Industrial Automation and Robotics Mr Muhajir Ab Rahim

Industrial Automation and Robotics Mr. Muhajir Ab. Rahim School of Mechatronic Engineering Uni. MAP

Production System • Production system is the collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company. • Production systems can be divided into two categories or levels.

Manufacturing Support Systems • The set of procedures used by the company to manage production and to solve the technical and logistics problems encountered in ordering materials, moving work through the factory, and ensuring that products meet quality standards. • Product design and certain business functions are included among the manufacturing support systems. Manufacturing Support Systems

Facilities • The facilities consist of the factory, the equipment in the factory, and the way in which the equipment is organized. Facilities: Factory Equipment

Automation in Production System • Automation – technology associated with the application of mechanical, electrical, and computer-based systems to operate and control production Computerization of the manufacturing support systems Automation of the manufacturing systems in the factory

Examples of Industrial Automation • Automated machine tools that process parts • Transfer lines that perform a series of machining operations • Automated assembly systems • Manufacturing systems that use industrial robots to perform processing or assembly operations • Automated material handling and storage systems to integrate manufacturing operations • Automatic inspection systems for quality control

All things are manufactured. . • Alarm clock that woke you up • Energy and water pressure for your shower • Cereal and bread for your breakfast • Bus that got you to school • Phone, shirts, pen…

Overview of Industrial Automation • Industrial automation is the use of robotic devices to complete manufacturing tasks. • In this day and age of computers, industrial automation is becoming increasingly important in the manufacturing process because computerized or robotic machines are capable of handling repetitive tasks quickly and efficiently. • Machines used in industrial automation are also capable of completing mundane tasks that are not desirable to workers.

Goals of Industrial Automation • Industrial automation is a vast and diverse discipline that encompasses machinery, electronics, software and information systems working together toward a common set of goals- increased productivity, improved quality, lower costs, and maximum flexibility.

The Challenges • Increase productivity, leads to lapses of quality • Keeping costs down can lower productivity • Improve quality often impacts flexibility Optimize- use faster computers, more reliable software, better networks, smarter devices.

Types of Industrial Automations 1. Fixed automation- used when the volume of production is very high, specialized equipment designed for efficiency. 2. Programmable automation- used when the volume of production is relatively low, and there is variety of products to be made, production equipment is designed to be adaptable to variations in product configuration

Types of Industrial Automations 3. Flexible automation- suitable for midvolume production range, typically consist of a series of workstations that are interconnected by material-handling and storage system, controlled by central computer

Product Variety Programmable Automation Flexible Automation Fixed Automation 100 10, 000 Production Quantity 1, 000

Building Blocks of Automation Drives Sensor Analyzer Actuator

The main difference? • Programmable automation- the products are made in batches, when one batch completed, the equipment is reprogrammed to process next batch • Flexible automation- different products can be made at the same time on the same manufacturing system Products can be produced on a flexible system in batches if that is desirable, or several different product styles can be mixed on the system. (realized by computational power)

Computerization of Manufacturing Support Systems • Computer Integrated Manufacturing (CIM) denotes the pervasive use of computer systems to design the products, plan the production, control the operations, and the perform the various business functions needed in a manufacturing company. • Computer Aided Design (CAD) denotes the use of computers to design and analyze the product. • Computer Aided Manufacturing (CAM) denotes the use of computers to perform computer numerical control. • CAD/CAM denotes the integration of CAD and CAM functions into a combined system in which engineering and manufacturing use information from a common product database.

Reasons for Automating 1. Increase labor productivity 2. Reduce labor cost 3. Mitigate the effects of labor shortages 4. Reduce or eliminate routine manual and clerical tasks 5. Improve worker safety 6. Improve product quality 7. Reduce manufacturing lead time 8. Accomplish processes that cannot be done manually 9. Reduce unit cost

Reasons for Not Automating • Task is too technologically difficult to automate • Short product life cycle • Customized product – one-of-a-kind • Flexibility in coping with changing demand

Human Vs. Robots Relative Strength of Human Relative Strength of Robots

Automation and Robotic‘s History

What is industrial robot? • An industrial robot is a reprogrammable, multifunctional manipulator designed to move materials, parts, tools, or special devices through variable programmed motions for the performance of a variety of tasks. - definition by RIA (Robotics Industries Association)

Industrial Applications of Robotics • • • Welding Machine Loading Forging and Die Casting Spray Painting Drilling Assembly