LOWCOSTAUTOMATION
LOWCOSTAUTOMATION
LOWCOSTAUTOMATION
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4 authors, including:
Mahesh Kulkarni
Bharati Vidyapeeths college of Engineering, Kolhapur
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I.INTRODUCTION
Automation is a set of technologies that results in operation of machines and systems without significant human
intervention and achieves performance superior than manual operation. It means to minimize the human control
in industry or any work field to increase productivity, increasing product quality, reducing manufacturing time,
reducing cost and increasing safety in working operations[1].
With increasing globalisation, industrialization and increasing demand of certain products in market, Industries
are concentrating on more and more automation by different methods to increase productivity and to increase
competitiveness in the market. Automation requires huge capital investment to replace conventional machines
by CNC‟s, VMC‟s etc. Large Scale Industries which do have large scale production and sells can afford huge
cost automation. But Medium and Small-Scale Industries which do not have that much production cannot afford
such huge cost automation, at such case alternative Low-CostAutomation(LCA) proves to be best solution.
Low Cost Automation (LCA) is the technology that is effective or promises to be helpful for any kind of
manufacturing organisation.
1.1 Concept of Low Cost Automation (LCA)
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Automation means to replace human control through machines and technology. This includes automation in any
unit i.e. storage systems, production lines, assembly lines, Software etc. Low Cost Automation (LCA) is defined
as technology that creates some degree of automation using existing tools, methods and equipment. Low cost
automation involves the introduction of standard equipment, mechanisms and devices to convert manual
operations to automatic ones. Investment cost is low, as the term itself implies, and the Return of Investment in
terms of improved productivity and better work efficiency is high. LCA may best be paraphrased as “simple
automation” Jigs, fixtures, drills etc are the few tools used in LCA.
1.2 Low Cost Automation (LCA) can be achieved by following methods-
Using mechanical tools or apparatus i.e. using shafts, gears etc.
Using fluid power I.e. pneumatics and hydraulics
By electrical or electronicmeans
1.3 Fluid power and its scope in low cost automation
Fluid power means using pressurized gas or liquid in a confined space to control force or to achieve certain
movement of the mechanical element. Fluid power consists of pneumatic and hydraulic systems. Pneumatic
system makes use of compressed gas for performing the work whereas in hydraulics pressurised liquid, oils,
petroleum etc is used for performing the work.
1.4 Merits of using fluid power system
Fluid power is easy to produce, transmit, regulate, control and can be operated easily.
Low weight to power ratio.
Multiplication and variation of forces.
Frictional resistance is less.
Noise and vibrations produced is minimal.
We can start, stop, accelerate, decelerate, reverse or position change with great accuracy using simple levers
and push buttons.
Economical
FPS can be used where safety is of vital importance. [2]
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• Easy maintenance;
• Environment-friendly working medium;
• Easily adjustable torques, speeds and forces, by means of simple devices;
• Pneumatic transmissions allow damage-free frequent starting and stopping, as well as sudden changes of
direction;
• Compliance etc.
The structure of a pneumatic actuation system generally includes a source of compressed air (compressor), an
air preparation system (filter, pressure regulator, and lubricator), adjustment and control elements of the
pneumatic quantities and final consumers(motors) that transform the input pneumatic energy into useful work.
2.1.2 Case study on pneumatic gripper used for Low Cost Automation
Problem definition
The Solar Panel manufacturing company was facing the problems in transferring the solar panels from one
station to another. The solar panel are made up of glasses and it is very delicate, so most of the time while
transferring, it was breaking. The company was breaking more panels than they were manufacturing. Also, they
were facing the problem of transferring the huge dimensioned solar panel. The 14” diameter parabola shaped
glass bowl solar panel they made was very delicate so every time while transporting, it was either being dropped
or being squeezed to their breaking point. They were disappointed with the downtime and broken product they
had suffered with what had been commercially available. Most available grippers in the market was not able to
handle the fragile glass. Also, the magnetic pick and transport is not possible as the glass is not magnetic. So,
they turned to pneumatic grippers which can grip the glass with the help of compressed air and can transport it
with ease. And due to breaking of glasses it caused many injuries to workers like cuts etc. which created unsafe
working conditions for workers.
Solution
The Pneumatic grippers were used which is specifically a type of pneumatic actuator that involves either a
parallel or angular motion i.e. the „tooling jaws, fingers or rubber suction diaphragm‟ that will grip on object. In
pneumatic grippers, the vacuum is created in the rubber cups by creating pressure difference with the help of the
force from the compressed air by compressor. The gripper is placed directly on a product and with vacuum
generation the rubber cups creates sucking action which in turn grip the object firmly and tightly. The 14”
parabolic shaped glass bowl solar panel is gripped firmly and is being transferred from one station to another
with ease and without breakage. Thus, the loss of company due to breaking is minimized by automating the
transfer line of the company using pneumatic gripping system.
Fig 1.- Image showing lifting of solar panel using pneumatic gripper
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Fig. 2- Image showing use of pneumatic grippers in other industries
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Moisture in air causes rusting of pneumatic cylinders and valves which can be minimized by using
lubricator
Pressure regulator can be used to vary system pressure. [3]
2.2.2 Construction and Working
It consists of three stations
At first station, the power in the form of pneumatic pressure (6-12 bar) is produced through pressurized air
system
Pressurized air system consists of following components
a. Air inlet
b. Filter, lubricator, regulator device
c. The safety valve and release valve
The second station of the system consists of hydraulic booster consisting of booster, check valve and
manifold.
The third and final station is clamping system to hold, support and support the workpiece.
2.2.3 Advantages
Increased production rate
Controlled clamping forces
Automatic sequencing of operations
Remote clamp operation
Consistent and repeatable operation
Automatically adjusting work support
2.2.4 Case Study on pneumatic power clamping system for low cost automation
Problem definition
In industry a plastic filter core was needed to be trimmed, drilled in length and ends to be reamed. The
machining on the plastic filter core was to be done on three separate working stations.so transferring the work
pieceafter each operation was very time consuming. Also, the set-up and material movement time resulted in a
bottleneck. As all the machining operations were done manually, many errors were present and the required
precision was not achieved. Also, as all operations were done manually so quality of the product was an issue.
Quality, slow production rate and low precision were the problems of the industry.
Solution
There is a machine that would perform the required operation of trimming, reaming, drilling etc. The machines
consists of the grippers mounted on the slides, take the 12” long core blank and placed it on the first station of
operation. The pneumatic hold-down clamps hold the tube blank firmly and the pneumatic clamp with a knife
blade mounted on the clamp arm, cuts the end of the tube at precise length. Then grippers grip the work piece
and then with the help of the sliders it is moved to the next station where it is drilled along the length. Then,
again with the help of the grippers and the sliders the work piece is moved to the final station where the inner
diameter of the tube is reamed on both ends. Pneumatic swing clamps hold the tubes during the operation.
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Fig. 4 - Pneumatic toggle clamp
III. CONCLUSION
The requirements of the industries like high productivity, low cost, etc. can be fulfilled by automating the
industries using pneumatics i.e. by using pneumatic grippers and pneumatic power clamped system at a very
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low cost. This technology is also portable and reliable as it has very small machine structures and can give the
large tonnage. Apart from this it also provides safety to the workers.
REFERENCES
[1]. G. Tamizharasi, S. Kathiresan, D. Balaji and S. Jegathiesan, “Low cost automation in power press”, Indian
Journal of Science and Technology, November 2015.
[2]. S R. Majumbdar, “Principles and Maintenance of Oil and Pneumatic systems”, McGraw Hill Education
publications.
[3]. M. Muthukkarapun and K. Manoj, “Low cost automation using pneumatic system- An online case study in
multi station part transfer, drilling and tapping machine,” 24th International Symposium on automation and
robotics in construction (ISARC 2007).
[4]. Antonio Carlos Valdiero Ivan Jr. Mantovani, Andrei Fiegenbaum, Giovani P. B. Dambroz,and Luiz A.
Rasia, “Development of a Pneumatically Driven Cell for Low Cost Automation”.
[5]. Sree Vani Yabaluri, C. Mukul, Mude Murali Mohan Naik, A. Manish, Chalivendula Srikar Rao,
“Utilization of Low Cost Automation (LCA) by Implementing Electro- Pneumatic System in Industries for
Printing Codes and Dates on Manufactured Bottles for Better Production Rate and Reduction of Labour
Work”, International Journal of Advanced Mechanical Engineering, November 2017.
[6]. Information on “Hydraulic and Hydro-pneumatic Clamping Elements for Production Tooling”.
[7]. Rituparna Datta and Bishakh Bhattarcharya, “Analysis and Optimization of Robotic gripper using
multiobjective genetic algorithm”.
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