A Paper on Automation and Simulation

7/29/2019 A Paper on Automation and Simulation

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Department of mechanical Engineering,PVPIT

Automation &Simulation

By-Bhushan Chhatre (T.E. Mech)

Sai Motling (T.E. Mech)


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Email ID:- [email protected] [email protected]

Abstract

Automation is the word inspired from word automatic

Nowadays; industries are adapting over to automation to increase their

productivity as well as quality to maintain their position in market.

Automation is next step forward from mechanization enabling more

precise and reliable outputs. Automation has become a key to success

for fastest growing industries. Along with automation, simulation

plays vital role in manufacturing giving an in detail information of

product even before it is going to manufacture.

In this paper we have emphasized on types of automation

which can be used as per manufacturers requirement. The merits of

automation with respect to demerits have been studied. It also focuses

on modern trends in automation that are being used in industries. The

exact purpose of simulation in manufacturing has been also defined.
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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INDEX

1. Introduction

2. History

3. Essence of Automation

4. Revolutionizing In Industries:

Types of Automation

5. Application

Automatic Sorting Machines

Automated Inspection for Quality Control

Industrial Robots

AGV

6. Advantages of Automation

7. Disadvantages of Automation

8. Simulation

Sheet metal forming simulation

Metal casting simulation


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Automation & Simulation

1. Introduction:

Automation is the use of machines, control systems and information

technologies to optimize productivity in the production of goods and

delivery of services. In the scope of industrialization, automation is a step

beyond mechanization. Whereas mechanization provides human operators

with machinery to assist them with the muscular requirements of work,

automation greatly decreases the need for human operators while increasing

load capacity, speed, and repeatability.

2. History:

The term automation, inspired by the earlier word automatic was

not widely used before 1947, when General Motors established the

automation department. At that time automation technologies were

electrical, mechanical, hydraulic and pneumatic. Between 1957 and 1964

factory output nearly doubled while the number of blue collar workersstarted to decline.


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3. Essence of Automation:

Control Systems: It is a device, or set of devices to manage,

command, direct or regulate the behavior of other devices or system.

Industrial control system (ICS):It contains several

types of control systems used in industrial production,

including supervisory control and data acquisition (SCADA)

systems, distributed control systems (DCS), and other smaller

control system configurations such as skid-mounted

programmable logic controllers (PLC) often found in the

industrial sectors and critical infrastructures.

Numerical control (NC): It refers to the automation of

machine tools that are operated by abstractly programmed

commands encoded on a storage medium, as opposed to

controlled manually via hand wheels or levers, or mechanically

automated via cams alone.

Robotics:It isthe branch of technology that deals with the

design, construction, operation, manufacture and application of

robots and computer systems for their control, feedback, and

information processing.

4. Revolutionizing In Industries:


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Industrial Automation is a discipline that includes

knowledge and expertise from various branches of engineering

including electrical, electronics, chemical, mechanical,

communications and more recently computer and software

engineering. Automation & Control by its very nature demands a cross

fertilization of these faculties.

Types in Automation:-

Fixed Automation:-

In this type, sequence of process is fixed in equipment

configuration.

Advantages:

1. Maximum efficiency.

2. Low unit cost.

3. High production rates.

Disadvantages:

1. High initial investments.

2. Inflexible to accommodate change in product design.

Programmable Automation-


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It includes equipment designed to accommodate a

specific class. It has capabilities to change sequence of operations by

reprogramming to accommodate different product configuration.

Advantages:-

1. Flexibility to do changes in product design.

2. Low unit cost for large batches.

3. Most suitable for batch production.

Disadvantages:-

1. New product needs long set up time.

2. High investments for costumed engineering systems.

Flexible Automation:

It includes system capable of changing over from one

job to another job to another job in least possible time.

Advantages

1. Flexibility to deal with new product design.

2. Useful in manufacturing of customized products.

Disadvantages:

1. High initial investments.

2. Medium production rates.

3. High unit cost.


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5. Applications:

1. Automatic Sorting Machines:

The Autosort is a multifunctional sorting system to

recover a wide range of pieces of material from different

waste streams, single stream, packaging, paper, household

waste and other sorting tasks looking for enhanced material

information and color in combination.

The Autosort uses the new DUOLINE scanning

technology which conducts a double scan on every pass.

Extremely fast and extremely reliable sensors take between

the scanner unit and the conveyer belt while maintaining

the high resolution. In order to sort different material grain

sizes, machines are available in a number of resolution

stages. The highest resolution is about 2.5 mm. alongside


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its superior sorting quality;it provides a high degree of

input material, built-in maintenance and control functions

of the valve units and the option of controlling and

monitoring the sorting unit from a control room.

Benefits:

1. Extremely fast process.

2. Low operating costs.

3. High quality sorting regarding purity, thought.

4. Switch able between wide ranges of sorting tasks.

5. Easily adaptable to your process.

2. Automated Inspection for Quality Control:

In present scenario, manual inspection is largely

replaced by automated inspection as errors are reduced to

great extent by automation of the process. Economic

justification of an automated inspection system depends on

whether the savings in labor cost & improvement in


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accuracy will be more than the investment and/or

development costs of the system. Automated inspection is

defined as the automation of one or more steps involved in

the inspection procedure. Automated or semi-automated

inspection can be implemented in the number of alternative

ways.Machine vision (MV) is the technology and methods

used to provide imaging-based automatic inspection and

analysis for such applications as automatic inspection,

process control, and robot guidance in industry.

Machine vision is the technology to replace or complement

manual inspections and measurements with digital cameras

and image processing. The technology is used in a variety

of different industries to automate the production, increase


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production speed and yield, and to improve product

quality. Machine vision in operation can be described by a

four-step flow:

1.Imaging: Take an image.

2. Processing and analysis: Analyze the image.

3. Communication: Send the result to the system in

control of the process.

4. Action: Take action depending on the vision system's

result.

In inspection applications the purpose of the visionsystem is to validate certain features, for example presence

or absence of a correct label on a bottle, screws in an

assembly, chocolates in a box, or defects. In the example to

the right, a camera inspects brake pads for defects.

3. Industrial Robots:-

Robots can substitute for humans in hazardous

work environments. Consistency and accuracy achieved by

robots not attainable by humans. They can be

reprogrammed. Most robots are controlled by computers

and can therefore be interfaced to other computer systems.

Robot manipulator consists of two sections:

1. Body-and-arm They are used for positioning of

objects in the robots work volume.

2. Wrist assembly It is required for orientation of

objects.

The two main types of robots are as follows:


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1. Grippers They grasp and manipulate objects (e.g.,

parts) during work cycle.

2. Tools They are used to perform a process, e.g., spot

welding, spray painting.

Applications:

1. Material handling applications

Material transfer pick-and-place, palletizing

Machine loading and/or unloading

2. Processing operations

Spot welding and continuous arc welding

Spray coating waterjet cutting, laser cutting, grinding.

3. AGV (Automated Guided Vehicles):

An automated guided vehicle or automatic guided

vehicle (AGV) is a mobile robot that follows markers or

wires in the floor, or uses vision or lasers. They are most

often used in industrial applications to move materials

around a manufacturing facility or a warehouse.

Advantages:

Clear floor space.


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Simple installation

High availability/reliability

Flexible performance increments.

Short installation times.

Tracking Methods

Optical Tracks contrasting color

Wire Embedded in floor

Inertial Gyro with magnets in floor.

Laser Triangulation from reflective target

Charging Method

Standard Charging (Battery swap)

In-Vehicle (Opportunity) Charging

Inductive Charging

6. Advantages of Automation

1.Increased throughput or productivity.

2. Improved quality or increased predictability.


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3. Improved consistency, of processes or product.

4. Reduce Production Cost

5. Better Floor Space Utilization

6. Reduce Waste

7. Disadvantages of automation

1. Security Threats/Vulnerability: An automated system may

have a limited level of intelligence, and is therefore more

susceptible to committing errors outside of its immediate scope

of knowledge.

2. Unpredictable/excessive development costs: Theresearch

and developmentcost of automating a process may exceed the

cost saved by the automation itself.

3. High initial cost: The automation of a newproduct orplant

typically requires a very large initial investment in comparison

with the unit cost of the product, although the cost of automation

may be spread among many products and over time.

4. Current technology is unable to automate all the desired tasks.

5. Lower skill levels of workers.

6. Not economically justifiable for small scale production.

5. Simulation:

In a traditional workflow, engineers frequently

could nottest and validate their control system designs

until late in the development cycle, when motors, sensors,

actuators, and other system hardware finally became
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available. This approach was sufficient when expected

system behavior was predictable. Simulation software is

based on the process of modeling a real phenomenon with

a set of mathematical formulas. It is, essentially, a program

that allows the user to observe an operation through

simulation without actually performing that operation.

Simulation software is used widely to design equipment so

that the final product will be as close to design specs as

possible without expensive in process modification.

Simulations are also used to test new theories. Aftercreating a theory of causal relationships, the theorist can

codify the relationships in the form of a computer program.

If the program then behaves in the same way as the real

process, there is a good chance that the proposed

relationships are correct.

Sheet metal forming simulation

Sheet metal forming simulation software utilizes

mathematical models to replicate the behavior of an actual

metal sheet manufacturing process.Essentially, it is a

computer program that converts a computer into a fully

functioning metal manufacturing prediction unit. efficiency


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in the metal forming.

Metal Casting Simulation

Metal castingsimulation is currently performed by

Finite Element Method simulation software designed as a

defect-prediction tool for the foundry engineer, in order to

correct and/or improve his/hercasting process, even before

prototype trials are produced. The idea is to use information to

analyze and predict results in a simple and effective manner to

simulate different processes such as:

1. Gravity sand casting.
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2. Gravity die casting.

3. Gravity tilt pouring.

4. Low pressure die casting.

5. High pressure


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Documents

A Paper on Automation and Simulation