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Automation

Automation

Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Automation plays an increasingly important role in the world economy and in daily experience.

Automation has had a notable impact in a wide range of industries beyond manufacturing (where it began). Once-ubiquitous telephone operators have been replaced largely by automated telephone switchboards and answering machines. Medical processes such as primary screening in electrocardiography or radiography and laboratory analysis of human genes, sera, cells, and tissues are carried out at much greater speed and accuracy by automated systems. Automated teller machines have reduced the need for bank visits to obtain cash and carry out transactions. In general, automation has been responsible for the shift in the world economy from industrial jobs to service jobs in the 20th and 21st centuries.

Advantages and disadvantage

The main advantages of automation are:

§  Replacing human operators in tasks that involve hard physical or monotonous work.

§  Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, underwater, etc.)

§  Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc.

§  Economy improvement. Automation may improve in economy of enterprises, society or most of humanity. For example, when an enterprise invests in automation, technology recovers its investment; or when a state or country increases its income due to automation like Germany or Japan in the 20th Century.

The main disadvantages of automation are:

§  Technology limits. Current technology is unable to automate all the desired tasks.

§  Unpredictable development costs. The research and development cost of automating a process may exceed the cost saved by the automation itself.

§  High initial cost. The automation of a new product or plant requires a huge initial investment in comparison with the unit cost of the product, although the cost of automation is spread in many product batches.

        Goals of automation (beyond productivity gains and cost reduction)

      In manufacturing, the purpose of automation has shifted to issues broader than productivity and costs.

       Reliability and precision

     The old focus on using automation simply to increase productivity and reduce costs was seen to be short-sighted, because it is also necessary to provide a skilled workforce who can make repairs and manage the machinery. Moreover, the initial costs of automation were high and often could not be recovered by the time entirely new manufacturing processes replaced the old. (Japan's "robot junkyards" were once world famous in the manufacturing industry.)

    Automation is now often applied primarily to increase quality in the manufacturing process, where automation can increase quality substantially. For example, automobile and truck pistonsused to be installed into engines manually. This is rapidly being transitioned to automated machine installation, because the error rate for manual installment was around 1-1.5%, but has been reduced to 0.00001% with automation.

      Health and environment

       The costs of automation to the environment are different depending on the technology, product or engine automated. There are automated engines that consume more energy resources from the Earth in comparison with previous engines and those that do the opposite too. Hazardous operations, such as oil refining, the manufacturing of industrial chemicals, and all forms of metal working, were always early contenders for automation.

      Convertibility and turnaround time

    Another major shift in automation is the increased demand for flexibility and convertibility in manufacturing processes. Manufacturers are increasingly demanding the ability to easily switch from manufacturing Product A to manufacturing Product B without having to completely rebuild the production lines. Flexibility and distributed processes have led to the introduction ofAutomated Guided Vehicles with Natural Features Navigation.

     Digital electronics helped too. Former analogue-based instrumentation was replaced by digital equivalents which can be more accurate and flexible, and offer greater scope for more sophisticated configuration, parametrization and operation. This was accompanied by the fieldbus revolution which provided a networked (i.e. a single cable) means of communicating between control systems and field level instrumentation, eliminating hard-wiring.

     Discrete manufacturing plants adopted these technologies fast. The more conservative process industries with their longer plant life cycles have been slower to adopt and analogue-based measurement and control still dominates. The growing use of Industrial Ethernet on the factory floor is pushing these trends still further, enabling manufacturing plants to be integrated more tightly within the enterprise, via the internet if necessary. Global competition has also increased demand for Reconfigurable Manufacturing Systems.

      Automation tools

     Engineers now can have numerical control over automated devices. The result has been a rapidly expanding range of applications and human activities. Computer-aided technologies (or CAx) now serve the basis for mathematical and organizational tools used to create complex systems. Notable examples of CAx include Computer-aided design (CAD software) and Computer-aided manufacturing (CAM software). The improved design, analysis, and manufacture of products enabled by CAx has been beneficial for industry.

     Information technology, together with industrial machinery and processes, can assist in the design, implementation, and monitoring of control systems. One example of an industrial control system is a programmable logic controller (PLC). PLCs are specialized hardened computers which are frequently used to synchronize the flow of inputs from (physical) sensors and events with the flow of outputs to actuators and events.

   Human-machine interfaces (HMI) or computer human interfaces (CHI), formerly known as man-machine interfaces, are usually employed to communicate with PLCs and other computers. Service personnel who monitor and control through HMIs can be called by different names. In industrial process and manufacturing environments, they are called operators or something similar. In boiler houses and central utilities departments they are called stationary engineers.

     Different types of automation tools exist:

§  ANN - Artificial neural network

§  DCS - Distributed Control System

§  HMI - Human Machine Interface

§  SCADA - Supervisory Control and Data Acquisition

§  PLC - Programmable Logic Controller

§  PAC - Programmable automation controller

§  Instrumentation

§  Motion control

§  Robotics 

Current limits

     Many roles for humans in industrial processes presently lie beyond the scope of automation. Human-level pattern recognition, language recognition, and language production ability are well beyond the capabilities of modern mechanical and computer systems. Tasks requiring subjective assessment or synthesis of complex sensory data, such as scents and sounds, as well as high-level tasks such as strategic planning, currently require human expertise. In many cases, the use of humans is more cost-effective than mechanical approaches even where automation of industrial tasks is possible

   

      Applications of Automation

§  Automated Video surveillance:

     The Defense Advanced Research Projects Agency (DARPA) started the research and development of automated Visual surveillance and Monitoring (VSAM) program 1997-99 and airborne Video Surveillance (AVS) program 1998-2002. Currently there is a major effort underway in the vision community to develop a fully automated tracking surveillance system. Automated video surveillance monitors people and vehicle in real time within a busy environment. Existing automated surveillance systems are based on the environment they are primarily designed to observe, i.e., indoor, outdoor or airborne, the amount of sensors that the automated system can handle and the mobility of sensor, i.e., stationary camera vs. mobile camera. The purpose of a surveillance system is to record properties and trajectories of objects in a given area, generate warnings or notify designated authority in case of occurrence of particular events.

§  Automated Highway Systems:

    As demands for safety and mobility have grown and technological possibilities have multiplied, interest in automation have grown. Seeking to accelerate the development and introduction of fully automated vehicles and highways, The United States Congress authorized more than $650 million over 6 years for intelligent transport systems (ITS) and demonstration projects in the 1991 Intermodal Surface Transportation Efficiency Act (ISTEA). Congress legislated in ISTEA that “The secretary [of transportation] shall develop an automated highway and vehicle prototype from which future fully automated intelligent vehicle-highway systems can be developed. Such development shall include research in human factors to ensure the success of the man-machine relationship. The goal of this program is to have the first fully automated highway roadway or an automated test track in operation by 1997. This system shall accommodate installation of equipment in new and existing motor vehicles." [ISTEA 1991, part B, Section 6054(b)].

     Full automation commonly defined as requiring no control or very limited control by the driver; such automation would be accomplished through a combination of sensor, computer, and communications systems in vehicles and along the roadway. Fully automated driving would, in theory, allow closer vehicle spacing and higher speeds, which could enhance traffic capacity in places where additional road building is physically impossible, politically unacceptable, or prohibitively expensive. Automated controls also might enhance road safety by reducing the opportunity for driver error, which causes a large share of motor vehicle crashes. Other potential benefits include improved air quality (as a result of more-efficient traffic flows), increased fuel economy, and spin-off technologies generated during research and development related to automated highway systems.

§  Automated manufacturing:

   Automated manufacturing refers to the application of automation to produce things in the factory way. Most of the advantages of the automation technology has its influence in the manufacture processes.The main advantage of the automated manufacturing are: higher consistency and quality, reduce the lead times, simplification of production, reduce handling, improve work flow and increase the morale of workers when a good implementation of the automation is made.

§  Home Automation

    Home automation (also called domotics) designates an emerging practice of increased automation of household appliances and features in residential dwellings, particularly through electronic means that allow for things impracticable, overly expensive or simply not possible in recent past decades.

Basic instrumentation

 Instrumentation

    Instrumentation is the process of measuring, calibrating, and controlling the physical variable such as pressure, flow, temperature etc using a instrument.

Calibration

      Calibration is the process of checking the accuracy and correctness of an instrument by comparing it with a standard instrument.

Accuracy

            The degree of closeness to the true value.

Precession

            Pressure of repeatability of measurement that is successive reading do not differ.

Error

            The deviation of the true value from the desire value.

Transducers

            Transducer is defined as a device that receives energy from one system and transmits it to another often in a different form. Basically there are two types of transducers:

1.     Electrical Transducers

2.     Mechanical Transducers

            An electrical transducer gives a sensing device by which the physical, mechanical, optical quantity to be measured, is transformed directly by a suitable mechanism into an electrical signal.

            Electrical transducers can be classified into two ways:

1.     Active Transducers

2.     Passive Transducers

Active Transducers

            Active transducers generate an electrical signal directly in response to the physical parameter and does not require external power source for its operation. Active transducers are self generating devices which operate under energy conversion principle and generate an equivalent output signal.

Passive Transducers

            Passive transducers operate under energy controlling principle which makes it necessary to use an external electrical source with them. They depend up on the change in an electrical parameter (R, L, C).

E.g. Strain Gauge, Thermistors

Selecting a Transducers

            Following should be considered while selecting a transducer:

1.     Operating range

2.     Sensitivity

3.     Environmental compatibility

4.     Accuracy