Industrial Automation: History, Components, and Applications
The Evolution of Industrial Automation
The history of industrial automation spans key developments:
- Origins: Began in the 18th century with the First Industrial Revolution.
- Electrification: Widespread use of electricity allowed flexible, efficient factory power distribution.
- Assembly Line: Henry Ford’s moving assembly line (1913) reduced production time and costs.
- PLCs: In the 1960s, Programmable Logic Controllers replaced hard-wired relay logic with software, offering flexibility and reliability in control systems.
- Computers and Microprocessors: In the 1970s-1980s, computers enabled more sophisticated automation and real-time control.
Industry 4.0 and Automation
Industry 4.0 includes:
- IoT: Connects physical devices to the internet for data exchange and real-time monitoring.
- AI & Machine Learning: Used in predictive maintenance, quality control, and autonomous operations.
- Big Data: Enables informed decision-making and process optimization.
- Cyber-Physical Systems (CPS): Integrates physical and digital systems for responsive, smart manufacturing.
Robotics in Automation
Robots:
- Industrial Robots: Automatically controlled, reprogrammable manipulators, programmable in three or more axes, fixed or mobile.
- Service Robots: Semi or fully autonomous robots for human services, excluding manufacturing.
Robotic Applications Across Industries
Robotic Applications:
- Security & Rescue: Used for threat detection, real-time data transmission, and transport.
- Agriculture: Used in fruit picking, crop monitoring, and sorting.
- Construction: For error detection and hazardous task automation.
- Healthcare: Collaborative robots transport supplies, assist surgeries, and provide telecare.
Types of Robots
Robot Types:
- Linear Robots: Three prismatic joints, aligned with cartesian coordinates.
- SCARA Robots: Two rotary joints for planar movement.
- Articulated Robots: Three or more rotary joints.
- Parallel Robots: Arms with concurrent prismatic or rotary joints.
- Cylindrical Robots: Axes form cylindrical coordinates.
Robotic Process Automation (RPA)
RPA (Robotic Process Automation):
- Efficiency: Automates repetitive tasks, reducing errors and time.
- Scalability: Easily adapts to increasing workload.
- Accuracy: Ensures consistent task performance.
- Cost-effective: Lowers operational costs.
- Integration: Works with existing systems to improve workflow.
Components of Industrial Robot Systems
Industrial robot systems have three main parts and six subsystems.
Main Parts of a Robot
Three main parts:
- Mechanical Parts
- Sensing Parts
- Control Parts
Subsystems of a Robot
Six subsystems:
Mechanical Structure System
- Robots are categorized into serial and parallel robots.
- In serial robots, moving one axis changes the coordinate origin of the others. In parallel robots, axis movement doesn’t affect other origins.
- A parallel mechanism is a closed-loop system where moving and fixed platforms are connected by independent kinematic chains, with two or more degrees of freedom.
Drive System
- Powers the mechanical structure.
- Classified by power source: hydraulic, pneumatic, electrical, or mechanical.
Perception System
- Converts internal and external signals into data for robot understanding.
- Comprised of internal and external sensors.
- Intelligent sensors enhance robot mobility, adaptability, and intelligence.
Robot Environment Interaction System
- Coordinates robot interaction with external equipment (e.g., manufacturing, welding, or assembly units).
Human-Computer Interaction System
- Interfaces for human-robot communication (e.g., terminals, consoles, displays, alarms).
Control System
- Manages robot movements and functions based on instructions and sensor feedback.
- Divided by control method: program control, adaptive control, or AI control.
- Control motion can be point-based or continuous trajectory.