Introduction To Automation

Introduction to Automation
Topics to be Discussed
▪ Basic Elements of an Automated System
▪ Advanced Automation Functions
▪ Levels of Automation
Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automation and Control Technologies in the
Production System
Automation Defined
Automation is the technology by which a process or

procedure is accomplished without human
assistance.
▪ Basic elements of an automated system:

1. Power - to accomplish the process and operate
the automated system
2. Program of instructions – to direct the process
3. Control system – to actuate the instructions
Elements of an Automated System
Electricity - The Principal Power Source
▪ Widely available at moderate cost
▪ Can be readily converted to alternative forms, e.g.,

mechanical, thermal, light, etc.
▪ Low level power can be used for signal transmission,

data processing, and communication
▪ Can be stored in long-life batteries
Power to Accomplish the Automated Process
▪ Power for the process

▪ To drive the process itself
▪ To load and unload the work unit
▪ Transport between operations
▪ Power for automation

▪ Controller unit
▪ Power to actuate the control signals
▪ Data acquisition and information processing
Program of Instructions
Set of commands that specify the sequence of steps in the
work cycle and the details of each step
▪ Example: CNC part program (work cycle programs)
▪ During each step, there are one or more activities

involving changes in one or more process parameters
▪ Examples:
▪ Temperature setting of a furnace (simplest
automated process)
▪ Axis position in a positioning system
▪ Motor on or off
Decision-Making in a Programmed Work
Cycle
▪ The following are examples of automated work cycles in which
decision making is required:
▪ Operator interaction
▪ Automated teller machine
▪ Different part or product styles processed by the system

▪ Robot welding cycle for two-door vs. four door car models
▪ Variations in the starting work units

▪ Additional machining pass for oversized sand casting
Features of a Work Cycle Program
▪ Number of steps in the work cycle

▪ Manual participation in the work cycle (e.g., loading
and unloading workparts)
▪ Process parameters - how many must be controlled?
Continuous or discreate? etc
▪ Operator interaction - does the operator need to enter
processing data?
▪ Variations in part or product styles
▪ Variations in starting work units - some adjustments in
process parameters may be required to compensate
for differences in starting units
Example: An Automated Turning Operation
▪ Consider an automated turning operation that generates a cone-
shaped product. The system is automated and a robot loads and
unloads the work units. The work cycle consists of the following steps:
(1) load starting workpiece, (2) position cutting tool prior to turning, (3)
turn, (4) reposition tool to a safe location at end of turning, and (5)
unload finished workpiece. Identify the activities and process
parameters for each step of the operation.
▪ Try at home
▪ Hint: In step (2), the activity is the movement of the cutting tool to a
“ready” position. The process parameters associated with this
activity are the x- and z-axis position of the tool.
Control System – Two Types
The control element of the automated system executes the program of
instructions. The control system causes the process to accomplish its
defined function, which is to perform some manufacturing operation.
1. Closed-loop (feedback) control system – a system in which the

output variable is compared with an input parameter, and any
difference between the two is used to drive the output into
agreement with the input
2. Open-loop control system – operates without the feedback loop

▪ Simpler and less expensive
▪ Risk that the actuator will not have the intended effect
(a) Feedback Control System and
(b) Open-Loop Control System
(a)
(b)
Possible Applications: Open-Loop Control System
▪ Actions performed by the control system are simple

▪ Actuating function is very reliable
▪ Any reaction forces opposing the actuation are small
enough as to have no effect on the actuation
▪ If these conditions do not apply, then a closed-loop control
system should be used
Positioning System Using Feedback Control
A one-axis position control system consisting of a

leadscrew driven by a dc servomotor and using an optical
encoder as the feedback sensor
In case of open loop, stepper motor is used.
Advanced Automation Functions
▪ Safety monitoring
▪ Maintenance and repair diagnostics
▪ Error detection and recovery
Made possible by including special subroutines in the

program
▪ Information only (preventive maintenance)
▪ Information and execution of action as well
(corrective)
Safety Monitoring
Use of sensors to track the system's operation and
identify conditions that are unsafe or potentially unsafe
▪ Possible responses to hazards:

▪ Complete stoppage of the system
▪ Sounding an alarm
▪ Reducing operating speed of process
▪ Taking corrective action to recover from the safety
violation (very sophisticated among all the above)
Some of the Possible Sensors
▪ Limit switches to detect proper positioning of a part
▪ Photoelectric sensors triggered by the interruption of a light beam
▪ Temperature sensors to indicate that a metal work part is hot enough
to proceed with a hot forging operation• Heat or smoke detectors to
sense fire hazards.
▪ Pressure-sensitive floor pads to detect human intruders in the work
cell.
▪ Machine vision systems to perform surveillance of the automated
system and its surroundings.
It should be mentioned that a given safety monitoring system is limited in

its ability to respond to hazardous conditions by the possible irregularities
that have been foreseen by the system designer.
Maintenance and Repair Diagnostics
▪ Status monitoring
▪ Monitors and records status of key sensors and
parameters during system operation
▪ Failure diagnostics
▪ Invoked when a malfunction occurs
▪ Purpose: analyze recorded values so the cause of
the malfunction can be identified
▪ Recommendation of repair procedure

▪ Provides recommended procedure for the repair crew
to effect repairs
▪ Expert systems are used
Error Detection and Recovery
▪ Error detection – functions:
▪ Use the system’s available sensors to determine

when a deviation or malfunction has occurred
▪ Correctly interpret the sensor signal
▪ Classify the error
▪ Design of the error detection subsystem must

begin with a systematic enumeration of all possible
errors that can occur during system operation
Classification of Errors
▪ (1) Random errors, (2) Systematic errors, (3) Aberrations.
▪ Random errors occur as a result of the normal stochastic

nature of the process.
▪ Large variations in part dimensions, even when the

production process is in statistical control, can cause
problems in downstream operations.
▪ By detecting these deviations on a part-by-part basis,

corrective action can be taken in subsequent operations.
▪ Systematic errors are those that result from some

assignable cause such as a change in raw material or drift
in an equipment setting.
▪ These errors usually cause the product to deviate from

specifications so as to be of unacceptable quality
▪ Aberrations, results from either an equipment failure or a

human mistake.
▪ Examples of equipment failures include fracture of a

mechanical shear pin, burst in a hydraulic line, rupture of a
pressure vessel, and sudden failure of a cutting tool.
▪ Examples of human mistakes include errors in the control

program, improper fixture setups, and substitution of the
wrong raw materials.
Two main design problems in error detection
▪ (1) Anticipating all of the possible errors that can occur in
a given process
▪ (2) Specifying the appropriate sensor systems and

associated interpretive software so that the system is
capable of recognizing each error.
▪ Solving the first problem requires a systematic evaluation of the

possibilities under each of the three error classifications.
▪ If the error has not been anticipated, then the error detection
subsystem cannot detect and identify it.
An Example: Error Detection in an Automated
Machining Cell
▪ Consider an automated cell consisting of a CNC (computer

numerical control) machine tool, a parts storage unit, and a
robot for loading and unloading the parts between the machine
and the storage unit.
▪ Possible errors that might affect this system can be divided into
the following categories: (1) machine and process, (2) cutting
tools, (3) workholding fixture, (4) part storage unit, and (5)
load/unload robot.
▪ Develop a list of possible errors (deviations and malfunctions)

that might be included in each of these five categories.
Solution
Error Detection and Recovery
▪ Error recovery – possible strategies:
▪ Make adjustments at end of work cycle

▪ Make adjustments during current work cycle
▪ Stop the process to invoke corrective action
▪ Stop the process and call for help
Example: Error Recovery in an Automated
Machining Cell
Levels of Automation
▪ Device level – actuators, sensors, and other hardware
components to form individual control loops for the next
level
▪ Machine level – CNC machine tools and similar
production equipment, industrial robots, material
handling equipment
▪ Cell or system level – manufacturing cell or system
▪ Plant level – factory or production systems level
▪ Enterprise level – corporate information system
Levels of Automation

Introduction To Automation

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Introduction To Automation

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Introduction to Automation

Automation is the technology by which a process or

▪ Basic elements of an automated system:

▪ Widely available at moderate cost

▪ Can be readily converted to alternative forms, e.g.,

▪ Low level power can be used for signal transmission,

▪ Can be stored in long-life batteries

▪ Power for the process

▪ Power for automation

▪ During each step, there are one or more activities

▪ Different part or product styles processed by the system

▪ Variations in the starting work units

▪ Number of steps in the work cycle

1. Closed-loop (feedback) control system – a system in which the

2. Open-loop control system – operates without the feedback loop

▪ Actions performed by the control system are simple

A one-axis position control system consisting of a

In case of open loop, stepper motor is used.

▪ Maintenance and repair diagnostics

▪ Error detection and recovery

Made possible by including special subroutines in the

▪ Possible responses to hazards:

It should be mentioned that a given safety monitoring system is limited in

▪ Recommendation of repair procedure

▪ Use the system’s available sensors to determine

▪ Design of the error detection subsystem must

▪ Random errors occur as a result of the normal stochastic

▪ Large variations in part dimensions, even when the

▪ By detecting these deviations on a part-by-part basis,

▪ Systematic errors are those that result from some

▪ These errors usually cause the product to deviate from

▪ Aberrations, results from either an equipment failure or a

▪ Examples of equipment failures include fracture of a

▪ Examples of human mistakes include errors in the control

▪ (2) Specifying the appropriate sensor systems and

▪ Solving the first problem requires a systematic evaluation of the

▪ Consider an automated cell consisting of a CNC (computer

▪ Develop a list of possible errors (deviations and malfunctions)

▪ Error recovery – possible strategies:

▪ Make adjustments at end of work cycle

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