INTRODUCTION TO AUTOMATION
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- Ronald Daniel
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1 INTRODUCTION TO AUTOMATION Automation system is the system effectiveness or devices to operate wisely, without or under minimal human monitoring level. Automation including 3 steps that is input ( sensor, keyboard, cd drive, tape) processing (PLC, CPU, software, relay, valve ) and output (actuator, monitor, AC/DC motor, servo, solenoid and valve) HISTORY INPUT PROCESSING OUTPUT MANUAL REPETATIVE MECHANIZATION AUTOMATION 1. MANUAL ULANG ALIK 2.PENJENTERAAN 3. AUTOMATION MANUAL REPETATIVE Kerja yang sama diulangi dengan menggunakan kekuatan fizikal dengan sdikit alat atau tanpa alat. PENJENTERAAN Mesin digunakan tapi tenaga manusia masih diperlukan utk menyiapkan kerja cth mesin pengisi memuatkan beras kedalam guni, tali sawat bg memudahkan kerja 3 INTELIGENT CONVEYOR SYSTEM (AUTOMATION)
2 AUTOMASI : tenaga manusia digantikan dgn mesin yg dikawal oleh pengawal utk menghasilkan sesuatu produk. Manusia hnya mengawal pada sistem kawalan dn akan mengurangkn buruh di pasaran. ADVANTAGES IN PROCESS FROM GRAPHICAL GIVE US; Automatically rice packaging, constant in amount for 1 packet of rice. Intelligent distribute system using in make whether to accept or reject the rice quality Robot Arm is using in goods handling and placing. AUTOMASI : sistem kawalan, mesin, proses, minimum 1 org pekerja KAWALAN AUTOMASI : plc, microcontroller, relay, pid (depend on cost, kesesuaian) Why we needs automation 1. to improve quality of the product and keeping quality consistency 2. to improve the quantity of the production line. 3. To reducing the manpower support. Which area that needs the automation system; 1. Assembly Line (Talian pemasangan) 2. Pengujian dan Pengemasan Bungkusan (Packaging) 3. Hazard and Dangerous Zone 4. High speed and precision process, computer integrated machine (CIM) THE ADVANTAGES OF AUTOMATION i) Reducing the labour cost ii) Improving the eff. In term of quality and quantity iii) Flexibility in market demand in term of product changes and rearrangement of the manuf. Process iv) Reliability : Duration of the process could be constantly operated by keeping the product quality. v) Repeatability : the output can be scheduled and controlled vi) Safe : To minimize and avoiding the human from contact with high risk / hazard area vii) Labor shortage problem solving
3 Definition of Industrial Automation Automation is basically the delegation of human control function to technical equipments for 1) Increasing Productivity 2) Increasing Quality 3) Reducing Cost 4) Increasing Safety in working conditions. 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 tasks that are not desirable to workers. In addition, the company can save money because it does not need to pay for expensive benefits for this specialized machinery. There are both pros and cons for a company when it comes to industrial automation. On the plus side, with soaring healthcare costs, paid days off, vacation time, and other costly employee benefits, companies can save money with industrial automation. While robotic machinery can initially be extremely expensive, the loss of monthly wages for production workers leads to incredible savings for the company. While machinery used for industrial automation can break down, it does not happen often. If it does, only a handful of maintenance or computer engineers are needed to handle repairs and get lines running smoothly again. Advantages and disadvantages of Automation Advantage of automation Disadvantages of automation Replacing human operators in tasks that Technology limits. Current technology is unable to automate all involve hard physical or monotonous the desired tasks. work. Replacing humans in tasks that should be done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, underwater, etc) Unpredictable development costs. The research and development cost of automating a process is difficult to predict accurately beforehand. Since this cost can have a large impact on profitability, it's possible to finish automating a process only to discover that there's no economic advantage in doing so. Making tasks that are beyond the human capabilities such as handling too heavy loads, too large objects, too Initial costs are relatively high. The automation of a new product required a huge initial investment in comparison with the unit cost of the product, although the cost of automation
4 hot or too cold substances or the requirement to make things too fast or too slow is spread in many product batches. The automation of a plant required a great initial investment too, although this cost is spread in the products to be produced. AUTOMATION IN PRODUCTION SYSTEMS Some elements of the production systems are likely to be automated,where as the others will be operated manually or clerically. For ourpurposes here, automation can be defined as a technology concernedwith the application of mechanical, electronic and computer basedsystems to operate and control production.in modern production systems, the two categories overlap to someextent, because the automated manufacturing systems operating on thefactory floor are themselves often implemented by computer systems andconnected to the computerized manufacturing support systems andmanagement information system operating at the plant and enterpriselevels. The term computer integrated manufacturing is used to indicatethis extensive use of computers in production systems
5 ARM ROBOTS Joint action Joint action any productive way in which multiple active resources participate in accomplishing a single function, including coordination, collaboration, cooperation, unwitting assistance, witting non-interference, and even competition. The critical factor is that the interaction among the resources acting jointly involves some communication on the part of each participating actor, and the joint action accomplishes some part of a function of the larger system. Reliability The reliability concern is: What are the business requirements for the system to be up and running, and can the integrated system meet those requirements? The requirements for the system to be up and running relate to the requirements for support of the business process, typically in terms of availability, timeliness, continuity, and maintenance of state. Degree Of Fredom Degree of freedom (DOF) of a mechanical system is the number of independent parameters that define its configuration. It is the number of parameters that determine the state of a physical system and is important to the analysis of systems of bodies in mechanical engineering, aeronautical engineering, robotics, and structural engineering. The position of a single car (engine) moving along a track has one degree of freedom, because the position of the car is defined by the distance along the track. A train of rigid cars connected by hinges to an engine still has only one degree of freedom because the positions of the cars behind the engine are constrained by the shape of the track. An automobile with highly stiff suspension can be considered to be a rigid body traveling on a plane (a flat, twodimensional space). This body has three independent degrees of freedom consisting of two components of translation and one angle of rotation. Skidding or drifting is a good example of an automobile's three independent degrees of freedom. Link And Joint Arotational joint (R) is identified by its motion, rotation about an exis perpendicular to the adjoint links. Here the length of adjoint links to do not change but the relative position of the link with respect to one another changes as the rotation takes places
6 Links and Joints In a robot, the connection of different manipulator joints is known as Robot Links, and the integration of two or more link is called as Robot Joints. A robot link will be in the form of solid material, and it can be classified into two key types input link and output link. The movement of the input link allows the output link to move at various motions. An input link will be located nearer to the base. There are five major types of joints such as: Rotational Joint: Rotational joint can also be represented as R Joint. This type will allow the joints to move in arotary motion along the axis, which is vertical to the arm axes.
7 Linear Joint: Linear joint can be indicated by the letter L Joint. This type of joints can perform both translational and sliding movements. These motions will be attained by several ways such as telescoping mechanism and piston. The two links should be in parallel axes for achieving the linear movement. Twisting Joint: Twisting joint will be referred as V Joint. This joint makes twisting motion among the output and input link. During this process, the output link axis will be vertical to the rotational axis. The output link rotates in relation to the input link. Orthogonal Joint:The O joint is a symbol that is denoted for the orthogonal joint. This joint is somewhat similar to the linear joint. The only difference is that the output and input links will be moving at the right angles. Revolving Joint: Revolving joint is generally known as V Joint. Here, the output link axis is perpendicular to the rotational axis, and the input link is parallel to the rotational axes. As like twisting joint, the output link spins about the input link. GRIPPERS Grippers are not only required for use with industrial robots: they are a universal component in automation. Grippers operate with: Industrial robots (handling and manipulation of objects). -assembling, machining, and packaging). -guided manipulators (remote prehension, medical, aerospace, nautical) -carrying equipment).
8 Possibilities for prehension of a spherical object. (1) pure enclosing without clamping, (2) partial form fit combine with clamping force, (3) pure force closure, (4) holding with vacuum air (pneumatic force closure), (5) retention using magnetic field (force field), (6) retention using adhensive media. Types of grippers used in industrial robot applications include the following: mechanical grippers, consisting of two or more fingers that can be actuated by the robot controller to open and dose to grasp the workpart; Figure 3.63 shows a two finger gripper vacuum grippers, in which suction cups are used to hold flat objects magnetized devices, for holding ferrous parts adhesive devices, where an adhesive substance is used to hold a flexible material such as a fabric simple mechanical devices such as hooks and scoops.
9 SENSOR General Characteristics of sensor Sensor is a device that when exposed to a physical phenomenon (temperature, displacement, force, etc.) produces a proportional output signal (electrical, mechanical, magnetic, etc.). The term transducer is often used synonymously with sensors. However, ideally, a sensor is a device that responds to a change in the physical phenomenon. Sensors are transducers when they sense one form of energy input and output in a different form of energy. For example, a thermocouple responds to a temperature change (thermal energy) and outputs a proportional change in electromotive force (electrical energy). Therefore, a thermocouple can be called a sensor and or transducer. Figurer 5.1: A typical control system Furthermore, sensors are classified as analog or digital based on the type of output signal. Analog sensors produce continuous signals that are proportional to the sensed parameter and typically require analog-to-digital conversion before feeding to the digital controller. Digital sensors on the other hand produce digital outputs that can be directly interfaced with the digital controller. Often, the digital outputs are produced by adding an analog-to-digital converter to the sensing unit. If many sensors are required, it is more economical to choose simple analog sensors and interface them to the digital controller equipped with a multi-channel analog-to-digital converter.
10 STEPPER MOTOR DESCRIBE THE THEORY: Stepper motors consist of a permanent magnetic rotating shaft, called the rotor, and electromagnets on the stationary portion that surrounds the motor, called the stator. Figure 1 illustrates one complete rotation of a stepper motor. At position 1, we can see that the rotor is beginning at the upper electromagnet, which is currently active (has voltage applied to it). To move the rotor clockwise (CW), the upper electromagnet is deactivated and the right electromagnet is activated, causing the rotor to move 90 degrees CW, aligning itself with the active magnet. This process is repeated in the same manner at the south and west electromagnets until we once again reach the starting position Figure 1 In the above example, we used a motor with a resolution of 90 degrees or demonstration purposes. In reality, this would not be a very practical motor for most applications. The average stepper motor's resolution -- the amount of degrees rotated per pulse -- is much higher than this. For example, a motor with a resolution of 5 degrees would move its rotor 5 degrees per step, thereby requiring 72 pulses (steps) to complete a full 360 degree rotation.
11 Figure 2 We may double the resolution of some motors by a process known as "half-stepping". Instead of switching the next electromagnet in the rotation on one at a time, with half stepping you turn on both electromagnets, causing an equal attraction between, thereby doubling the resolution. As you can see in Figure 2, in the first position only the upper electromagnet is active, and the rotor is drawn completely to it. In position 2, both the top and right electromagnets are active, causing the rotor to position itself between the two active poles. Finally, in position 3, the top magnet is deactivated and the rotor is drawn all the way right. This process can then be repeated for the entire rotation. THEORY : Stepper motors have smooth armatures and include a permanent magnet core that is magnetized widthwise or perpendicular to its rotation axis. These motors usually have two independent windings, with or without center taps. The most common step angles for PM motors are 45 and 90, but motors with step angles as fine as 1.8 per step as well as 7.5, 15, and 30 per step are generally available. Armature rotation occurs when the stator poles are alternately energized and de-energized to create torque. A 90 stepper has four poles and a 45 stepper has eight poles, and these poles must be energized in sequence. Permanent -magnet steppers step at relatively low rates, but they can produce high torques and they offer very good damping characteristics. Stepper motors are controlled directly. The primary command and control variable is the step position. This is in contrast to d.c motors where the control variable is the motor voltage and the command variable may be either position or velocity. A d.c motor requires a feedback control system and controls the position indirectly. A stepper motor system is normally operated open loop.
12 REFER TO THE PICTURE BELOW AND BY USING ALL YOUR KNOWLEDGE AND SOURCE, GIVE AN EXPLANATION TO DESCRIBE THE THEORY AND ITS FUNCTION IN OUR INDUSTRY TODAY.. Penjelasan kepada huraikan teori Motor stepper menyediakan satu cara untuk kedudukan terperinci dan kawalan kelajuan tanpa menggunakan sensor maklum balas. Operasi asas motor stepper membolehkan aci bergerak jumlah yang tepat dari darjah setiap kali satu denyutan elektrik dihantar kepada motor. Oleh kerana aci motor bergerak hanya beberapa darjah yang ia direka untuk apabila setiap nadi dihantar, anda boleh mengawal denyutan yang dihantar dan mengawal kedudukan dan kelajuan. Pemutar motor menghasilkan tork daripada interaksi antara medan magnet di pemegun dan pemutar. Kekuatan medan magnet adalah berkadar dengan jumlah arus dihantar ke pemegun dan bilangan lilitan pada belitan. Motor pelangkah menggunakan teori beroperasi magnet untuk membuat aci motor bertukar jarak yang terperinci apabila satu denyutan elektrik disediakan. Rajah 1 menunjukkan pandangan tipikal keratan rentas pemutar dan pemegun motor stepper. Daripada rajah ini anda dapat melihat bahawa pemegun (pegun penggulungan) mempunyai lapan tiang, dan pemutar mempunyai enam tiang (tiga magnet lengkap). Pemutar akan memerlukan 24 denyutan elektrik untuk menggerakkan 24 langkah-langkah untuk membuat satu putaran lengkap. Satu lagi cara untuk mengatakan ini adalah bahawa pemutar akan bergerak tepat 15 untuk setiap nadi elektrik motor menerima. Bilangan darjah pemutar akan bertukar apabila satu denyutan elektrik dihantar ke motor boleh dikira dengan membahagikan bilangan darjah dalam satu putaran aci (360 ) dengan jumlah kutub (utara dan selatan) di pemutar. Dalam motor stepper ini 360 dibahagikan dengan 24 untuk mendapatkan 15. Apabila tiada kuasa dibekalkan kepada motor, baki kemagnetan dalam magnet pemutar akan menyebabkan pemutar untuk menahan atau menyelaraskan satu set kutub magnet dengan kutub magnet salah satu magnet pemegun. Ini bermakna bahawa pemutar akan mempunyai 24 kedudukan penahan. Apabila pemutar adalah dalam kedudukan Penahan, ia akan mempunyai cukup tenaga magnet untuk menjaga aci daripada bergerak ke kedudukan seterusnya. Inilah yang membuat pemutar merasa seperti ia menekan dari satu kedudukan ke depan kerana anda memutar pemutar dengan tangan tanpa kuasa digunakan.
13 Fungsi dalam industri hari ini Motor stepper telah menjadi komponen penting untuk aplikasi dalam pelbagai industri yang berbeza. Yang berikut adalah senarai industri menggunakan motor stepper: Pesawat - Dalam industri pesawat, motor pelangkah digunakan dalam instrumentasi pesawat, antena dan penderiaan aplikasi dan peralatan pengimbasan Automotif - Industri automotif melaksanakan motor pelangkah untuk aplikasi berkaitan kawalan pelayaran, peranti penderiaan, dan kamera. Pihak tentera juga menggunakan motor stepper dalam pemakaiannya antena kedudukan Kimia - Industri kimia menggunakan motor stepper untuk dicampur dan persampelan bahan. Mereka juga menggunakan pengawal motor stepper dengan motor stepper tunggal dan multi-paksi untuk ujian peralatan Elektronik Pengguna dan Peralatan Pejabat - Di dalam industri elektronik pengguna, motor pelangkah digunakan secara meluas dalam kamera digital untuk fokus dan fungsi zoom ciri. Dalam peralatan pejabat, motor pelangkah dilaksanakan dalam peralatan imbasan berasaskan PC, pemacu storan data, pemacu cakera optik memandu mekanisme, pencetak, pengimbas dan Permainan - Dalam industri permainan, motor pelangkah digunakan secara meluas dalam aplikasi seperti slot dan mesin loteri, pemintal roda, dan walaupun shufflers kad Industri - Di dalam industri perindustrian, motor pelangkah digunakan dalam tolok automotif, mesin alat dengan tunggal dan multi-paksi stepper motor pengawal, dan kit retrofit yang menggunakan pengawal motor pelangkah juga. Motor stepper juga boleh didapati dalam kawalan mesin CNC Perubatan - Dalam industri perubatan, motor pelangkah digunakan dalam pengimbas perubatan, kawalan gerakan mikroskopik atau nanoscopic peranti automatik, pendispensan pam, dan alat kromatografi automatik penyuntik. Motor stepper juga ditemui di dalam fotografi digital pergigian (X-RAY), pam cecair, alat pernafasan, dan analisis jentera darah, centrifuge Peralatan Saintifik Instrumen -Scientific melaksanakan motor stepper dalam kedudukan sebuah balai cerap teleskop, spectrographs, dan centrifuge Sistem Pengawasan - motor stepper digunakan dalam pengawasan kamera FUNCTION IN INDUSTRY : Used in automotive applications for electronic throttle control, dashboard indicators, and climate control systems. Also found in industrial equipment such as robotics, electronic component handlers, testers, dispensers and other manufacturing equipment. Stepper motors are often controlled using special function ICs that provide limited control functionally.
14 FUNCTION: Motors convert electrical energy into mechanical energy. A stepper motor converts electrical pulses into specific rotational movements. The movement created by each pulse is precise and repeatable, which is why stepper motors are so effective for positioning applications.
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