This document provides an overview of an advanced industrial automation and robotics course. It outlines the course prerequisites, outcomes, and covers topics like automated manufacturing systems, reasons for automating production, basic elements of automated systems, principles of automation, levels of automation, and classification of manufacturing systems. The key topics are automated manufacturing systems, basic elements of an automated system (power, program, control), and levels of automation (manual, semi-automated, automated).

1. Rajarambapu Institute of Technology, Rajaramnagar
Department of Mechanical Engineering
Advanced Industrial Automation & Robotics
UNIT I

2. Course Prerequisites
In order to understand this course, students
should posses the knowledge of:
1. Manufacturing process
2. Plant layout
3. Types of production
4. Basics of robotics such as anatomy, drive
systems, end effectors.

3. Course Outcomes (COs)
After successful completion of the course, the
students should be able to:
1. Analyze workstation breakdown of transfer lines
2. Determine the efficiency of transfer lines with and without buffer
storages.
3. Determine efficiency of automated assembly machines.
4. Analyze forward and reverse kinematics of robot.
5. Analyze image processing of robot
6. Do economic analysis of robot

4. AUTOMATION IN PRODUCTION SYSTEMS
(1) Automation of the manufacturing systems in the factory and
(2) Computerization of the manufacturing support systems

5. AUTOMATION IN PRODUCTION SYSTEMS
(1) Automation of the manufacturing systems in the factory and
(2) Computerization of the manufacturing support systems

6. Automated Manufacturing Systems
• Automated machine tools that process parts
• Transfer lines that perform a series of machining
operations
• Automated assembly systems
• Manufacturing systems that use industrial robots to
perform processing or assembly operations
• Automatic material handling and storage systems to
integrate manufacturing operations
• Automatic inspection systems for quality control

7. Automated Manufacturing Systems
Classification:
• Fixed automation.
• Programmable automation, and
• Flexible automation.
Manufacturing automation is defined as making use of mechanical /
electronics / computer based systems to operate and control production
processes.

8. Fixed Automation
• High initial investment for custom-engineered
equipment
• High production rates
• Relatively inflexible in accommodating product
variety

9. Programmable Automation
• High investment in general purpose equipment
• Lower production rates than fixed automation
• Flexibility to deal with variations and changes in
product configuration
• Most suitable for batch production

10. Flexible Automation
• High investment for a custom-engineered system
• Continuous production of variable mixtures of
products
• Medium production rate,
• Flexibility to deal with product design variations

11. Reasons for Automating
1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or eliminate routine manual and
clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead lime
8. To accomplish. processes that cannot be done
manually
9. To avoid the high cast of not automating

12. Basic Elements of an Automated System
• Power to Accomplish the Automated Process
• Program of Instructions
• Control System
Elements of an automated system: (1) power, (2) program of instructions, and (3) control systems.

13. Automation Principles and Strategies
1. USA Principle
2. Ten strategies for automation and production
systems
3. Automation migration strategy

14. USA Principle
The USA Principle is a common sense approach
to automation projects.
USA stands for:
1. Understand the existing process
2. Simplify the process
3. Automate the process.

15. Ten Strategies for Automation and Production Systems
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing (CIM).

16. Automation Migration Strategy
Phase 1: Manual production
Phase 2· Automated production
Phase 3: Automated integrated production

17. Basic Elements of an Automated System
• Power to Accomplish the Automated Process
• Program of Instructions
• Control System
Elements of an automated system: (1) power, (2) program of instructions, and (3) control systems.

18. Power to Accomplish the Automated Process
• Power for the Process.
• Loading and unloading the work unit
• Material transport between operations
•Power for Automation
• Controller unit
• Power to actuate the control signals
• Data acquisition and information processing

19. Program of Instructions
• Single step work cycle
• Multi step work cycle
• Decision-Making in the Programmed Work Cycle
• Operator interaction
• Different part or product styles processed by the
System
• Variations in the starting work units

20. Control System
The control element of the automated system executes
the program of instructions. The control system causes
the process to accomplish its defined function. which for
our purpose is to carry out some manufacturing
operation.
Types:
• Closed loop (feedback)
• Open loop

21. Control Systems
• Closed Loop Control System
• Open Loop Control System

22. Control Systems
• Closed Loop Control System

23. Control Systems
Open loop systems are usually appropriate when the following
conditions apply:
1. The actions performed by the control system are simple,
2. The actuating function is very reliable, and
3. Any reaction forces opposing the actuation are small
enough to have no effect on the actuation.

24. In addition to executing work cycle programs, an
automated system may be capable of executing advanced
functions that are not specific to a particular work unit. In
general these functions are concerned with enhancing the
performance and safety of the equipment.
Advanced automation functions include the following:
• Safety monitoring
• Maintenance and repair diagnostics and
• Error detection and recovery
ADVANCED AUTOMATION FUNCTIONS

25. Functions of safety monitoring
• To protect human workers in the vicinity of the
system and
• To protect the equipment associated with
system.
Safety Monitoring

26. Possible responses to various hazards might
include one or more of the following:
• Complete stoppage of the automated system.
• Sounding an alarm
• Reducing the operation speed of the process
• Taking corrective actions to recover from the
safety violation
Safety Monitoring

27. The following list suggests some of the possible
sensors and their application for the safety
monitoring:
• Limit switches.
• Photoelectric sensors
• Temperature sensors
• Heat or smoke detectors
• Pressure sensitive floor pads
• Machine vision system
Safety Monitoring

28. Maintenance and Repair Diagnostics refers to the
capabilities of an automated system to assist in the
identification of the source of potential or actual
malfunctions and failures of the system. Three
modes of the operation are typical of a modern
maintenance and repair diagnostics subsystems:
• Status monitoring
• Failure diagnostics
• Recommendation of repair procedure
Maintenance and Repair Diagnostics

29. Status monitoring serves two important functions
in machine diagnostics:
• Providing information for diagnosing a current
failure and
• Providing data to predict a future malfunction
or failure
Status monitoring

30. Error Detection: As indicated by the term, error
detection and recovery consists of two steps:
• Error detection and
• Error recovery.
In analyzing a given production operation, the
possible errors can be classified into one of three
general categories
• Random errors
• Systematic errors and
• Aberrations
Error Detection and Recovery

31. Error recovery is concerned with applying
necessary corrective action to overcome the error
and bring the system back to normal operation.
1. Make adjustments at the end of current cycle
2. Make adjustments during the current cycle
3. Stop the process to invoke corrective action
4. Stop the process and call for help
Error Recovery

32. 1. Device level
2. Machine level
3. Cell or system level
4. Plant level
5. Enterprise level
LEVELS OF AUTOMATION

33. Manufacturing Systems
1. One worker tending one machine, which operates on semi-automatic cycle
2. A cluster of semi-automatic machines, attended by one worker
3. A fully automated assembly machine, periodically attended by a human
worker
4. A group of automated machines working on automatic cycles to produce a
family of similar parts.
5. A team of workers performing assembly operations on a production line.

34. Production Machines
1. Manually operated,
2. Semi-automated, or
3. Fully automated.

35. Material Handling System
1. Loading and unloading work units and
2. Positioning the work units at each station.
In manufacturing systems composed of multiple workstations, a means of
3. Transporting work units between stations is also required.
Most material handling systems used in production also provide
4. A temporary storage function.

36. Material Handling System
General issues relating to the material handling system.
1. Loading, Positioning and Unloading
2. Work Transport Between Stations
i. Variable routing and
ii. Fixed routing.
3. Pallet Fixtures and Work Carriers in Transport Systems

37. Material Handling System
Types of routing in multiple station manufacturing systems: (a) variable routing
and (b) fixed routing.

38. Material Handling System
Common Material Transport Equipment Used for Variable and Fixed Routing in
Multiple Station Manufacturing Systems
Type of Part
Routing
Material Handling Equipment
Variable routing Automated guided vehicle system Power-and-free
overhead conveyor Monorail system, Cert-on-track
conveyor
Fixed routing Powered roller conveyor, Belt conveyor,
Drag chain conveyor, Overhead trolley conveyor,
Rotary indexing mechanisms, Walking beam
transfer equipment

39. Material Handling System
Pallet Fixtures and Work Carriers in Transport Systems
1. Pallet fixtures
2. Modular Pallet Fixtures
3. Work Carriers
4. Direct Transport

40. Computer Control System
Pallet Fixtures and Work Carriers in Transport Systems
1. Communicate instructions to workers
2. Download part programs to computer-controlled
machines
3. Material handling system control
4. Schedule production
5. Failure Diagnosis
6. Safety monitoring
7. Quality control
8. Operations management

41. Human Resources
1. Direct Labour
2. Indirect Labour

42. CLASSIFICATION OF MANUFACTURING SYSTEMS
Factor Alternatives
Types of operations
performed
Processing operations versus assembly operations
Type of processing or assembly operation
Number of workstations
and system layout
One station versus more than one station
For more than one station, variable routing versus fixed
routing
Level of automation Manual or semi-automated workstations that require
full-time operator attention versus fully automated that
require only periodic worker attention
Part or product variety All work units identical versus variations in work units
that require differences in processing

43. Level of Automation
1. Manually operated
2. Semi-automated
3. Automated
Manning Level Mi

44. Automation in the Classification Scheme
1. Type I M Single-station manned cell
2. Type I A Single station automated cell
3. Type II M Multi-station manual system with variable routing
4. Type II A Multi-station automated system with variable
routing
5. Type II H Multi-station hybrid system with variable routing
6. Type III M Multi-station manual system with fixed routing
7. Type III A Multi-station automated system with fixed routing
8. Type III H Multi-station hybrid system with fixed routing