So far…
• Determines Product,
Market Demand and Economic
Constraints
Product and • Determines the particular
Context scale and scope of required
operations
Scale and • Determines the type of factory layout and
Scope
manufacturing systems required
Manufacturing • Determines the
System Type complexity of operations
Complexity • Determines the type of
modeling and analysis
required to make
decisions
Basic Metrics
Cycle Time
Production/Plant Capacity
Production Rate Little’s Law:
WIP= 𝜆 MLT
Manufacturing Lead Time
Work In Process
Availability
Even for the most generalised cases
Utilisation
Automation, Control and NC Systems
Automation and Control Technologies in the Production System
History of Automation
Automation is the technology by which a process or procedure is
accomplished without human assistance
History Continued
Cyber-Physical Systems ? (Internet of Things, Industry 4.0)
Scope of Automation
Introduction to Automation
This Lecture
1. Basic Elements of an Automated System
2. Advanced Automation Functions
3. Levels of Automation
• Understand basic automation technology
• Select suitable applications for automation
• Specify the type of automation to be used in specific cases.
Automation
Basic elements of an automated system:
1. Power - to accomplish the process and operate the automated
system
2. Program of instructions – to direct the process
3. Control system – to actuate the instructions
Program of Instructions
Set of commands that specify the sequence of steps in the work cycle
and the details of each step
Example: CNC part program
During each step, there are one or more activities involving changes
in one or more process parameters
Examples of process parameters:
Temperature setting of a furnace
Axis position in a positioning system
Motor on or off
Decision-Making in a Programmed Work Cycle
Decisions may need to be made that adjust the path of execution based on
inputs
Operator interaction
Automated teller machine
Variations in the starting work units
Additional machining pass for oversized sand casting
Features of a Work Cycle Program
Number of steps in the work cycle
Manual participation in the work cycle (e.g., loading and unloading work
parts)
Process parameters - how many must be controlled?
Operator interaction - does the operator enter processing data?
Variations in part or product styles – product scope facilitated by the work
cycle
Variations in starting work units - some adjustments in process
parameters may be required to compensate for differences in starting units
Control System – Two Types
Closed-loop (feedback) control system
Open-loop control system – operates without the
feedback loop
Positioning System Using Feedback Control
A one-axis position control system consisting of a leadscrew driven by a dc
servomotor and using an optical encoder as the feedback sensor
When to Use an Open-Loop Control System
Actions performed by the control system are simple and well defined.
Actuating function is very reliable
Any reaction forces opposing the actuation are small enough as to have no
effect on the actuation
If these conditions do not apply, then a closed-loop control system should be
used
Advanced Automation Functions
1. Safety monitoring
2. Maintenance and repair diagnostics
3. Error detection and recovery
Cooperation between distributed automated systems;
Auctioning and Bargaining;
Multi-Agent Systems;
Self Regulating Production Systems;
KBS – Knowledge Based Systems; Expert Systems
Safety Monitoring
Use of sensors to track the system's operation and
identify conditions that are unsafe or potentially unsafe
Reasons for safety monitoring
To protect workers and equipment
Possible responses to hazards:
Complete stoppage of the system
Sounding an alarm
Reducing operating speed of process
Taking corrective action to recover from the safety violation
IEEE – Human Robot Collision Study
Maintenance and Repair Diagnostics
Status monitoring
Monitors and records status of key sensors and parameters
during system operation
Failure diagnostics
Invoked when a malfunction occurs
Purpose: analyze recorded values so the cause of the
malfunction can be identified
Recommendation of repair procedure
Provides recommended procedure for the repair crew to effect
repairs
Error Detection and Recovery
1. Error detection – functions:
Use the system’s available sensors to
determine when a deviation or malfunction has
occurred
Correctly interpret the sensor signal
Classify the error
2. Error recovery – possible strategies:
Make adjustments at end of work cycle
Make adjustments during current work cycle
Stop the process to invoke corrective action
Stop the process and call for help
Levels of Automation
1. Device level – actuators, sensors, and other hardware
components to form individual control loops for the next
level
2. Machine level – CNC machine tools and similar
production equipment, industrial robots, material
handling equipment
3. Cell or system level – manufacturing cell or system
4. Plant level – factory or production systems level
5. Enterprise level – corporate information system
Levels of Automation
ERP/MRP
MES
SCADA
CNC
FIELDBUS/HARDWARE
AUTOMATION
