industrial automation

1. Sai Anjaneya
History of Automation

2. Applications of Automation
 Home Automation –
 Air Conditioner, Geyser, Washing Machine,
Cleaning Robot
 Building Automation –
 Elevators, Automatic door opening, fire alarms,
automatic parking
 Office Automation –
 Fax, Printer, MS Word, Smart Phones, PC
 Mobility Automation –
 Aircraft, Boats, ships, bikes, cars, rails
 Industrial Automation –
 Robots, Design and Manufacturing Software, Whole
plant

3. Industrial Automation

4. Automation Video

5. Year Casting Deformation Joining Machining Ceramics Plastics
4000 B.C. Stone, clay
molds
Bending, forging
(Au, Ag, Cu)
Riveting Stone, emery,
corundum,
garnet, flint
Earthenware Wood, natural
fiber
2500 BC Lost wax
(bronze)
Shearing, sheet
forming
Soldering,
brazing
Drilling, sawing Glass beads,
potter's wheel
1000 BC Hot forging
(iron), wire-
drawing (?)
Forge welding,
gluing
Iron saws Glass pressing,
glazing
0. A.D. Coining (brass),
forging (steel)
Turning (wood),
filing
Glass blowing
1000 Wire drawing Stoneware,
porcelain
(China)
1400 Sand casting,
cast iron
Water hammer Sandpaper Majolica, crystal
glass
1600 Permanent mold Tinplate can,
rolling (Pb)
Wheel lathe
(wood)
1800 Flasks Deep drawing,
rolling, (steel),
extrusion (Pb)
Boring, turning,
screw cutting
Plate glass;
porcelain
(Germany)
1850 Centrifugal,
molding
machine
Steam hammer,
tinplate rolling
Shaping, milling,
copying lathe
Window glass
from slit cylinder
Vulcanization
History of material processing technologies

6. Year Casting Deformation Joining Machining Ceramics Plastics
1875 Rail rolling,
continuous
rolling
Turret lathe,
universal mill,
vitrified wheel
Celluloid, rubber
extrusion,
molding
1900 Tube rolling,
extrusion (Cu)
Oxyacetylene,
arc welding,
electrical
resistance
welding
Geared lathe,
automatic screw
machine,
hobbing, high-
speed steel,
synthetic SiC,
Al2O3
Automatic bottle
making
1920 Die casting W wire (from
powder)
Coated
electrode
Bakelite, PVC
casting, cold
molding,
injection
molding
1940 Lost wax for
engineering
parts, resin-
bonded sand
Extrusion (steel) Submerged arc Acrylics, PMMA,
P.E., nylon,
synthetic rubber,
transfer
molding,
foaming
1950 Ceramic mold,
modular iron,
semi-conductors
Cold extrusion
(steel)
TIG welding,
MIG welding,
electroslag
EDM ABS, silicones,
fluorocarbons,
polyurethane
1960 Plasma arc Manufactured
diamond
Float-glass Acetals,
polycarbonate,
polypropylene
History of material processing technologies

7. Selected Events in the History of Automation
• Organized automation, mechanization: Industrial revolution, 1770-
, England, Europe, US
• Hard automation and transfer lines: Henry Ford, 1900-, USA
• Numerically Controlled (NC) machine tools, 1952 (US Air Force,
MIT)
• Microchip computers: late 1960-, USA
• CNC (computer numerical controlled) machine tools, 1970-, USA
• Industrial Robots, USA, Japan, 1970-
• Computer networks, DARPA USA, 1970-
• Flexible Manufacturing Systems (FMS), Japan, 1980-.

8. Functions of Industry

9. Types of Automation
9
Programmable
automation
Flexible
automation
Fixed
automationManual
Low Medium High Parts per year
Low
Medium
High
Number of
different parts
Production Volume
Production
Variety

10. Examples of Automation
Automatic rice cooker
Put the rice and water in it in the morning, set it to start cooking at 6pm.
It turns on automatically.
When the rice is cooked, it switches to “keep warm” mode.
Q1. How does it control when to turn
on?
Q2. What type of sensor(s) and actuators are inside this
machine?
Q5. The cooker can be set to cook different food types (rice, congee, fish…
How is the logic for so many functions controlled?
Q4. How can the rice be kept warm for up to 12 hours?
Q3. How would you sense when the rice is cooked?

11. Examples of Automation
Park and Shop
The sales clerk ‘swipes’ item across a glass sheet on top of the counter.
The price (and name) of the item are automatically printed on the receipt.
The receipt also calculates the total price of all items you have bought.
Q1. Identify the sensors and actuators in this
example.
Q5. How can the information of “which item is purchased” be used
to improve customer service?
Q4. How does the system know the price and name of the item?
Q3. How does the system know what item was swiped?
Q2. Is this an example of digital or analog control?

12. Open Loop, Closed Loop Systems
Actuator DeviceSignal
Actuator DeviceSignal -
Sensor
feedback

13. Basic Structure of Automatic Control System
Computers
Communication network
A/D
converterAnalog
Signals
Digital Signals
Sensors and Actuators
Network Interface
Physical Process
Analog controls
D/A
converter
MicroprocessorPLC

14. Technologies
14

15. CNC Milling Machine
4-Feb-1715

18. 3D Printing
18

19. What are levels of automation
Video

20. Levels of Automation
Levels Description Attributes
Level 0 Labor Mechanization
Level 1 Scripts Automation
Level 2 Orchestration Level 1 + Adaptability
Level 3 Autonomics Level 2 + Awareness
Level 4 Pre-cognitive Level 3 + Analytics
Level 5 Cognitive Level 4 + Alive

21. REASONS FOR AUTOMATING
21
 Increased productivity.
 High cost of labor.
 Labor shortages.
 Trend of labor towards service sector.
 Safety.
 High cost of raw materials.
 Improved product quality.
 Reduced manufacturing lead-time.
 Reduction of in process inventory.
 High cost of not automating.

22. ARGUMENTS AGAINST AUTOMATION
22
Automation will result in the subjugation of the human
being via machine.
There will be a reduction in the labor force with resulting
unemployment.
Automation will reduce purchasing power.

23. ARGUMENTS IN FAVOUR OF AUTOMATION
23
 Automation is the key to the shorter work week.
 Automation brings safer working conditions for the
workers.
 Automated production results in lower prices and
better products.
 The growth of automation industries will itself provide
employment opportunities.
 Automation is the only means of increasing our
standard of living.

24. the Near Future

25. Industry 4.0

26. Internet of Things
Source: IAC

27. Wearable technologies

28. Autonomous Car