I would recommend computer integrated manufacturing for a factory that has: - Moderate to high production volumes - Frequent changes in product mix and design - Short product life cycles - Need for flexibility to accommodate changes efficiently Computer integrated manufacturing allows for high levels of integration between different manufacturing systems and processes through use of computers and information networks. This facilitates flexible and reconfigurable production suitable for the conditions above.

1. Introduction to
Automation and Artificial
Intelligence

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2023
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VISION AND MISSIONS OF INSTITUTE
 Vision of Institute
❖ To be a premier institution of technical education, aiming at becoming a valuable resource for industry
and society.
 Missions of Institute
❖ To provide technologically inspiring environment for learning.
❖ To promote creativity, innovation and professional activities.
❖ To inculcate ethical and moral values.
❖ To cater personal, professional and societal needs through quality education.

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2023
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PRESENTATION OUTLINE
 Vision of Department
❖ To be a pre-eminent department for transformation of students in mechanical engineering into
technically and ethically sound professionals.
 Missions of Department
❖ To impart quality education through practical oriented initiatives.
❖ To prepare industry ready professionals with ethical and moral values.
❖ To promote entrepreneurship by creating various opportunities.
VISION AND MISSIONS OF DEPARTMENT

4. Course Objectives:
1. To understand the need and justification of automation
2. To study design of pneumatic and hydraulic circuits
3. To study and understand electropneumatic circuits and PLC Design
4. To familiarize with robotic systems in automated manufacturing processes
5. To study and understand AI and machine learning technologies for automation
Course Outcomes:
1. Illustrate basics of industrial Automation and AI
2. Design and develop pneumatic/ hydraulic circuits
3. Design electro-pneumatic circuits and write a program in PLC for process Industry
4. Demonstrate basic working of robotic control system
5. Demonstrate understanding of Machine learning Algorithms
6. Demonstrate understanding of Artificial Neural Network.
Term Test - 20 M
End Sem - 80 M
Total - 100 M

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2023
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BLOOM’S TAXONOMY

6. Difference between Automation and Artificial
Intelligence ?

8. Automation?
Automation is basically delegation of human
control function to technical equipment for
Increasing Productivity
Increasing Quality
Reducing Cost
Increasing safety in working Conditions

9. Artificial Intelligence (AI)
Artificial Intelligence (AI), the ability of a digital computer or computer-
controlled robot to perform tasks commonly associated with intelligent
beings.

10. Automation and Artificial Intelligence
PLC
Electronic
Control
Pneumatic &
hydraulic
Controls
Machine
Learning
Artificial Neural
Network

11. Skills Required:
▪ Sensors & Actuators
▪ PLC (Used in Process Industries)
▪ Good Fundamental Knowledge of Mechanical Engineering & Electronics
▪ Machine Learning Skills
▪ Python, R

12. Areas of Application
1) Manufacturing
2) Food/Beverage
3) Aerospace
4) Printing Industry
5) Autonomous Vehicles

13. Syllabus:
1. 1.1 Introduction to Automation Definition and fundamentals of automation,
Elements of Automated system, Automation principles and strategies, Levels of
automation, types of automation, Advanced automation functions 1.2 Introduction
to Artificial Intelligence Introduction, Historical development, Intelligent
Systems, Types of Intelligent Agents, Components of AI, Foundations of AI,
Scope of AI, Current trends in AI, Relevance to Mechanical Engineering
2. 2.1 Design of Pneumatic Circuits Design of Pneumatic sequencing circuits
using Cascade method and Shift register method (up to 2 cylinders) 2.2 Design of
Hydraulic Circuits Basic Hydraulic Circuits: Meter in, meter out and Bleed off
circuits; Intensifier circuits, Regenerative Circuit, Counter balance valve circuit
and sequencing circuits.
3. 3.1 Electro-pneumatic Circuits Design of Electro-Pneumatic Circuits using
single solenoid and double solenoid valves; with and without grouping; 3.2 PLC
Discrete Control Systems Design of Pneumatic circuits using PLC Control
(ladder programming only) up to 2 cylinders, w

14. 4) Robots and their applications: Introduction to Robots, Types, Classifications, Selection
of Robots, Robot Degrees of freedom, Robot configuration, Accuracy and repeatability,
Specification of a Robot, Robot feedback controls: Point to point control and Continuous
path control, Control system for Robot joint, Adaptive control, Drives and transmission
systems, End effectors, Industrial robot applications, Nex-gen robots.
5) (Concept and Algorithms, No programming or numericals) 5.1 Problem Solving:
Tree and Graph Search, Uninformed v/s informed search, uninformed methods: depth first
search, breadth first search, Informed search: heuristic search, Best first search, branch and
bound 5.2 Machine Learning: Introduction, types of machine learning: supervised,
unsupervised, reinforcement learning 5.3 Learning with Decision Trees: Introduction to
Decision Trees, Classification and Regression Trees, K means clustering algorithm, K
nearest neighbours algorithm, hierarchical clustering, Concept of ensemble methods:
bagging, boosting, random forests
6) Concept and Algorithms, No programming or numericals) 6.1 Learning with
regression: Linear regression, Logistic regression 6.2 Artificial Neural Networks Concept
of ANN, Basic Models of Artificial Neural Networks Important Terminologies of ANNs
McCulloch-Pitts Neuron, NN architecture, perceptron, delta learning rule, backpropagation
algorithm, Gradient Descent algorithm, feed forward networks, activation functions 6.3
Introduction to AI Technologies in the realm of Automation Concept of Natural Language
Processing, Machine Vision, Deep learning, Expert systems, Genetic Algorithms, Industry
4.0

15. Question Paper pattern
Module no Topic Marks
1 Introduction to Automation 10
(Theory)
2 Design of Pneumatics 25
(Numerical +Theory )
3 Design of Electro-Pneumatic 25
(Numerical +Theory )
4 Robots 15
(Theory)
5 Machine Learning 20 (Theory )
6 ANN 20 (Theory)

16. Scope:
 Project Engineer
 Robotics Engineer
 Electro-mechanical Engineer
 Mechanical Design Engineer
 Systems Engineer
 AI Engineer
 Data Analyst

17. Module I
 Introduction to Automation:
 Definition and fundamentals of automation, reasons for Automating,
basic elements of an automated system: Power, Program and control
system
 Advanced automation functions:
 safety, maintenance & repair diagnosis, error detection and recovery
 Levels of automation
 Automation principles and strategies:
 USA principle, ten strategies of automation and production system,
automation migration strategy

18. Basics of Automation
 Industry Definition: Systematic Economic Activity that could be
related to Manufacture/Service/ Trade.
 The word ‘Automation’ is derived from greek words “Auto”(self)
and “Matos” (moving). Automation therefore is the mechanism for
systems that “move by itself”
 Definition: Automation is a set of technologies that results in
operation of machines and systems without significant human
intervention and achieves performance superior to manual
operation

19.  A Definition from Encyclopedia
 The application of machines to tasks once performed by
human beings or, increasingly, to tasks that would
otherwise be impossible. Although the term mechanization
is often used to refer to the simple replacement of human
labour by machines, automation generally implies the
integration of machines into a self-governing system.
 Why does an automated system achieve superior
performance compared to a manual one?
 Can you give an example where this happens?

20. Role of automation in industry
 Since an industry is essentially a “systematic economic activity”, the
fundamental objective of any industry is to make profit.
Profit = (Price/unit – Cost/unit) x Production Volume (1)
 So profit can be maximized by producing good quality products, which may
sell at higher price, in larger volumes with less production cost and time.
 Automated Welding Robots for Cars
 Automated Assembly line of Automobile

21. Production Volume
 Automated Guided Vehicles, Industrial Robots, Automated Crane and Conveyor
Systems reduce material handling time.
 Automation also reduces cost of production significantly by efficient usage of
energy, manpower and material.
 The product quality that can be achieved with automated precision machines and
processes cannot be achieved with manual operations.
 The same quality would be achieved for thousands of parts with little variation.

22.  Economy of Scale
 Definition: Reduction in cost per unit resulting from increased
production, realized through operational efficiencies. Economies
of scale can be accomplished because as production increases, the
cost of producing each additional unit falls.
 Economy of Scope
 Definition : The situation that arises when the cost of being able
manufacture multiple products simultaneously proves more
efficient than that of being able manufacture single product at a
time.
 Electronics Components

23.  A. Can you give an example of an industry where economy of
scope is more significant than the economy of scale?
 B. Can you give an example of an industry where economy of scale
is more significant than the economy of scope?
 C. Can you give an example of an industry where both economy of
scope, and economy of scale are significant?

24. Basic elements of Automated System:
1. Power
2. Program of instructions
3. Control System
1. Power: Power is required to drive the process and controls. The principal source of
power electricity.
Power is required for:
 Processing operations, Material transport
 Controller unit
 Signal, transmission, storage, data acquisition and information processing.

25. 2. Program of Instructions: Actions performed in an automated process are defined by a
program of instructions.
 Work cycle programs consists of steps which is to maintain a single process parameter
at a defined level.
 Process parameters are temperature setting, flow control, Motor on/off, rpm
 In work cycle features are i) number and sequence of processing steps
ii) the process parameter change in step
Decision making in programmed cycle:
 Operator Interaction
 Different part or product styles
 Variation in starting work units.

26. 3. Control System:
Control system of the automated system executes the program of instructions
Two types i) Open loop ii) Closed loop
i) Open loop
 It operates without feedback loop
 No comparison is made between actual value of output and the desired input
parameter.
 They are mostly used when a) actions performed by control system are simple, b)
actuating function is reliable, c)reaction forces opposing the actuation are small
enough.

27. Closed Loop:
 Operated with feedback loop where output variable is compared with an input parameter.
 Input parameter is set to set point
 Sensor is used to measure output variable and it closes loop between input and output.
 Controller makes comparison between input and output

28. Advanced Automation Functions:
1) Safety Monitoring:
Main reason for safety monitoring is to
i) To protect human workers in vicinity of system
ii) To protect the equipment associated with the system
2) Maintenance and repair diagnostics:
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.
There are three modes:
i) Status monitoring: In these system monitors and record the status of key sensors during normal operation.
These data is used for future purpose.
ii) Failure diagnostics: These occurs when malfunction or failure occurs. It interprets the current data and
analyse the stored values so failure cause be found out
iii) Recommendation of repair procedure: Here procedure to repair is recommended
from stored data. Method for developing recommendation depends on use of expert
judgement (Artificial Intelligence)

29. Level of Automation

30. Migration Strategy

31. Phase 1 – Manual production
Manual production using single station manned cells operating independently. This is used for
introduction of the new product for reasons already mentioned: quick and low cost tooling to get
started.
Phase 2 – Automated production
Automated production using single station automated cells operating independently. As demand for the
product grows, and it becomes clear that automation can be justified, then the single stations are
automated to reduce labor and increase production rate.
Phase 3 – Automated integrated production
Automated integrated production using a multistation automated system with serial operations and
automated transfer of work units between stations.
When the company is certain that the product will be produced in mass quantities and for several years,
then integration of the single station automated cells is warranted to further reduce
labor and increase production rate.

32. Types of production systems

33.  Fixed Automation
 Programmable Automation
 Flexible Automation
Types of Automation Systems

34. Types of Automation Systems
 Fixed Automation
 It is used in high volume production with dedicated equipment, which has a
fixed set of operation and designed to be efficient for this set.
 Continuous flow and Discrete Mass Production systems use this automation.
 Example : Distillation Process, Conveyors, Paint Shops, Transfer lines etc.
 A process using mechanized machinery to perform fixed and repetitive
operations in order to produce a high volume of similar parts.

35. Fixed Automation
 Fixed automation is appropriate in the following circumstances.
 Low variability in product type as also in size, shape, part count and material
 Predictable and stable demand for 2- to 5-year time period, so that
manufacturing capacity requirement is also stable
 High production volume desired per unit time
 Significant cost pressures due to competitive market conditions. So automation
systems should be tuned to perform optimally for the particular product.

36. Types of Automation Systems
 Programmable Automation
 It is used for a changeable sequence of operation and configuration of the
machines using electronic controls.
 Non-trivial programming effort may be needed to reprogram the machine or
sequence of operations.
 Investment on programmable equipment is less
 As production process is not changed frequently. It is typically used in Batch
process where job variety is low and product volume is medium to high, and
sometimes in mass production also.
 Example : Steel Rolling Mills, Paper Mills etc.

37. Flexible automation
 Flexible automation used in the following situations.
 Significant variability in product type. Product mix requires a combination of
different parts and products to be manufactured from the same production
system
 Product life cycles are short. Frequent upgradation and design modifications
alter production requirements
 Production volumes are moderate, and demand is not as predictable

38.  During a technical visit to an industry how can you identify the type of
automation prevailing there from among the above types?

39.  During a technical visit to an industry how can you identify the type of
automation prevailing there from among the above types?
 Whether automatic control exists for majority the equipment
 Whether supervisory control is manual, partially automated or largely
automated
 Whether operator interfaces are computer integrated or not.
 Whether communication with individual control units can be done from
supervisory interfaces through computers or not
 Whether any information network exists, to which automation system and
controllers are connected
 Product variety, product volumes, batch sizes etc.
 Whether the material handling systems are automated and if so to what
extent.

40.  For what kind of a factory would you recommend computer integrated
manufacturing and why?
 What kind of automation would you recommend for manufacturing
 Light bulbs
 Garments
 Textile
 Cement
 Printing
 Pharmaceuticals
 Toys

41. What kind of automation would you
recommend for manufacturing
 Light bulbs
 Fixed
 Garments
 Flexible
 Textile
 Programmable
 Cement
 Programmable
 Printing
 Flexible
 Pharmaceuticals
 Flexible
 Toys
 Flexible