ROBOTIC AND AUTOMATIONBDX30103

Name: Suhaimi bin Hassan

C09 – 006 – 02

019-2817721

About this course

• Introduction to Automation, Logical Design of Automation Circuits, Elements of Electro-Pneumatic Components, PLCs Principle and Programming, Robotics Technology, Classification of Robots, Industrial robotics.

Learning outcomes• CLO1. Design/Development of Solutions – Propose

solutions of automation and robotics for broadly-defined engineering technology problems to the design of systems or processes to meet application in industry (LOD3, PLO3, C5)

• CLO2. Modern Tool Usage – Conduct appropriate automation and robotics programming techniques through broadly-defined engineering activities with an understanding of the limitations (LOD5, PLO5, P4)

• CLO3. Communication – Perform an effectively communication and cooperate in a group in order to solve the problems related to industrial automation and robotics (LOD8, PLO10, P4)

CONTENTS

1. Introduction To Automation

2. Elements Of Electro Pneumatic Components

3. Hydraulic And Pneumatic System

4. PLCs Principles And Programming

5. Robotics Technology

6. Classification Of Robots

7. Industrial Robotics

Assessment

1. Test 1: 15% (CLO1)

2. Test 2: 15% (CLO1)

3. Group project: 20% (CLO2)

4. Group presentation: 10% (CLO3)

5. Final Exam: 40% (CLO 1)

Industrial Automation - Machines

• Storage Systems• Handling Systems• Assembly Lines

– Assembly Cells– Machines

• Actuators• Sensors

• Production Lines– Production Cells– Machines

• Actuators• Sensors

Industrial Automation - Computing

Computers

Controllers

Actuators

Sensors

Software

Manufacturing of Cars at Ford

11

Automated Assembly Line

12

Production of Cars with Industrial

Robots

13

MecLab® Station Stack Magazine

14

MecLab® Station Conveyor

15

MecLab® Station Handling

16

DefinitionAutomation (automation, Automation):

1) set of all measures aiming at replacing human work through machines(e.g. automation is a applied science)

2) the technology used for this purpose(e.g. this company has an automation department)

Automation (automatisation, Automatisierung)

1) replacement of human work through machines(e.g. the automatisation of the textile factory caused uproar of the workers)

2) replacement of conscious activity by reflexes(e.g. drill of the sailors allows the automatisation of ship handling)

automation and automatisation are often confounded, in english, it is the same word.

Automation ApplicationsPower generation hydro, coal, gas, oil, shale, nuclear, wind, solar

Distribution electricity, water

Process paper, food, pharmaceutical, metal production and processing, glass, cement,chemical, refinery, oil & gas

Manufacturing computer aided manufacturing (CIM)flexible fabrication, appliances, automotive, aircrafts

Storage

Building heat, ventilation, air conditioning (HVAC)access control, fire, energy supply, tunnels, parking lots, highways,....

Transportation rolling stock, street cars, sub-urban trains,busses, trolley busses, cars, ships, airplanes, rockets, satellites,...

silos, elevator, harbor, retail houses, deposits, luggage handling

Transmission electricity, gas, oil

Automated System

Examples:• Automated machine tools• Transfer lines• Automated assembly systems• Industrial robots• Automated material handling and storage systems• Automatic inspection systems for quality control

AutomatedSystem

PeriodicWorker

Transformation Process

Automation Systems - World Players

Company (alpha. order) Location Major mergers

ABB CH-SE Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-

Bailey

Alstom FR Alsthom, GEC, CEGELEC, ABB Power,..

Ansaldo IT

Emerson US Fisher Rosemount

General Electric US

Hitachi JP

Honeywell US

Rockwell Automation US Allen Bradley, Rockwell,..

Schneider Electric FR Télémécanique, Square-D, ...

Invensys UK Foxboro, Siebe, BTR, Triconex,…

Siemens DE Plessey, Landis & Gyr, Stäfa, Cerberus,..

Yokogawa JP

Four distinct businesses

automation equipment

(control & command)

engineering & commissioning

primary technology(mechanical, electrical)

maintenance& disposal

seldom offered by the same company

Life-phases of a Plant (Example: Rail Vehicle)

Maintenance(entretien, Unterhalt)

Start on service

Recycling(Recyclage, Wiederverwertung)

Out of service

Commissioning(mise en service, Inbetriebnahme)

Sleeping Wagon XL5000 PlusEngineering(bureau d’étude, Projektierung)

Equipment Production(production, Herstellung)

air conditioning brakescontrolEquipment Design(développement, Entwicklung)

brakes

brakesreplacement

Manufacturers

Assembler (ensemblier)

Client, Service

car body design by assembler

Expectations of automation

• Energy, material and time savings• Quality improvement and stabilisation • Reduction of waste, pollution control• Compliance with regulations and laws, product tracking• Increase availability, safety• Fast response to market• Connection to management and accounting (SAP™)

-> Human-Machine Interface (MMC = Man-Machine Communication)

-> Acquisition of large number of “Process Variables”, data mining

Personal costs reduction

Process Optimisation

• Simplify interface• Assist decision• Require data processing, displays, data base, expert systems

Expectations of automation

• Automation of engineering, commissioning and maintenance• Software configuration, back-up and versioning• Life-cycle control• Maintenance support

Asset Optimisation (gestion des moyens de production)

-> Engineering Tools

Automation Migration Strategy

Three Automation Types

Programmable

AutomationFlexible

AutomationFixed

Automation

Variety

Quantity

Fixed Automation

Sequence of processing (or assembly) operations is fixed by the equipment configuration

Typical features:• Suited to high production quantities• High initial investment for custom-engineered equipment• High production rates• Relatively inflexible in accommodating product variety

Programmable Automation

Capability to change the sequence of operations throug reprogramming to accommodate different product configurations

Typical features:• High investment in programmable equipment• Lower production rates than fixed automation• Flexibility to deal with variations and changes in product configuration• Most suitable for batch production• Physical setup and part program must be changed between jobs

(batches)

Flexible Automation

System is capable of changing over from one job to the next with little lost time between jobs

Typical features:• High investment for custom-engineered system• Continuous production of variable mixes of products• Medium production rates• Flexibility to deal with soft product variety

Levels of Automation & Control in Manufacturing

Reasons for Automating

1. To increase labor productivity2. To reduce labor cost3. To mitigate the effects of labor shortages4. To reduce or remove routine manual and clerical

tasks5. To improve worker safety6. To improve product quality7. To reduce manufacturing lead time8. To accomplish what cannot be done manually9. To avoid the high cost of not automating

Automation Principle

1. Understand the existing process – Input/output analysis

– Value chain analysis

– Charting techniques and mathematical modeling

2. Simplify the process – Reduce unnecessary steps and moves

3. Automate the process– Ten strategies for automation and production

systems

– Automation migration strategy

Automation Strategies

1. Specialization of operations2. Combined operations3. Simultaneous operations4. Integration of operations5. Increased flexibility6. Improved material handling and storage7. On-line inspection8. Process control and optimization9. Plant operations control10.Computer-integrated manufacturing

Aircraft Manufacturing

Aircraft Manufacturing

Robotic Aircraft Manufacturing

Robotic Aircraft Manufacturing

Automation Software

1. Automation Studio

2. Cx-Programmer – Omron

3. COSIMIR Educational