Introduction to mechanical Engineering

Module 4
INDUSTRIAL AUTOMATION
Automation: The word ‘Automation’ is derived from greek words “Auto”(self) and
“Matos” (moving). Automation therefore is the mechanism for systems that “move by
itself”. However, apart from this original sense of the word, automated systems also
achieve significantly superior performance than what is possible with manual systems, in
terms of power, precision and speed of operation.

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

Advantages for Automation

1. Automating a manufacturing operation usually increases production rate and
labor productivity. This means greater output per hour of labor input.
2. To reduce labor cost.
3. To migrate 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 cost of not automating.

Disadvantages of Automation
1. Higher Start-up cost and the cost of operation.
2. Higher Cost of Maintenance.
3. Obsolescence/Depreciation Cost.
4. Unemployment.
5. Not economically justifiable for small scale production.

Dr. Kiran M D, Asst. Professor, Dept. of Mechanical Engg, BMSIT&M, Bangalore Page 1
Introduction to mechanical Engineering
Basic Elements of Automation
An automated system consists of three basic elements:
1. Power to accomplish the process and operate the system.
2. Program of instructions to direct the process, and
3. Control system to actuate the instructions.

Power to accomplish the process and operate the system:

An automated system is used to operate some process, and power is required to drive the
programs as well as the controls. The principal source of power in automated systems is
electricity. Electric power has many advantages in automated as well as nonautomated
processes.
Program of instructions to direct the process:
The actions performed the automated process arc defined by a program of instructions.
Whether the manufacturing operation involves low, medium, or high production, each part
or product style made in the operation requires one or more processing steps that are unique
to that style.
Control system to actuate the instructions:
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 of Automation:
1. Programmable Automation
2. Flexible Automation
3. Integrated Automation

Dr. Kiran M D, Asst. Professor, Dept. of Mechanical Engg, BMSIT&M, Bangalore Page 2
Introduction to mechanical Engineering

Fixed Automation:
• It is a system designed to do specific task with specialized equipment produces high
volume at low cost and inflexible in nature.
• 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. e.g.
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.
• The typical features of fixed automation are:
➢ High initial investment for custom-engineered equipment
➢ High production rates
➢ Relatively inflexible in accommodating product changes

Flexible Automation:
• It is a robot or equipment that has been designed to easily change the production
line. It can change variety of products mixes or with new product.
• A flexible automated system is one that is capable of producing a variety of
products (or parts) with virtually no time lost for changeovers from one product
to the next.
• Changing the part programs is generally accomplished by preparing the
programs offline on a computer system and electronically transmitting the
programs to the automated production system. There is no production time lost

Dr. Kiran M D, Asst. Professor, Dept. of Mechanical Engg, BMSIT&M, Bangalore Page 3
Introduction to mechanical Engineering
while reprogramming the system and altering the physical setup (tooling, fixtures
and machine settings).
• Consequently, the system can produce various combinations and schedules of
products, instead of requiring that they be made in separate batches.
• The essential features that distinguish flexible automation from programmable
automation are the capacity to change part programs with no lost production
time, and the capability to change over the physical setup, again with no lost
production time.
• The features of flexible automation can be summarized as follows:
➢ Continuous production of variable mixtures of products
➢ Medium production rates
➢ Flexibility to deal with product design variations

Programmable Automation:
• Programmable automation may be reprogrammed to do many different tasks by
using general purpose equipment produces high variety with low volume and
more flexible in nature.
• In programmable automation, the production equipment is designed with the
capability to change the sequence of operations to accommodate different
product configurations.
• The operation sequence is controlled by a program, which is a set of instructions
coded so that the system can read and interpret them. New programs can be
prepared and entered into the equipment to produce new products.
• Automated production systems that are programmable are used in low and
medium- volume production.
• The parts or products are typically made in batches. To produce each new batch
of a different product, the system must be reprogrammed with the set of machine
instructions that correspond to the new product and the physical setup of the
machine must also be changed over.
• Some of the features that characterize programmable automation include:
➢ High investment in general-purpose equipment
➢ Low production rates relative to fixed automation
➢ Flexibility to deal with changes in product configuration
➢ Most suitable for batch production

Dr. Kiran M D, Asst. Professor, Dept. of Mechanical Engg, BMSIT&M, Bangalore Page 4