Industrial Automation: Types, Strategies, and Applications
1. Defining Automation
Automation uses technology to execute procedures or processes with or without the aid of people. Five reasons to automate are:
- Increase productivity
- Reduce cost
- Mitigate the effects of labor shortages
- Eliminate routine manual defects
- Improve safety for employees
2. Strategies and Phases of Automation
Phase 1: Manual Production
Using manual production stations, cells operate independently. This phase is used for reasons of cost and time.
Phase 2: Automated Production
Using automated production cells, stations operate independently. As demand increases, automation becomes justified to reduce automated work and increase the production rate.
Phase 3: Integrated Automated Production
Using a multi-station automated system with operations in series and automated job transfer units.
3. Flexible Manufacturing Systems (FMS)
What is an FMS?
A system of machine tools integrated by a system linked by automatic handling of materials and conventional or CNC technology.
Example of an FMS
Bottling plant
Classification of FMS Based on the Number of Machines
- Single Machine Manufacturing Cell (1)
- Flexible Manufacturing Cell (2-3)
- Flexible Manufacturing System (4…)
Components of an FMS
Workstations, a material storage and handling system, a computer control system, and human resources.
Layout Configurations of an FMS
In-line distribution, circular distribution, and ladder-type distribution.
Applications of an FMS
Systems with laminated presses and systems for automated manufacturing.
4. Defining Automated Manufacturing
Used for the production of parts that require several operations. Each operation is taken to a workstation. The stations are integrated by a system that transfers information to each workstation in an automated production chain.
5. Configurations of an Automated Manufacturing System
- In-line: Divided into segments
- Rotational: Workstations arranged in a line
- ATCM: Consists of two or more sections used in line transfer
- International: Workstations placed in a circle
6. Levels of Automation
- Level 1 (Hardware): Devices, sensors, actuators, etc.
- Level 2 (Individual Machines): Machinery
- Level 3 (Cell or System): Manufacturing systems, machine groups
- Level 4 (Plant): Production system
- Level 5 (Enterprise): Corporate information system
7. Workstations
Load/Unload Stations
Loading and unloading can be carried out manually, with automated processes, or a combination of both. Security.
Machining Stations
Using CNC machines. They are used for non-rotational and rotational parts.
Other Processing Stations
FMS will also apply to other machining operations such as sheet metal fabrication, which involves punching, shearing, bending, etc.
Assembly
Some FMS are designed to carry out assembly operations. Generally, robots are programmed to perform various tasks in sequence and move to accommodate different products.
Other Stations and Equipment
Inspection can be incorporated into the FMS, as well as parts cleaning, arrangement of platforms, central cooling systems, etc.
8. Auxiliary Control
Instant Control
This mode of control stops the line immediately when a defect or malfunction occurs. This reaction to a problem is the simplest, most reliable, and easiest to implement.
Memory Controller
It is designed to continue operating the line. If there is a failure in some part, the program sends a signal that no work was done on the following workstations until it reaches the end of the line.