PROCESS

AUTOMATION
PROCESS AUTOMATION

Computer and electronic communication developments have led to

the improvement of manufacturing process efficiency. This
development also has led to (CIM) computer integrated
manufacturing. In this chapter we will study one segment of CIM:
process automation.
The following aspects are related to automation: (Simulation,
material handling, robotics, group technology, and flexible
manufacturing systems).
PROCESS AUTOMATION
 SIMULATION
Simulation is the process of developing mathematical models of a
real system to evaluate the behaviour of the system parameters at
the output.
Depending on the computer program, used to simulate
manufacturing processes, simulation can be out of the following
types:

Discrete Event Simulation: It is accomplished by random

sampling from probability distribution

simulation Dynamic Simulation: is time-based evaluation of the system

behaviour (with respect to time).

Continuous Process Simulation: For continuous processes that

have no discrete events (e.g. Chemical industry, and pumps).
 AUTOMATION
Automation involves 1) automatic handling between machines and
2) continuos automatic processing at the machines.
Combining two or more automatic operations on one machine does not
constitute an automated system.
Machines are
considered
automated only when
they are
mechanically
joined for continuous
automatic handling
and processing:
Example: An
automatic lathe machine
that is joined to a robot to
load and unload
parts from and to a
conveyor
Purposes for Automation
1. Direct labour costs are reduced
2. Uniform quality is obtained because operator fatigue and boredom.
3. Safety (less accidents)
4. Shop efficiency is improved (automatic distribution of parts during
loading, unloading and inspection).
5. Use of standard tools instead of specially designed tools (tools are
located in carousels)
Part and Process Design
Part and process design should be related to each other so part designers
and process designers should have close cooperation.
The aim of that is to provide the highest possible flexibility and
efficiency of the process, and to avoid excessive cost of the automatic
process design as a result of excessive accuracy of the part design.

This cooperation helps to decide on the following issues:

1. Power Source: (electrical, hydraulic, and pneumatic) Selection of
power source depends on amount of power, space and speed
requirements.
2. Transfer Equipment: (Mechanical loading by robots, conveyors, and
mechanical arms).
3. Parts Orientation: Important in automatic assembly lines.
 ROBOTS
A robot is a reprogrammable multifunctional manipulator designed to
move materials, parts or tools through variable programmable motions
for the performance of variety of tasks.

Robots are used in light and heavy

manufacturing, foundry, automotive, electrical,
and aerospace industries.

(Typical jobs for robots: spraying,

grinding, deburring, welding, packaging,
searching, loading and unloading, and
tool positioning).
Robot Components:
1. Manipulator: consists of main frame (arm) + wrist + end effector (e.g.
spray gun, welding head, gripper).
2. Controller: is the brain of the robot. It stores data and directs
movements. The controller functions: a) initiates and terminates
motions of the manipulator in a desired sequence; b) stores position
and sequences data in memory; c) interface with other mfg operations
3. Power supply.
Classification of Robots:

1.Manual 2. Fixed- sequence 3. Variable-sequence

Manipulator Robot: The Robot: In this case,
(worked by an manipulator the pattern of motion
operator). performs repetitive may be changed
operations according
to a predetermined
pattern of motions
that cannot be
changed
Classification of Robots:

4. Playback Robot: 5. NC Robot: uses 6. Intelligent Robot:

This report stores numerical data (e.g. has sensors for vision
information into its punched data). and touch senses.
memory. Desired
information will be
recalled when
required.
Types of Robot Controllers (Classification of Robots according to
Controllers Types):
1. Non-servo controlled Robots: (end point, pick-and-place, bang
bang, and limited-sequence robots). Their arms travel only at one
speed and can stop only at the end point of their axes. (+)High
speed, good repeatability, low maintenance, and low cost , (-)
Less flexible, limited application.
2. Servo-controlled Robots: have servomechanisms that allow the
arm to change direction in mid-air without having to trip a
mechanical switch. They can vary speed at any point. (+)ability
to move heavy loads, flexible (uses more than one program).
Robot Paths
Servo-controlled robots are further classified as:
1. Point to point path: for tool and part handling
2. Continuous path : The robots are taught to perform these paths
by moving the robot manipulator through separate points (point
to point path) or through a path (continuous path).
Coordinate Systems (Degrees of Freedom) for Robots
1. Cartesian Coordinate Robots: Motions travel in right angle (no radial motions).
2. Cylindrical Coordinate Robots: A horizontal rotating shaft goes in and out and rides
up and down on a vertical rotating shaft.

3. Jointed Spherical Coordinate (Jointed Arm) Robots: Can perform similar actions to
a human’s shoulder, arm, and elbow .
4. Spherical (Polar) Coordinate Robots: The arm moves in and out, and is raised and
lowered through an arc while rotating about the base. The work envelop of the robot
forms the outline of a sphere.
Coordinate Systems (Degrees of Freedom) for Robots
Note: Envelope is the area in space the robot can touch.
Robotic Sensors (for Intelligent Robots)
By means of sensors robots can have humanlike capabilities (vision, eye
hand coordination, touch, and hearing).
1. Vision Sensors: (video camera, light sources, image processing)
2. Tactile Sensors: provide the robot with
the capability to respond to contact
forces between itself and other objects
by defining various sensations
(pressure, shape, temperature).

3. Voice Sensors: By defining voice and sound recognition the

robot is able to define malfunction (air leaks, abnormal
vibrations).
FLEXIBLE MFG SYSTEMS (FMS)
Flexible mfg systems are arrangements of individual workstations,
machining cells, and robots under the control of a computer. Workpieces
are mounted on pallets, which move through the system transferred by
conveyors. Most of mfg processes are
combined in a FMS. Equipment,
machine tools, and mfg cells are
located along the material transfer
highway. The parts transferred
along this highway do not need all
the equipment or cells.
Pallet transfer to and from machines
is done by automatically guided
vehicles (AGVs = self controlled
vehicles that follow specified paths
in a plant floor to move materials,
tools, and other items).
In FMSs, it is necessary to clean chips away
(continuous control and cleaning if chips).
FMSs are integrated with CAD and CAM.