1. Part II AUTOMATION AND CONTROL TECHNOLOGIES
Chapters:
Introduction to Automation
Industrial Control Systems
Hardware Components for Automation and Process Control
Numerical Control
Industrial Robotics
Discrete Control Using Programmable Logic Controllers and Personal Computers
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2. Automation and Control Technologies in the Production System (Fig. 4
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3. Ch 4 Introduction to Automation
Sections:
Basic Elements of an Automated System
Advanced Automation Functions
Levels of Automation
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4. Automation Defined
“Automation is the technology by which a process or procedure is accomplished without human assistance”
Basic elements of an automated system:
Power - to accomplish the process and operate the automated system
Program of instructions – to direct the process
Control system – to actuate the instructions
It is implemented using a Program of Instructions combined with
a Control System that executes the instructions.
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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover

5. Elements of an Automated System
Fig. 4.2
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6. Power to Accomplish the Automated Process
Power for the process
To drive the process itself
To load and unload the work unit (into proper position and orientation for the process to be performed)
Transport between operations
Power for automation
Controller unit
Power to actuate the control signals
Data acquisition and information processing
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7. Controller Unit (digital computer)
Read program of instructions
Make the control calculations
Execute instructions by transmitting the proper commands to the actuating devices
Actuaters are electromechanical devices such as switches and motors.
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8. 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
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9. 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
During each step, there are one or more activities involving changes in one or more process parameters
Examples:
Temperature setting of a furnace
Axis position in a positioning system
Motor on or off
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10. A new part or parts are completed during each work cycle.
The actions performed by an automated process are defined by a “Program of Instructions”.
A new part or parts are completed during each work cycle.
The particular processing steps for the work cycle are specified in a “Work Cycle Program” (part programs).
The program of instructions is repeated each work cycle without deviation.
In many cases, the corresponding instructions for dealing with variations are incorporated into the regular program.
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11. 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 (nonstandard/unidentical parts)
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12. 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?
Operator interaction – is operator required 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
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13. Control System
The Control element of the automated system executes the program of instructions.
The control system causes the process to accomplish its defined function, to carry out some manufacturing operation.
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14. Control System – Two Types
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
Open-loop control system – operates without the feedback loop
Simpler and less expensive
Risk that the actuator will not have the intended effect
E.g. Car parking sensors
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15. Input Parameter (set point) represents the desired value of the output
The process is the operation or function being controlled (output value)
A sensor is used to measure the output variable and close the loop between input and output.
The controller compares the output with the input and makes the required adjustment in the process to reduce the difference between them.
The adjustment is accomplished using one or more actuators which are the hardware devices that physically carry out the control actions.
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16. (a) Feedback Control System and (b) Open-Loop Control System
An open-loop control system operates without the feedback loop.
No comparison is made between the actual value of the output and the desired input parameter.
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17. 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
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18. When to Use an 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
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19. Advanced Automation Functions
In addition to executing work cycle programs, an automated system may be capable of executing advanced functions that are not specific to a particular work unit.
In general, functions are concerned with enhancing the safety and performance of the equipment.
Advanced automation functions are made possible by special subroutines included in the program of instructions.
Safety monitoring
Maintenance and repair diagnostics
Error detection and recovery
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20. Safety Monitoring
“Use of sensors to track the system's operation and identify conditions that are unsafe or potentially unsafe”
Reasons for safety monitoring
To protect workers and equipment
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
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21. Safety monitoring - Examples
Temperature sensors
Heat or smoke detectors
Pressure sensitive floor pads
Vision systems
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22. Maintenance and Repair Diagnostics
Maintenance and Repair Diagnostics refer to the capabilities of an automated system to assist in identifying the source of potential or actual malfunctions and failures of the system.
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23. Maintenance and Repair Diagnostics
Status monitoring
Monitors and records status of key sensors and parameters during system operation
Provide information for diagnosing a current failure
Provide data to predict a future malfunction or failure
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
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24. Errors
Random errors occur as a result of the normal stochastic nature of the process
Systematic errors are those that result from some assignable cause such as a change in raw material properties
Aberrrations (disorders) result from either an equipment failure or a human mistake
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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover

25. 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
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
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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover

26. Levels of Automation
Device level – actuators, sensors, and other hardware components to form individual control loops for the next level (lowest level in the hierarchy)
Machine level – CNC machine tools and similar production equipment, industrial robots, material handling equipment
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27. Levels of Automation
Cell or system level – a manufacturing cell or system is a group of machines or workstations connected and supported by a material handling system, computer and other equipment appropriate to the manufacturing process
Part dispatching and machine loading
Coordination among machines and material handling system
Collecting and evaluating inspection data
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28. Levels of Automation Plant level – factory or production systems level
Order processing
Process planning
Inventory control
Purchasing
Material Requirements Planning
Shop floor control
Quality control
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29. Levels of Automation Enterprise level – corporate information system
Marketing/Sales
Accounting
Design
Research
Aggregate planning
Master Production Scheduling
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30. Levels of Automation
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