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Anish Vijay s
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In todays modern industrial society companies mustbe competitive in the market place in order to survive.
Companies are continually trying to improve their
productivity in order to be more competitive.
Automating many industrial processes and tasks can be
an effective way of improving productivity.
Many industrial tasks and processes consist of
operations that are repeated over and over again.
These type of tasks can usually be carried out very
effectively by automatic machines.
Computers are ideal for controlling these automatic
machines
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Automation is the use of control systems andinformation technologies to reduce the need forhuman work in the production of goods andservices.
In simple words it is a system where a userprovides the input, the machine or computercarries out the process and provides you withoutput.
Automation is a step beyond mechanisation.
The term automation, inspired by the earlier wordautomatic (coming from automaton), was notwidely used before 1947, when General Motorsestablished the automation department.
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Car Manufacture
Coke Production
Automated Milk System
Aircraft Manufacture
Spray Tanning
Everyday Life?
Washing Machine
Video Recorder
Dishwasher
Microwave
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Speed
Tasks are carried out more quickly. (e.g. more items can bemanufactured each day, repairs can be carried out morequickly)
Hazardous (Dangerous) environment
Automated system can be designed to perform tasks inplaces where it is extremely dangerous for people to work.(e.g. nuclear reactors, in chemical factories, on North Seaoil platforms)
Repetitive tasks
Humans get bored when carrying out the same task timeafter time. Automated systems are able to carry out the sametask over and over again without making mistakes orslowing down
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Accuracy
Automated systems can produce exactly the same highquality product in a factory time after time.
They follow precisely the instructions in the programswhich control them. This guarantees 100% accuracy.
E.g. An automated system designed to cut metal parts for anaero plane will produce the parts with absolute precision. Itis capable of error only if the programmer has made a
mistake when entering the instructions or if a mechanicalfault develops.
Efficiency
Automated systems are very efficient because they are veryaccurate, they do not make mistakes and they waste no time
or materials.
E.g. Every part produced by an automated system for anaero plane will be the exact size and shape, there will be noparts thrown away because there are mistakes, there will beno time lost mending errors or replacing parts.
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Adaptability
Automated systems can be designed to be flexible
and handle a range of different tasks.
A robot arm can be programmed to spray a car one
week, the following week it could be programmed
to lift equipment onto a conveyor belt.
Other automated systems are adaptable because
they are equipped with a range of sensors to help
them detect the need to change their output.
An automated system regulating pressures in a
petrochemical plant has sensors which feed it data
about gas escapes and rises and drops in pressure.
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Depending on the exact function, one of several different
tools may be responsible for an automated system:
An Autonomous Guided Vehicle
An artificial neural network, Distributed control system,
Human machine interface,
Supervisory control and data acquisition,
A programmable logic controller.
PAC - Programmable automation controller
Instrumentation
Motion control
Robotics
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An Autonomous Guided Vehicle is a vehicle
that is programmed by a computer system to
move about a factory floor delivering parts to
work stations or removing waste.
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An artificial neural network is a mathematical or
computational model whose rhythms mimic those
of biological neurons.
The structure of the network is adaptive, meaningit can change based on the external or internal
exchange of information throughout the network
Applications include e-mail spam filtering, system
control (such as in a car), pattern recognition insystems (such as radars), pattern recognition in
speech, movement, and text, and financial
automated trading systems.
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A distributed control system is one in which there
are separate controls throughout the system.
These kinds of systems are typically used in
manufacturing processes, especially when theaction or production is continuous.
The controllers can be specified for a given
process, and monitor machine performance.
Traffic lights are usually controlled by distributedcontrol systems.
They can also be applied in oil refining and
central station power generation.
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A (SCADA) is a larger, industrial control network
that is often comprised of smaller sub-systems,
including human machine interface systems
connected to remote terminal units,They work to translate sensor signals into
comprehensible data.
SCADA systems bear a high resemblance to
distributed control systems.The key difference lies in what they ultimately
doSCADA systems do not control each process
in real time, rather they coordinate processes
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Commonly referred to as a user interface, a human
machine interface system depends on human
interaction with the system in order to function.
A user will provide input, and the system in turnwill produce output that coincides with the users
intent.
ATM
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Programmable logic controllers are real time
systems, meaning there is a set deadline and
timeframe in which the desired result must be
achieved.
Programmable logic controllers can be used to
program a variety of day-to-day applications, such
as amusement park rides.
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A robot is a machine that is controlled by a
computer and is flexible enough to be able to
do a variety of tasks.
A jointed arm robot has a waist, shoulder,elbow and wrist. The hand of the robot can be
changed or modified to suit the task the robot is
programmed to do.
These different hands are called end effectors
and they could be a gripper, suction cup, paint
spray or a collar.
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A robot arm has a
number of joints
like a human's:
- waist,
- shoulder,
- elbow,
- wrist,- end-effector.
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Stationary robots.
A robot arm has a number of joints like a human's.
Eg. Robot arm
Mobile robots
A robot that moves (on wheels or tracks with a
motor) is a mobile robot e.g. a robot buggy
(vehicle) carrying parts around a warehouse, a
bomb disposal robot.
Intelligent robot
A robot that has sensors on board and can makedecisions/ adapt behaviour based on environment
using artificial intelligence.
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o AI is the study of how to make computers do
things that at the present time people can
do better.
EXPERT SYSTEMS programs that mimicthe decision-making and problem-solving
thought processes of human experts.
ROBOTICS machines that can move and
relate to objects as humans can.
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Replacing human operators in tasks that involve hard
physical or monotonous work. Replacing humans in tasks done in dangerous
environments (i.e. fire, space, volcanoes, nuclearfacilities, underwater, etc.)
Performing tasks that are beyond human capabilities of
size, weight, speed, endurance, etc. Economy improvement: Automation may improve in
economy of enterprises, society or most of humanitylike Germany or Japan in the 20th Century.
Reduces operation time and work handling time
significantly. Frees up workers to take on other roles.
Provides higher level jobs in the development,deployment, maintenance and running of theautomated processes.
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Security Threats/Vulnerability: An automatedsystem may have a limited level of intelligence,and is therefore more susceptible to committing anerror.
Unpredictable development costs: The researchand development cost of automating a process mayexceed the cost saved by the automation itself.
High initial cost: The automation of a new product
or plant requires a huge initial investment incomparison with the unit cost of the product,although the cost of automation is spread amongmany products.
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Jobs losses
Reduces morale having robots
Need to retrain for other jobs
Work 24/7
Less injuries for workers
Improved working conditions
More social time
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Program machine to move slowly
Fit sensors and provide feedback
Cover moving parts
Cover the battery and processor
Safety guidelines in place
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High running costs
Higher initial cost
Cheaper in the long run
Larger output = more money
Repair costs
More accuracy = less waste
Expensive to replaceLess employee wages = larger profits
Redundancy costs
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Automated video surveillance
Automated highway systems
Automated manufacturing
Home automation
Industrial automation
Agent-assisted automation
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