Automations in Toolings
Transcript of Automations in Toolings
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BY
MARUTHI BHAJANTRI
GTTC-HUBLI
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Automation is basically the delegation of human control
function to technical equipment for
Increasing Productivity
Increasing Quality
Reducing Cost
Increasing Safety in working conditions
It is the technologyassociated with the use of electrical, mechanical and computer
based systems to operate and control production in order to increase reliability andefficiency. This is usually accomplished through programmed commands combined
with automatic feedback controlto ensure proper execution of the instructions.
The resulting system is capable of operating without human intervention.
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Automation is encompassing virtually every walk of life
Automation solutions are required right from agriculture tospace technology
Plant automation is the necessity for the manufacturing
industry to survive in todays globally competitive market
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In 1970 with the coming of microprocessor and associated
peripheral chips, the whole processes of control and
automation underwent a radical change.
Companies dealing with automations like Fanuc and Festo and
other major company's made these changes at very faster
rate and advanced methods in the recent years.
And CAD related companies are also made flexible and realisticautomation design facility in software's.
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Increases productivity
Reduces labor cost
Alleviates the effects of labor shortages
Reduces or eliminates the routine manual and clerical tasks
Improves worker safety
Improves product quality
Reduces manufacturing lead time
Accomplishes processes that cannot be done manually
Reduces unit cost Performs repetitive tasks consistently
Multiple tasks can be performed at the same time
High forces and power can be applied
Performs computations quickly
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Worker displacement
High costs of designing, fabricating, and installing
equipments/machines
A higher level of maintenance needed than with a manually
operated machine
Requires relatively extensive labor training in order to make
labor capable of operating automated machines
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Manual control Automatic control
1) All the actions related to process control are taken by the
operator .
1) All the actions related to process control are taken automatically.
2) Likely human errors, consequently quality of the final product will
be low.
2) Errors are very low , consequently quality of product will be high
and accurate.
3) The production safety, energy consumption and usage of raw
material are all subjected to correctness and accuracy of human
actions.
3) The production safety, energy consumption and usage of raw
material is low as compared to manual control.
4) Manually you need to make documentations. Like counting,
production reports & inspection reports etc.
4) Generates documentations automatically with the help of software.
5) Space required is more 5) Less space required.
6) Maintenance will be difficult 6) Ease of maintenance
7) High labour cost 7) Reduced labor cost
8) No flexibility in design. 8) Tremendous flexibility in design.
9) Generates high man power. 9) Less man power required.
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Ergonomics is the science of designing the job, equipment, and workplace to fit the worker.
Proper ergonomic design is necessary to prevent repetitive strain injuries, which can
develop over time and can lead to long-term disability
Derived from two Greek words:
Nomoi meaning natural laws
Ergon meaning work Hence, ergonomists study human capabilities in relationship to work
demands.
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Time management refers to a range of skills, tools, and techniques used
to manage time when accomplishing specific tasks, projects and goals.
This set encompasses a wide scope of activities, and these
include planning, allocating, setting goals, delegation, analysis of time
spent, monitoring, organizing, scheduling, and prioritizing. Initially time
management referred to just business or work activities, but eventually
the term broadened to include personal activities as well. A time
management system is a designed combination of processes, tools andtechniques.
FIRST GENERATION: reminders based on clocks and watches, but with
computer implementation possible; can be used to alert a person when
a task is to be done.
SECOND GENERATION: planning and preparation based on calendarand appointment books; includes setting goals.
THIRD GENERATION: planning, prioritizing, controlling (using a
personal organizer, other paper-based objects, or computer or PDA-
based systems) activities on a daily basis. This approach implies
spending some time in clarifying values and priorities.
Fourth generation: being efficient and proactive using any of the above
tools; places goals and roles as the controlling element of the systemand favors importance over urgency.
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AN INDUSTRIAL ROBOT is officially defined by ISO
as an automatically controlled, reprogrammable,
multipurpose manipulator programmable in three or
more axes. The field of robotics may be more
practically defined as the study,
design and use of robot systems for manufacturing (a
top-level definition relying on the prior definition ofrobot).
Typical applications of robots include welding,
painting, assembly, pick and place, packaging and
palletizing, product inspection, and testing, all
accomplished with high endurance, speed, and
precision.
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Pneumatics
Pneumatics is a branch of technology, which deals with the study and
application of use of pressurized gas to affect mechanical motion.
Pneumatic systems are extensively used in industry, where factories are
commonly plumbed with compressed air or other compressed inert
gases. This is because a centrally-located and electrically-powered
compressor that powers cylinders and other pneumatic devices through
solenoid valves is often able to provide motive power in a cheaper,
safer, more flexible, and more reliable way than a large number of
electric motors and actuators.
Hydraulics
Hydraulics is the science of transmitting force and/or motion through
the medium of a confined liquid. In a hydraulic device, power is
transmitted by pushing on a confined liquid. The transfer of energy
takes place because a quantity of liquid is subject to pressure. To
operate liquid-powered systems, the operator should have a
knowledge of the basic nature of liquids. This chapter covers the
properties of liquids and how they act under different conditions.
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Kaizen (Japanese for "improvement" or "change for the better") refers to a philosophy or practices that focus
upon continuous improvement of processes in manufacturing, engineering, supporting business processes, and
management. It has been applied in healthcare, government, banking, and many other industries. When used in
the business sense and applied to the workplace, kaizen refers to activities that continually improve all functions,
and involves all employees from the CEO to the assembly line workers. It also applies to processes, such as
purchasing and logistics, that cross organizational boundaries into the supply chain. By improving standardized
activities and processes, kaizen aims to eliminate waste
Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and
minimizing variability in manufacturing and business processes. It uses a set of quality management methods, including
statistical methods, and creates a special infrastructure of people within the organization ("Black Belts", "Green Belts", etc.)
who are experts in these methods. Each Six Sigma project carried out within an organization follows a defined sequence of
steps and has quantified targets. These targets can be financial (cost reduction or profit increase) or whatever is critical to
the customer of that process (cycle time, safety, delivery, etc.).
TOTAL PROJECT MANAGEMENT AND TOTAL QUALITIY MANAGEMENT
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Automations application s in tooling now is huge. Automations are used in moulds for actuations of
side core and internal side cores , in press tools for strip feeders and slug removing units, in jigs and
fixtures for clamping, tool guiding units.
And majorly used in molding machines for taking out the component after completion of cycle time
automatically.
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Hydraulic actuation is used to move side cores in
moulds & Die casting tools
Injection Moulding machines are built with
Hydraulics systems
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Press machines are built with Hydraulics
systems
Automatic strip feeding is done by Pneumatic
automations
Finished component separation systems
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Work holding devices Indexing unit
Inspection/ Testing fixture
SPM
Etc.
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Digital manufacturing helps companies to achieve the highest levels of innovation, quality,
and cost control that are transforming the way they do business.
Now a days cad software's are providing real-time modeling and process simulation and
animations of whole process.
Major software in the field of automation design are
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LIST OF MAJOR COMPANIES INVOLVED IN AUTOMATIONS DESIGN SALES AND SERVICE
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THANK YOU
PRESENTED BY
MARUTHI BHAJANTRI
GOVT. TOOL ROOM AND TRAINING CENTREHUBLI-30
9902101010