can, Wheel lathe
rolling (Pb) (wood)
1800 Flasks Deep drawing, Boring, turning, Plate glass;
rolling, (steel), screw cutting porcelain
extrusion (Pb) (Germany)

1850 Centrifugal, Steam hammer, Shaping, milling, Window glass Vulcanization

molding tinplate rolling copying lathe from slit cylinder
machine
 History of material processing technologies
Year Casting Deformation Joining Machining Ceramics Plastics
1875 Rail rolling, Turret lathe, Celluloid, rubber
continuous universal mill, extrusion,
rolling vitrified wheel molding

1900 Tube rolling, Oxyacetylene, Geared lathe, Automatic bottle

extrusion (Cu) arc welding, automatic screw making
electrical machine,
resistance hobbing, high-
welding speed steel,
synthetic SiC,
Al2O3
1920 Die casting W wire (from Coated Bakelite, PVC
powder) electrode casting, cold
molding,
injection
molding
1940 Lost wax for Extrusion (steel) Submerged arc Acrylics, PMMA,
engineering P.E., nylon,
parts, resin- synthetic rubber,
bonded sand transfer
molding,
foaming
1950 Ceramic mold, Cold extrusion TIG welding, EDM ABS, silicones,
modular iron, (steel) MIG welding, fluorocarbons,
semi-conductors electroslag polyurethane

1960 Plasma arc Manufactured Float-glass Acetals,

diamond polycarbonate,
polypropylene
Selected Events in the History of Automation

• Organized automation, mechanization: Industrial revolution, 1770-

, England, Europe, US

• Hard automation and transfer lines: Henry Ford, 1900-, USA

• Numerically Controlled (NC) machine tools, 1952 (US Air Force,

MIT)

• Microchip computers: late 1960-, USA

• CNC (computer numerical controlled) machine tools, 1970-, USA

• Industrial Robots, USA, Japan, 1970-

• Computer networks, DARPA USA, 1970-

• Flexible Manufacturing Systems (FMS), Japan, 1980-.

Functions of Industry
 9

Types of Automation

Number of
different parts

Programmable
High automation

Production
Variety Flexible
Medium automation

Fixed
Low Manual automation

Low Medium High Parts per year

Production Volume
Examples of Automation

Automatic rice cooker

Put the rice and water in it in the morning, set it to start cooking at 6pm.
It turns on automatically.
When the rice is cooked, it switches to “keep warm” mode.

Q1. How does it control when to turn

on?
Q2. What type of sensor(s) and actuators are inside this
machine?
Q3. How would you sense when the rice is cooked?

Q4. How can the rice be kept warm for up to 12 hours?

Q5. The cooker can be set to cook different food types (rice, congee, fish…
How is the logic for so many functions controlled?
Examples of Automation

Park and Shop

The sales clerk ‘swipes’ item across a glass sheet on top of the counter.
The price (and name) of the item are automatically printed on the receipt.
The receipt also calculates the total price of all items you have bought.

Q1. Identify the sensors and actuators in this

example.
Q2. Is this an example of digital or analog control?

Q3. How does the system know what item was swiped?

Q4. How does the system know the price and name of the item?

Q5. How can the information of “which item is purchased” be used

to improve customer service?
Open Loop, Closed Loop Systems

Signal Actuator Device

Signal - Actuator Device

feedback
Sensor
Basic Structure of Automatic Control System

PLC Microprocessor Computers

Communication network

Network Interface

Analog controls
A/D D/A
Analog converter converter Digital Signals
Signals

Sensors and Actuators

Physical Process
 Technologies

14
 CNC Milling Machine

15 4-Feb-17
 3D Printing

18
What are levels of automation

Video
Levels of Automation
Levels Description Attributes
Level 0 Labor Mechanization
Level 1 Scripts Automation
Level 2 Orchestration Level 1 + Adaptability
Level 3 Autonomics Level 2 + Awareness
Level 4 Pre-cognitive Level 3 + Analytics
Level 5 Cognitive Level 4 + Alive
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REASONS FOR AUTOMATING

 Increased productivity.
 High cost of labor.
 Labor shortages.
 Trend of labor towards service sector.
 Safety.
 High cost of raw materials.
 Improved product quality.
 Reduced manufacturing lead-time.
 Reduction of in process inventory.
 High cost of not automating.
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ARGUMENTS AGAINST AUTOMATION

Automation will result in the subjugation of the human

being via machine.
There will be a reduction in the labor force with resulting
unemployment.
Automation will reduce purchasing power.
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ARGUMENTS IN FAVOUR OF AUTOMATION

 Automation is the key to the shorter work week.

 Automation brings safer working conditions for the
workers.
 Automated production results in lower prices and
better products.
 The growth of automation industries will itself provide
employment opportunities.
 Automation is the only means of increasing our
standard of living.
the Near Future
Industry 4.0
Internet of Things

Source: IAC
Wearable technologies
Autonomous Car