Introduction The topic “INDUSTRIAL AUTOMATION & ROBOTICS” Deals with the study & analysis of highly developed & efficient Manufacturing processes, with help of automated controlling systems, robots, & robotic technology. These production systems are ruling the industrial markets in highly developed countries like Japan, America,China…etc. Automation & Robotics gave a huge momentum for the development to the overall manufacturing & mechanical engineering industries. so let us move ahead…..

Reasons for Automating 1. To increase labor productivity 2. To reduce labor cost 3. To mitigate the effects of labor shortages 4. To reduce or remove routine manual and clerical tasks 5. To improve worker safety 6. To improve product quality 7. To reduce manufacturing lead time 8. To accomplish what cannot be done manually 9. To avoid the high cost of not automating

Introduction to PROGRAMMABLE LOGIC CONTROLLERS

Heart of automation…! A programmable logic controller(PLC) is the core part of automation system. The PLC’s are nothing but small computers dedicated to automation task in an industrial environment,cabled relay control (hence 'logic'), analog (pneumatic, hydraulic) “governors, real-time (embedded) computer with extensive input/output

 The programmable logic controllers are computers based devices capable of controlling many types of industrial equipment & entire automated system.  The plc’s are also called as programmable logic controllers because its operations requires logic functions to be performed.  PLC’S were introduced in 1969 & today they are widely used in software’s instead of relays.  A PLC produces on/off voltage outputs & can actuate elements such as electric motors, fans, heaters, light switches etc.  Today there are hundreds of diff. PLC’S available in market. They differ in their memory size, input capacity,o/p capacity & the features offered.

Components of PLC’S 1)PROCESSOR: - ( executes a program to perform the specific operations.) 2 ) CPU-. ( Brain of PLC) 3)ALU.-( Performs mathematical calculations & makes logic decision) 4)Input/output interface :- ( it is designed to receive process & machine signals & convert them into PLC acceptable form.) 5) HOUSING- (elements of PLC are installed in suitable casing to withstand the shop environment)

1.Programming the plc is much easier than making the connections to the control panel. 2.PLC can be interfaced with plant computer system more easily than conventional relay controls. 3. PLC requires less floor space than relay controls. 4. It is more reliable & has easy maintenance 5.They are reprogrammable. 6. CAN be used in home automation, traffic signals, etc

 TO CONTROLL, MEASURE & PROTECT THE ENTIRE AUTOMATED SYSTEM.  Instrumentation of flow meters,tempreture, & position of machine parts.  HUMAN MACHINE INTERFACE(HMI) when exsists is limited to service help and controll operators display.  displays  To feed the programme & perform the operations as designed in the programmes.

SUPERVISAORY CONTROL & DATA AQUISIATION It is the computer system which monitors & controls computer industrial infrastructure, or facility based process. The SCADA, is a software which runs the entire automation process.

Industrial automation comprises of mechanical, electronic & computer based manufacturing system. It is nothing but higher degree of automation, where all the manufacturing processes is without any human aid. In this type of manufacturing system there is no any manual operation and labor work. It means that operator is required only for supervision and can operate number of machines at one time. Automation means a closed loop system in which there is a provision of feedback. There are four main types of automation i.e. 1.Fixed automation 2.Programmable automation 3. Flexible automation 4.Integrated automation

 The machines are arranged as per the sequence of operations to be performed.  The product design is constant for a long period of time.  For example, transfer lines, automated assembly lines etc

 The sequence of the operations depends on the program.  The program & physical setup has to be changed for new product.  Flexible to deal with variations & changes in the product configuration.  Used for low volume production where parts are produced in batches.  Eg:- NC machine tool, PLC, Industrial robots, etc.

 Capable of producing variety of parts.  No lost of time for change over when product design changes.  High initial investment.  Continous type of production.  Flexible to deal with product’s design variations.  Eg- flexible manufacturing systems.

 Manufacturing func. are linked through an integrated computer network.  These manufacturing func. Includes production planning & control, shop floor control, quality control, purchasing, marketing etc.  Allow changes in design to reduce cost & to optimize production requirments.  Eg- computer integrated manufacturing. ( C I M)

a)MAGAZINE LOADED AUTOMATIC MACHINE. b)AUTOMATIC BAR MACHINES. (single & multi spindle) c)AUTOMATIC TRANSFER MACHINES d)TRANSFER LINES. e)TRANSFER MACHINES. (in-line, rotary, drum)

In automation when machines,electronics & computers are used to control a system, It is called as control systems. It is nothing but an arrangement of different physical elements connected in such a manner so as to regulate, direct or command itself or some other system. Elements of control sysytem-  OPEN LOOP CONTROL SYSTEM- (highly prefered, easy to design hence economical).  FEED BACK/CLOSED LOOP CS- (can sense environmental changes,modifies error, noise & distortion is reduced).  SERVO CONTROL SYSYTEM- (It is used to correct perfomance of mechanism, by means of error sensing feed back, uses servomotor & runs as per servomechanism).  Process, measurment,limi switches, proximity switches,mechanical connections, servo motor, power supply units, sensors,controllers,etc. are other important parts of AUTOMATED SYSTEM.

TRANSFER LINES. AUTOMATED ASSEMBLY LINES. NC MACHINES, INDUSTRIAL ROBOTS. PACKAGING INDUSRIES. TEXTILE INDUSTRIES. IT & COMPUTER SECTOR. MANY OTHER FIELDS.

Industrial and Factory Automation affects employment, but is capable of increasing the income of an enterprise or entire national economy, as demonstrated in manufacturing hubs like Germany and Japan. Emerging markets for industrial and factory automation include high growth industries in Brazil, China, India and other developing Asian countries. In INDIA also the industrial automation is a taking place of conventional manufacturing systems to go hand in hand with global markets. Companies such as AMS,MAHINDRA & MAHINDRA,CUMMINS INDIA are leaders in the country.

Business in 2011, about $7000 MILLION INR= /-

By having a glance at all the factors of “ROBOTICS & INDUSTRIAL AUTOMATION”, it seems that these two sectors can create tremendous revoution in entire industrial field, and has great scope for high profile jobs & also bright future for worlds economy & market.

Our hearty regards & warm thanks to…  Almighty god  Internet resources  MDJIT, BHOSE  DANEKAR SIR (lect. in mechanical dept, mdjit, bhose)  SHARAD INST. OF TECH. YADRAW, ICHALKJARANJI Thank’s a lot …..