UNIT I

INTRODUCTION TO AUTOMATION
Objective:
 Too know about the Automation and types of Automations in the industries.

Outcome:
 Students will understand the process of automation and types

Introduction: Types and strategies of automation, pneumatic and hydraulic components

circuits, Automation in machine tools, Mechanical Feeding and to changing and machine
tool control transfer the automation

UNIT –I

1. Types of Automation System with examples

Automated production systems can be classified into three basic types:

1. Fixed automation,
2. Programmable automation, and
3. Flexible automation.
2. Fixed Automation examples

FIXEDAUTOMATION
It is a system in which the sequence of processing (or assembly) operations is fixed by the
equipment configuration. The operations in the sequence are usually simple. It is the
integration and coordination of many such operations into one piece of equipment that
makes the system complex. The typical features of fixed automation are:

a. High initial investment for custom–Engineered equipment;

b. High production rates; and
c. Relatively inflexible in accommodating product changes.

The economic justification for fixed automation is found in products with very high
demand rates and volumes. The high initial cost of the equipment can be spread over a very
large number of units, thus making the unit cost attractive compared to alternative methods
of production. Examples of fixed automation include mechanized assembly and machining
transfer lines.

PROGRAMMABLEAUTOMATION
In this the production equipment is designed with the capability to change the sequence of
operations to accommodate different product configurations. The operation sequence is
controlled by a program, which is a set of instructions coded so that the system can read
and interpret them. New programs can be prepared and entered into the equipment to
produce new products. Some of the features that characterize programmable automation
are:
 a. High investment in general-purpose equipment;
b. Low production rates relative to fixed automation;
c. Flexibility to deal with changes in product configuration; and
d. Most suitable for batch production.

Automated production systems that are programmable are used in low and medium volume
production. The parts or products are typically made in batches. To produce each new
batch of a different product, the system must be reprogrammed with the set of machine
instructions that correspond to the new product. The physical setup of the machine must
also be changed over: Tools must be loaded, fixtures must be attached to the machine table
also be changed machine settings must be entered. This changeover procedure takes time.
Consequently, the typical cycle for given product includes a period during which the setup
and reprogramming takes place, followed by a period in which the batch is produced.
Examples of programmed automation include numerically controlled machine tools and
industrial robots

FLEXIBLEAUTOMATION
It is an extension of programmable automation. A flexible automated system is one that is
capable of producing a variety of products (or parts) with virtually no time lost for
changeovers from one product to the next. There is no production time lost while
reprogramming the system and altering the physical setup (tooling, fixtures, and machine
setting). Consequently, the system can produce various combinations and schedules of
products instead of requiring that they be made in separate batches. The features of flexible
automation can be summarized as follows:

1. High investment for a custom-engineered system.

2. Continuous production of variable mixtures of products.
3. Medium production rates.
4. Flexibility to deal with product design variations.

The essential features that distinguish flexible automation from programmable automation
are:

1. the capacity to change part programs with no lost production time; and
2. the capability to changeover the physical setup, again with no lost production time.

These features allow the automated production system to continue production without the
downtime between batches that is characteristic of programmable automation. Changing
the part programs is generally accomplished by preparing the programs off-line on a
computer system and electronically transmitting the programs to the automated production
system. Therefore, the time required to do the programming for the next job does not
interrupt production on the current job. Advances in computer systems technology are
largely responsible for this programming capability in flexible automation. Changing the
physical setup between parts is accomplished by making the changeover off-line and then
moving it into place simultaneously as the next part comes into position for processing.
The use of pallet fixtures that hold the parts and transfer into position at the workplace is
one way of implementing this approach. For these approaches to be successful; the variety
of parts that can be made on a flexible automated production system is usually more
limited than a system controlled by programmable automation.

The relative positions of the three types of automation for different production volumes
and product varieties are depicted in the following figure.

3. Automation in Production system

Types of production automation

Understand, simplify and automate the process

Following the USA Principle is a good first step in any automation project.
The USA Principle is a common sense approach to automation projects. Similar procedures
have been suggested in
the manufacturing and automation trade literature, but none has a more captivating title
than this one.
USA stands for:
1. Understand the existing process
2. Simplify the process
3. Automate the process.
It may turn out that automation of the process is unnecessary or cannot be cost justified
after it has been simplified.

If automation seems a feasible solution to improving productivity, quality, or other

measure of performance, then
the following ten strategies provide a road map to search for these improvements.
These ten strategies seem as relevant and appropriate today as they did in 1980. We refer to
them as strategies for
automation and production systems because some of them are applicable whether the
process is a candidate for
automation or just for simplification.
1. Specialization of operations
The first strategy involves the use of special-purpose equipment designed to perform one
operation with the
greatest possible efficiency.
This is analogous to the concept of labor specialization, which is employed to improve
labor
productivity.
2. Combined operations
Production occurs as a sequence of operations.
Complex parts may require dozens, or even hundreds, of processing steps. The strategy of
combined operations
involves reducing the number of distinct production machines or workstations through
which the part must be routed.
This is accomplished by performing more than one operation at a given machine , thereby
reducing the number of
separate machines needed.
Since each machine typically involves a setup, setup time can usually be saved as a
consequence of this
strategy. Material handling effort and non-operation time are also reduced.
Manufacturing lead time is reduced for better customer service.
3. Simultaneous operations
A logical extension of the combined operations strategy is to simultaneously perform the
operations that are
combined at one workstation. In effect, two or more processing (or assembly) operations
are being performed
simultaneously on the same workpart, thus reducing total processing time.
4. Integration of operations
Another strategy is to link several workstations together into a single integrated
mechanism, using automated
work handling devices to transfer parts between stations. In effect, this reduces the number
of separate machines
through which the product must be scheduled.
With more than one workstation, several parts can be processed simultaneously, thereby
increasing
the overall output of the system.

5. Increased flexibility
This strategy attempts to achieve maximum utilization of equipment for job shop and
medium volume situations
by using the same equipment for a variety of parts or products. It involves the use of the
flexible automation concepts.
Prime objectives are to reduce setup time and programming time for the production
machine. This normally
translates into lower manufacturing lead time and less work-in-process.
6. Improved material handling and storage
A great opportunity for reducing nonproductive time exists in the use of automated
material handling and storage
systems.
Typical benefits include reduced work-in-process and shorter manufacturing lead times.
7. On-line inspection
Inspection for quality of work is traditionally performed after the process is completed.
This means that any poor
quality product has already been produced by the time it is inspected. Incorporating
inspection into the manufacturing
process permits corrections to the process as the product is being made.
This reduces scrap and brings the overall quality of product closer to the nominal
specifications
intended by the designer.
8. Process control and optimization
This includes a wide range of control schemes intended to operate the individual processes
and associated
equipment more efficiently. By this strategy, the individual process times can be reduced
and product quality
improved.
9. Plant operations control
Whereas the previous strategy was concerned with the control of the individual
manufacturing process, this strategy
is concerned with control at the plant level. It attempts to manage and coordinate the
aggregate operations in the
plant more efficiently.
Its implementation usually involves a high level of computer networking within the
factory.
10. Computer-integrated manufacturing (CIM)
Taking the previous strategy one level higher, we have the integration of factory operations
with engineering
design and the business functions of the firm.

• It is a hardware which converts a controller command signal into a change in a

physical parameter
• It requires amplifier to strengthen the controller command
• Types

– Electrical
– Hydraulic
– Pneumatic

Basic Components of a Hydraulic System

Hydraulic systems are power-transmitting assemblies employing pressurized

liquid as a fluid for transmitting energy from an energy-generating source to an
energy-using point to accomplish useful work. Figure 1.1 shows a simple circuit
of a hydraulic system with basic components.

Load
Motor 1 – Off 2 – Forward 3– Return

1
3 2
Pressure
Filter
regulator

Pump

Direction
control
valve
Actuator
Oil tank

Figure 1.1 Components of a hydraulic system

Functions of the components shown in Fig. 1.1 are as follows:

1. The hydraulic actuator is a device used to convert the fluid power into mechanical
power to do useful work. The actuator may be of the linear type (e.g., hydraulic
cylinder) or rotary type(e.g., hydraulic motor) to provide linear or rotary motion,
respectively.

2.The hydraulic pump is used to force the fluid from the reservoir to rest of the
hydraulic circuit by converting mechanical energy into hydraulic energy.
3.Valves are used to control the direction, pressure and flow rate of a fluid flowing
through the circuit.
4. Piping system carries the hydraulic oil from one place to another.
5. Filters are used to remove any foreign particles so as keep the fluid system clean
and efficient, as well as avoid damage to the actuator and valves.
6. Pressure regulator regulates (i.e., maintains) the required level of pressure in the
hydraulic fluid.

The piping shown in Fig. 1.1 is of closed-loop type with fluid transferred from
the storage tank to one side of the piston and returned back from the other side of
the piston to the tank. Fluid is drawn from the tank by a pump that produces fluid
flow at the required level of pressure. If the fluid pressure exceeds the required
level, then the excess fluid returns back to the reservoir and remains there until
the pressure acquires the required level.

Cylinder movement is controlled by a three-position change over a control valve.

1. When the piston of the valve is changed to upper position, the pipe
pressure line is connected to port A and thus the load is raised.

2. When the position of the valve is changed to lower position, the pipe
pressure line is connected to port B and thus the load is lowered.

3. When the valve is at center position, it locks the fluid into the
cylinder(thereby holding it in position) and dead-ends the fluid line (causing all
the pump output fluid to return to tank via the pressure relief).

In industry, a machine designer conveys the design of hydraulic systems using

a circuit diagram. Figure 1.2 shows the components of the hydraulic system using
symbols. The working fluid, which is the hydraulic oil, is stored in a reservoir.
When the electric motor is switched ON, it runs a positive displacement pump
that draws hydraulic oil through a filter and delivers at high pressure. The
pressurized oil passes through the regulating valve and does work on actuator.
Oil from the other end of the actuator goes back to the tank via return line. To
and fro motion of the cylinder is controlled using directional control valve.
 Cylinder
Extended

Retract

Directional control
Motor valve

Pump

Pressure regulator
Filter

Breather

Reservoir

Figure 1.2 Components of a hydraulic system (shown using symbols).

The hydraulic system discussed above can be broken down into four main
divisions that are analogous to the four main divisions in an electrical system.

4. The power device parallels the electrical generating station.

5. The control valves parallel the switches, resistors, timers, pressure switches,
relays, etc.

6. The lines in which the fluid power flows parallel the electrical lines.

7. The fluid power motor (whether it is a rotating or a non rotating cylinder

or a fluid power motor) parallels the solenoids and electrical motors.
Basic Components of a Pneumatic System

Power Opens when set

supply pressure is reached
Load

Pressure 1 – Off 2 – Forward 3- Return

switch 1
Motor 3 2
Storage
Air cooler reservoir
Air filter

Air compressor

Direction
control
Air from
valve
atmosphere
Air actuator
Air to atmosphere

Figure 1.3 Components of a pneumatic system.

The functions of various components shown in Fig. 1.3 are as follows:

1. The pneumatic actuator converts the fluid power into mechanical power to
perform useful work.
2. The compressor is used to compress the fresh air drawn from the atmosphere.
3. The storage reservoir is used to store a given volume of compressed air.
4. The valves are used to control the direction, flow rate and pressure of compressed air.
5. External power supply (motor) is used to drive the compressor.
6. The piping system carries the pressurized air from one location to another.

Air is drawn from the atmosphere through an air filter and raised to required
pressure by an air compressor. As the pressure rises, the temperature also rises;
hence, an air cooler is provided to cool the air with some preliminary treatment to
remove the moisture. The treated pressurized air then needs to get stored to
maintain the pressure. With the storage reservoir, a pressure switch is fitted to start
and stop the electric motor when pressure falls and reaches the required level,
respectively.

The three-position change over the valve delivering air to the cylinder operates
in a way similar to its hydraulic circuit.
Rotating electric motor

Solenoid

Cylinder and Piston

DEPARTMENT OF MECHANICAL ENGINEERING

NC:
NC is a form of programmable automation in which the mechanical actions of machine tools
are controlled by a program containing coded alphanumeric data.

Basic components of NC

• Part program: set of instructions or step by step commands

• Punched tape was the medium used whereas flexowriter was used to write/punch
program on it.

• Now magnetic tapes, disks, CDs are commonly used mediums

 UNIT I
POWER POINT PRESENTATION SLIDES
PRINCIPLES AND AN OVER VIEW OF AUTOMATION
IN MANUFACTURING
INTRODUCTION TO AUTOMATION
 Automation is the technology by which a process or
procedure is accomplished without human assistance.
 It is implemented using a program of instructions
combined with a control system that executes the
instructions. To automate a process,power is required,
both to drive the process itself and to operate the
program and control system.
 Although automation can be applied in a wide variety
of areas, it is most closely associated with the
manufacturing industries.
HISTORY OF AUTOMATION
The history of automation can .be traced to the development of basic
mechanical devices, such as
 The wheel (circa 3200 B.C.),
 Lever, winch (circa 600 B.C.),
 Cam (circa A,D. 1000),
 Screw(A.D. 1405),
 Windmills (circa A.D. 650),
 Steam engines (A.D.1765).
 Flour mills ( circa 85 B.C. ),
 Weaving machines (flying shuttle, 1733),
 Machine tools (boring mill, 1775),
 Steamboats (1787),
 Railroad locomotives (1803).
 Electrification (starting in 1881 )
HISTORY OF AUTOMATION CONT…
 The moving assembly line (1913), Mechanized transfer lines for mass
production, whose programs were fixed by their hardware configuration
(1924),
 A mathematical theory of control systems (1938 and 1948); and
 The MARK I electromechanical computer at Harvard University (1944).
 The first electronic digital computer was developed at University of
Pennsylvania in 1946.
 The first numerical control machine tool was developed and
demonstrated in 1952 at Massachusetts Institute of Technology based
on a concept proposed by John Pamons and Frank Stulen
 By the late 1968 and early 1970s, digital computers were being
connected to machine tools.
 In 1954, the first industrial robot was designed and patented (issued
1961) by George Devol
 The first commercial robot was installed to unload parts in a die casting
operation in 1961.
HISTORY OF AUTOMATION CONT…
 In the late 1968, the first flexible manufacturing system in
the United States was installed at Ingersoll Rand Company
to perform machining operations on a variety of parts .
 Around 1969, the first programmable logic controller was
introduced.
 In 1978, the first commercial personal computer (PC) had
been introduced by Apple Computer, although a similar
product had been introduced in kit form as early as 1975.
 Developments in computer technology were made possible
by advances in electronics, including the transistor (1948),
 hard disk for computer memory (1956),
 Integrated circuits (1960),
 The microprocessor (1971)
HISTORY OF AUTOMATION CONT…
 Random accesss memory (1984),
 Megabyte capacity memory chips (circa 1990),
 The Pentium microprocessors (1993).
 Software developments related to automation have been
equally important, including the FO RTRAN computer
programming language (1955),
 The APT programming language for numerical control (NC)
machine tools (1961),
 The UNIX operating system (1969),
 The VAL language for robot programming (1979),
 Microsoft Windows (1985),and the JAVA programming
language (1995).
 Advances and enhancements in these technologies
continue
BASIC ELEMENTS OF AN AUTOMATED SYSTEM

(1)Power,
(2)Program of instructions, and
(3)Control systems.
1. POWER TO ACCOMPLISH THE AUTOMATED
PROCESS

Common manufacturing process and their power requirements

2. PROGRAM OF INSTRUCTIONS
 The actions performed by an automated process are
defined a program of instructions.
 Whether the manufacturing operation involves low,
medium, or high production each part or product style
made in the operation requires one or more
processing steps that are unique to that style.
 These processing steps are performed during a work
cycle.
 A new part is completed during each work cycle.
 The particular processing steps for the work cycle are
specified in a work cycle program
FEATURES OF WORK CYCLE PROGRAMS USED
IN AUTOMATED SYSTEMS
3. 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, which for our purpose is to carry
out some manufacturing operation.
 Let us provide a brief introduction to control systems
here.
 The controls in an automated system can be either
closed loop or open loop
A FEEDBACK CONTROL SYSTEM
OR CLOSED LOOP CONTROL SYSTEM
 Open loop control system

A positioning system consist of a lead screw driven by a DC Motor

ADVANCED AUTOMATION FUNCTIONS

Advanced automation functions include the

following:
(1) safety monitoring,
(2) Maintenance and repair diagnostics and
(3) error detection and recovery.
1. SAFETY MONITORING
The following list suggests some of the possible sensors and
their applications for safety monitoring:

 Limit switches to detect proper positioning of a part in a

work holding device
 Photoelectric sensors triggered by the interruption of a light
beam
 Temperature sensors to indicate that a metal workpart 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 into
the work cell.
 Machine vision systems to supervise the automated system
and its surroundings
2. MAINTENANCE AND REPAIR
DIAGNOSTICS
1.Status monitoring: In the status monitoring mode, the
diagnostic subsystem monitors and records the status of key
sensors and parameters of the system during normal
operation
2. Failure diagnostics: The failure diagnostics mode is invoked
when a malfunction or failure occurs.
3. Recommendation of repair procedure: In the third mode of
operation, the subsystem provides a recommended
procedure to the repair crew as to the steps that should be
taken to effect repairs.
ERROR DETECTION AND RECOVERY
 In the operation of any automated system, there are
hardware malfunctions and unexpected events that occur
during operation. These events can result in costly delays
and loss of production until the problem has been corrected
and regular operation is restored.
 Traditionally, equipment malfunctions are corrected by
human workers, perhaps with the aid of a maintenance and
repair diagnostics subroutine.
 With the increased use of computer control for
manufacturing processes, there is a trend toward using the
control computer not only to diagnose the malfunctions but
also to automatically take the necessary corrective action to
restore the system to normal operation.
 The term error detection and recovery is used when the
computer performs these functions
LEVELS OF AUTOMATION
1. Device level: This is the lowest level in our
automation hierarchy. It includes the actuators,
sensors, and other hardware components that
comprise the machine level. The devices are
combined into the individual control loops of the
machine; for example, the feedback control loop for
one axis of a CNC machine or one joint of an
industrial robot
2. Machine level: Hardware at the device level is
assembled into individual machines. Examples
include CNC machine tools and similar production
equipment, industrial robots, powered conveyors,
and automated guided vehicles. Control functions at
this level include performing the sequence of steps
in the program of instructions in the correct order
and making sure that each step is properly
3. Cell or system level: This is the manufacturing cell or system
level, which operates under instructions from the plant
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. Production lines
are included in this level. Functions include part dispatching
and machine loading, coordination among machines and
material handling system, and collecting and evaluating
inspection data.
4. Plant level: This is the factory or production systems level. It
receives instructions from the corporate information system
and translates them into operational plans for production.
Likely functions include: order processing, process planning,
inventory control, purchasing, material requirements
planning, shop floor control, and quality control.
5. Enterprise level: This is the highest level,
consisting of the corporate information
system. It is concerned with all of the
functions necessary to manage the
company: marketing and sales, accounting,
design, research, aggregate planning, and
master production scheduling.
 UNIT I
INDUTRIAL APPLICATIONS
 UNIT I
ASSIGNMET
 Unit-I

1.

a). Differentiate fixed and programmable automation.

b). What are the principles of automation?

2.

a). What are the objectives of flow line automation?

b). What are the design and fabrication considerations in an automated flow lines.

3.

a). Define Automation. Discuss various levels of automation.

b). Differentiate between fixed and flexible automation.

4.

Explain the following linear transfer mechanisms:

(a) Walking beam system.

(b) Powered roller conveyor system.

5. Explain any two mechanical feeding device with neat sketch.

6. Explain ten Strategies of Automation ?

 UNIT I
SHORT ‘Q’ & TUTORIAL
 UNIT-I

1. What are the types of Automation?

Automated production systems can be classified into three basic types:

1. Fixed automation,
2. Programmable automation, and
3. Flexible automation.

2. Write short notes on Fixed Automation.

It is a system in which the sequence of processing (or assembly) operations is fixed by the
equipment configuration.

The typical features of fixed automation are:

a. High initial investment for custom–Engineered equipment;

b. High production rates; and
c. Relatively inflexible in accommodating product changes.

3. Write short notes on Programmable automation.

In this the production equipment is designed with the capability to change the sequence of
operations to accommodate different product configurations.

a. Low production rates relative to fixed automation;

b. Flexibility to deal with changes in product configuration
4. Write short notes on Flexible Automation.
A flexible automated system is one that is capable of producing a variety of products (or parts)
with virtually no time lost for changeovers from one product to the next.

1. High investment for a custom-engineered system.

2. Continuous production of variable mixtures of products.
3. Medium production rates.
4. Flexibility to deal with product design variations.
5. Differentiate between flexible automation and programmable automation.

The essential features that distinguish flexible automation from programmable automation are:

1. The capacity to change part programs with no lost production time; and
2. The capability to changeover the physical setup, again with no lost production time.

6. What is USA principle in Automation?

USA stands for:
1. Understand the existing process
 2. Simplify the process
3. Automate the process.
It may turn out that automation of the process is unnecessary or cannot be cost justified
after it has been simplified.
7. Write any five strategies of automation.
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility

8. What is hydraulic actuator?

The hydraulic actuator is a device used to convert the fluid power into mechanical
power to do useful work. The actuator may be of the linear type (e.g., hydraulic
cylinder) or rotary type (e.g., hydraulic motor) to provide linear or rotary motion,
respectively.
9. What are the functions of pneumatic system?
1. The pneumatic actuator converts the fluid power into mechanical power to
perform useful work.

2. The compressor is used to compress the fresh air drawn from the atmosphere.

3. The storage reservoir is used to store a given volume of compressed air.

4. The valves are used to control the direction, flow rate and pressure of compressed air.
10. What are Mechanical feeders?

1. Belt feeders

2. Apron feeders

3. Vibratory feeders

4. Screw feeders