Industrial Automation and

Robotics (MET-352)
by

Dr. Jastej Singh

Asstt. Professor
Department of Mechanical Engineering
Chandigarh University, Punjab (India)

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Automation: Introduction

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 Automation: Definition
• Automation can generally be defined as the process of following a predetermined

sequence of operations with little or no human labour, using specialized equipment

and devices that perform and control manufacturing processes.

• Automation in its full sense, is achieved through the use of a variety of devices,

sensors, actuators, techniques and equipment that are capable of observing the

manufacturing process, making decisions concerning the changes that need to be

made in the operation, and controlling all aspects of it.

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Automation: Definition

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 Automation

➢ Industrial Robots are said to be the most visible part of automation.

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Three positive reasons for automating industrial facilities

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Manufacturing Automation

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Various considerations to take account before automating

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Mechanization vs. Automation

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Advantages of Automation

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 Goals of Automation
Automation has certain primary goals as listed below:

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 Low-Cost Automation (LCA)

✓ LCA is a technology that creates some degree of automation

around the existing equipment, tools, methods, people etc. by

using mostly standard components available in the market.

✓ It allows low investment so that the pay back period is short,

typically of the order of a few weeks to less than a year.

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 Low-Cost Automation (LCA)

✓ A wide range of activities such as loading, feeding, clamping,

machining, welding, forming and packing can be subjected to low-

cost automation.

✓ Low-cost automation is very useful for process industries,

manufacturing, chemical, oil or pharmaceuticals. Many operations

in food processing can also be done by low-cost automation

system.
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 Low-Cost Automation (LCA)- Advantages
Some of the major advantages features of LCA are:

1. Financial constraints do not hinder the application of LCA. While

capital equipment is expensive and has long pay back period, LCA
is built around existing resources. Hence, the investments required
are lower and payback period short.
2. Labour productivity can be enhanced substantially using LCA.

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 Low-Cost Automation (LCA)- Advantages

3. Expensive automation needs sufficiently large turnover to be

cost-effective. Lower batch/production sizes, typical of small to
medium scale industries, can be made viable using LCA.
4. Raw material costs have been rising steadily; This necessitates
better utilization of material, less Work In Progress (WIP) and less
rejection. LCA can help curtail such wastage.
5. Overall, LCA helps in better utilization of the material and
process consistency leading to less rejections.
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 Low-Cost Automation (LCA)- Limitations
The judicious application of LCA systems, however, should be based on an
understanding of its limitations. Some of them are listed below:
1. When a readymade automatic machine/system is purchased, the time that
needs to be spent in developing it, troubleshooting, and for making
modifications is avoided. In contrast, LCA systems that are typically
custom-built (generally in-house) take more time to develop.
2. A technology like Computer Numerical Control (CNC), for instance needs
very little time for changing from one drawing/design to another, since the
skill is inbuilt into the program. LCA, however, uses manual participation
and hence takes more time to learn, especially when a change09-Mar-23
is
incorporated.
 Low-Cost Automation (LCA)- Applications

A wide range of activities such as loading, feeding,

clamping, machining, welding, forming, gauging, assembly
and packing can be subjected to LCA systems adoption.

LCA has proven to be useful for process industries

manufacturing chemicals, oils, or pharmaceuticals.

The mode and efficiency of downstream operations like

packaging, printing, and labeling of any product can be
augmented considerably using the LCA approach.

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 Low-Cost Automation (LCA)- Applications

The other possible beneficiaries include agriculture, in

which the functions of tilling, sawing, plucking etc., can be
mechanized to varying degrees.
Operations involved in stock breeding, such as controlled
mixing, and distribution of feed can be another LCA
candidate.
Many operations in food processing industries which need
to be carried out under totally hygienic conditions can also
be rendered easy through LCA systems.

The width of applications of LCA is considerable, and its

evaluation for adoption in specific manufacturing situations
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is worthwhile.
 Types of Automation
Fixed Automation (Hard Automation)

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 Types of Automation
Fixed Automation (Hard Automation)
Advantages

Disadvantages

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 Types of Automation
Programmable Automation

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 Types of Automation
Programmable Automation
Advantages

Disadvantages

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 Types of Automation
Flexible Automation (Soft Automation)

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 Types of Automation
Flexible Automation (Soft Automation)
Advantages

Disadvantages

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Reasons for Automation

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Reasons for Automation

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Reasons for not Automation

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Issues for Automation in factory operations

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Strategies for Automation

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Automation can be defined as the technology by which a process or procedure is
accomplished without human assistance. It is implemented using a program of
instructions combined with a control system that executes the instructions. To
automate a process, power is required, both to drive the process itself and to
operate the program and control system. Although automation is applied in a wide
variety of areas, it is most closely associated with the manufacturing industries. It
was in the context of manufacturing that the term was originally coined by an
engineering manager at Ford Motor Company in 1946 to describe the variety of
automatic transfer devices and feed mechanisms that had been installed in Ford’s
production plants. It is ironic that nearly all modern applications of automation are
controlled by computer technologies that were not available in 1946.

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 Basic Elements of an Automated System

An automated system consists of three basic elements: (1) power to accomplish the process and operate the system,
(2) a program of instructions to direct the process, and (3) a control system to actuate the instructions. The
relationship among these elements is illustrated below.

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 Levels of Automation
Automated systems can be applied to various levels of factory operations. One normally associates
automation with the individual production machines. However, the production machine itself is made
up of subsystems that may themselves be automated. For example, a modern computer numerical
control (CNC) machine tool is a highly automated system that is composed of multiple control systems.
Any CNC machine has at least two axes of motion, and some machines have more than five axes.
Each of these axes operates as a positioning system, and is, in effect, an automated system. Similarly,
a CNC machine is often part of a larger manufacturing system, and the larger system may be
automated. For example, two or three machine tools may be connected by an automated part handling
system operating under computer control. The machine tools also receive instructions (e.g., part
programs) from the computer. Thus, three levels of automation and control are included here (the
positioning system level, the machine tool level, and the manufacturing system level). Five levels of
automation can be identified, and their hierarchy is explained.
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1. Device level. This is the lowest level in the automation hierarchy. It includes the

actuators, sensors, and other hardware components that comprise the machine

level. The devices are combined into the individual control loops of the machine, for

example, the feedback control loop for one axis of a CNC machine or one joint of an

industrial robot.

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5. Enterprise level. This is the highest level, consisting of the corporate information system. It is
concerned with all the functions necessary to manage the company: marketing and sales, accounting,
design, research, aggregate planning, and master production scheduling. The corporate information
system is usually managed using Enterprise Resource Planning.

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Introduction to Fluid Power

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Basic Elements of Fluid Power System

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Advantages of Fluid Power

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Disadvantages of Fluid Power

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Single and Double Acting Cylinders

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When comparing single-acting vs double-acting
hydraulic cylinders, the most visible difference is the
number of couplers or connection ports. A single-acting
hydraulic cylinder includes just one port. This is where
the hydraulic fluid enters and forces the plunger out in
one direction. A double-acting cylinder includes two
ports. One for the hydraulic fluid to enter and extend the
plunger, and the other for retracting the cylinder.

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A Single Acting cylinder will have one port for the connection
of a hydraulic cylinders Hydraulic Hose Fittings A Double
Acting cylinder will have TWO ports. The first port is where
the “advance” (extend) Hydraulic Hose Fittings will attach
and the second is where the “retract” Hydraulic Hose
Fittings will attach.

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Comparison

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ADVANTAGES OF SINGLE-ACTING CYLINDERS
•Reliability
•Simplicity
•Compact
•Economical

WHAT APPLICATIONS ARE BEST SUITED FOR SINGLE-ACTING CYLINDERS

•Clamping
•Positioning
•Punching
•Reciprocating engines
•Pumps
•Hydraulic rams 09-Mar-23
ADVANTAGES OF DOUBLE-ACTING CYLINDERS
•Most commonly used cylinder type
•Energy-saving
•Accuracy
•Precision

WHAT APPLICATIONS ARE BEST SUITED FOR DOUBLE-ACTING CYLINDERS?

•Large scale engines
•Industrial furnaces
•Digging machines
•Lift shafts
•Steering mechanisms
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Applications of Fluid Power

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Pneumatics vs. Hydraulics

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Differences between Hydraulics and Pneumatics

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Differences between Hydraulics and Pneumatics

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Pneumatics: Advantages

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Pneumatics: Disadvantages

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Hydraulics: advantages

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Hydraulics: Disadvantages

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Applications of Pneumatics

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Applications of Hydraulics

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Basic Pneumatic System

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Basic Pneumatic System

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Basic Pneumatic System

limit and it is automatically turned on when the pressure is about to fall below the low limit.

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Basic Pneumatic System

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Basic Pneumatic System

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Basic Hydraulic System

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Basic Hydraulic System

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Basic Hydraulic System

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Basic Hydraulic System

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Basic Hydraulic System

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Hydraulic fluid properties
The properties and characteristics of any hydraulic oil are vitally important to the
capability of your hydraulic system to work within the operating conditions you need to
use it in. For a hydraulic oil to be useful it needs to have the below properties:
•Good incompressibility
•Thermally stable, within a range of operating temperatures
•Fire resistance
•Non-corrosive to its system
•Anti-wearing to its system
•Tolerance to water (resistance to water contamination)
•Stable viscosity characteristics
•Long life
•Cost-effective
•Minimum toxicity
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 CAD/CAM/CIM

• Computer-aided design is the use of computers to aid in

the creation, modification, analysis, or optimization
of a design.
• This software is used to increase the productivity of the
designer, improve the quality of design, improve
communications through documentation, and to create a
database for manufacturing.

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CAD/CAM/CIM

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Product Design and CAD

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Product Design and CAD

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 CAM, CAD/CAM, and CAD
CIM is sometimes spoken of interchangeably with CAM and CAD/CAM. Although the
terms are closely related, CIM has a broader meaning than CAM or CAD/CAM.

Computer-aided manufacturing (CAM) involves the use of computer technology in

manufacturing planning and control. CAM is most closely associated with functions in
manufacturing engineering, such as process planning and numerical control (NC) part
programming. The applications of CAM can be divided into two broad categories: (1)
manufacturing planning and (2) manufacturing control.

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Manufacturing Planning

CAM applications for manufacturing planning are those in which the computer is used
indirectly to support the production function, but there is no direct connection between
the computer and the process. The computer is used to provide information for the
effective planning and management of production activities. The following list surveys the
important applications of CAM in this category:

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Manufacturing
Control. The
second category
of CAM
applications is
concerned
with computer
systems to control
and manage the
physical
operations in the
factory. These
applications
include the 09-Mar-23

following:
CAD/CAM

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CIM
Computer-integrated manufacturing includes all of the engineering functions of CAD/

CAM, but it also includes the firm’s business functions that are related to manufacturing.

The ideal CIM system applies computer and communications technology to all the

operational functions and information-processing functions in manufacturing from order

receipt through design and production to product shipment. The scope of CIM, compared

with the more limited scope of CAD/CAM, is depicted in Figure 23.5. Also shown are the

components of CAD, CAM, and the business functions.

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Designation of Valves

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Symbols for Valve Actuators

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Methods of Valve Actuation

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Methods of Valve Actuation

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Methods of Valve Actuation

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Methods of Valve Actuation

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Methods of Valve Actuation

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Methods of Valve Actuation

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Methods of Valve Actuation

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Methods of Valve Actuation

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Methods of Valve Actuation

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DC Valves with actuators

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Pressure Relief Valve

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Pressure Relief Valve

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Pressure Relief Valve

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Flow control valves

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