Exploring the types of industrial automation
Various types of industrial automation are applied in the world today. Industrial automation solutions can fall into any of the following four categories:
- Fixed automation system
- Programmable automation system
- Flexible automation system
- Integrated automation system
In the next few sections, you will discover what these categories are in detail. Let's have a look.
Fixed automation system
In a fixed automation system, the series of operations that must be performed on the raw material are fixed. This type of automation is used to perform fixed and repetitive operations to achieve high production rates. The machines involved are programmed or configured to produce a specific design for a product. Once adopted, it is relatively difficult to change the design or style of the product. Fixed automation systems are used when the same style of product is to be manufactured or assembled. The series of operations that are involved in the production or manufacturing process are designed or programmed based on the product. This type of automation system is characterized by a high production rate, high efficiency, and high initial cost and is suitable for manufacturing a large volume of products that will have a low cost per product.
Examples of fixed automation systems are as follows:
- Paint and coating automation process
- Automatic assembly machines
- Bread production lines
- Steel rolling mills
- Papermills
- Metal pressing/stamping machines in a vehicle assembly line in the automobile industry
Let's have a look at programmable automation systems.
Programmable automation system
In a programmable automation system, the machines involved can be used to manufacture different styles of products. However, this requires reprogramming and changeover for each new style of product, which takes time to accomplish and creates downtime in production.
This type of automation is suitable for manufacturing where identical or similar styles of products are produced within a certain time frame. This is usually referred to as batch production. A long setup time is required to modify the program or reconfigure the sequence of operations for the new product design or batch to be manufactured.
Examples of programmable automation systems are as follows:
- Industrial robot: This is a type of robot (programmed machine) that's used in the manufacturing industry. It consists of a power supply, a controller, and a mechanical arm that can move in three or more axes. It can be programmed and configured for different kinds of tasks.
The following figure shows a robot designed to be able to do any work that can be programmed (within its limits and work envelope) simply by changing the program. Here, the robot was programmed for writing:
Figure 1.2 – KUKA industrial robot
This image is licensed under Wikimedia Commons: https://creativecommons.org/licenses/by-sa/4.0/deed.en.
- Computer Numerical Control (CNC) machine: This is a type of automated machine in which geometric code (G-code) and miscellaneous code (M-code), which are alphanumeric, form the basic program instructions for different kinds of tasks. This type of machine can automate drilling, milling, or 3D printing using a computer or controller.
The following figure shows a CNC machine (KVR-4020A). This can be used for practically any type of application, including manufacturing or production, die-molding, heavy and hard milling, and more:
Figure 1.3 – CNC vertical machining center (Kent CNC KVR 4020A)
This image is licensed under Wikimedia Commons:
https://creativecommons.org/licenses/by-sa/4.0/deed.en.
Let's proceed to learn about flexible automation systems.
Flexible automation system
Flexible automation systems are an advanced form of programmable automation systems. They also require reprogramming and changeover for each new style of product, but this does not take time to accomplish as it is done in a programmable automation system. Hence, a flexible automation system reduces the downtime that's experienced in a programmable automation system. The product styles that a flexible automation system can produce are sufficiently limited so that the changeover can be accomplished very quickly and automatically. A flexible automation system allows a different range of products to flow through the line with little downtime.
Examples of flexible automation systems are as follows:
- Automated guided vehicles (AGVs): AGVs are vehicles without an onboard driver that are used mostly to transport materials/goods in a factory or warehouse. They can navigate along a pre-defined path using several guidance technologies, which makes it easy for them to change routes and expand the operation of the system in response to changes to a scalable and flexible material handling solution. AGVs can be used alongside an industrial robot to provide a very cost-effective material handling solution in a factory or warehouse. The AGV can transport pallets, cartons, and products that have been loaded onto it using an industrial robot, and then send them to various areas of the manufacturing facility or warehouse.
The following figure shows an example of an AGV:
Figure 1.4 – Automated guided vehicle by AIUT
This image is licensed under Wikimedia Commons: https://creativecommons.org/licenses/by-sa/4.0/deed.en.
- Flexible Assembly System (FAS): A FAS is an assembly system that can produce a variety of products in small to medium batches with rapid changeover and reprogramming for a new set of product designs or styles.
Let's now have a look at integrated automation systems.
Integrated automation system
As the name implies, an integrated automation system integrates various machines and tools such as CAD, robots, cranes, conveyors and other automated machineries to work under a single control system to execute an automation system of a production process. In this, separate machines, data, and processes are made to work together and controlled by a single control system. It allows the entire manufacturing plant to be automated and controlled by computers with less human intervention.
Integrated automation system is used in computer integrated manufacturing (CIM) in which computers control the entire production process with little human intervention. It is also used in various kinds of advanced process automation systems. Integrated automation system can give room for the implementation of various advanced technologies such as automated material handling systems, Radio Frequency Identification (RFID), barcode tracking systems, Manufacturing Execution System (MES), Computer Aided Process Planning (CAPP), automated conveyors and cranes, and many others.
In this section, you learned about the various types of industrial automation available while looking at relevant examples. This knowledge will help you have a better understanding of the next section and other topics that will be covered in this book.
