ESE616 Industrial Automation &

Robotic
Chapter 2
Automation System in Industry
Main source: Mikell P. Groover,
Automation, Production Systems, and
Computer-Integrated Manufacturing
Video source: Youtube

Types of Operation
Automation system in industry operated on the physical product, example:
Automated machine tools that process parts

Use energy such as mechanical, thermal, electrical, and chemical to alter

a workparts shape, physical properties, or appearance.

include the process of shaping operations, property-enhancing

operations and surface processing operation.

Example:
Automated
shaping
operation (CNC
milling)

Types of Operation
Transfer lines that perform a series of machining operations

Series of machining operation

Types of Operation
Automated assembly systems

Example: Automated cap assembly

Types of Operation
Manufacturing systems that use industrial robots to perform processing or

assembly operations

Example: USB
memory stick
assembly using
industrial robot

Types of Operation
Automatic material handling and storage systems to integrate manufacturing

operations

Example: Automated
material handling
system

Types of Operation
Automatic inspection systems for quality control
Physical inspection
Functionality

Type of Automation in Industry

Fixed automation
Also known as hard automation, refers to an automated production facility in
which the sequence of processing operations is fixed by the equipment
configuration.
The programmed commands are contained in the machines in the form of
cams, gears, wiring, and other hardware that is not easily changed over from
one product style to another. This form of automation is characterized by high
initial investment and high production rates.
It is therefore suitable for products that are made in large volumes. Examples of
fixed automation include machining transfer lines found in the automotive
industry, automatic assembly machines, and certain chemical processes.

Type of Automation in Industry

Programmable automation
Is a form of automation for producing products in batches. The products are
made in batch quantities ranging from several dozen to several thousand units at
a time. For each new batch, the production equipment must be reprogrammed
and changed over to accommodate the new product style.
This reprogramming and changeover take time to accomplish, and there is a
period of nonproductive time followed by a production run for each new batch.
Production rates in programmable automation are generally lower than in fixed
automation, because the equipment is designed to facilitate product changeover
rather than for product specialization.
A numerical-control machine tool is a good example of programmable
automation. The program is coded in computer memory for each different
product style, and the machine tool is controlled by the computer program.
Industrial robots are another example.

Type of Automation in Industry

Flexible automation
Is an extension of programmable automation. The disadvantage with
programmable automation is the time required to reprogram and change over
the production equipment for each batch of new product. This is lost
production time, which is expensive.
In flexible automation, the variety of products is sufficiently limited so that the
changeover of the equipment can be done very quickly and automatically.
The reprogramming of the equipment in flexible automation is done off-line;
that is, the programming is accomplished at a computer terminal without using
the production equipment itself. Accordingly, there is no need to group
identical products into batches; instead, a mixture of different products can be
produced one right after another.

Automated Assembly System

Automated assembly refers to the use of mechanized and automated devices to

perform the various assembly tasks in an assembly line or cell.

Performs a sequence of automated assembly operations to combine multiple
components in a single entity.
Automated assembly technology should be considered when the following
Condition exists.
High product demand Millions of units (or close).
Stable product design Changing workstation tools and assembly sequence can
be costly.
The assembly consists of no more than a limited number of components
Recommends a maximum of around a dozen parts.
The product is designed for automated assembly.

Automated Assembly System

A typical automated assembly system consists of the following subsystems
One or more workstations at which the assembly steps accomplished.
Part feeding devices that deliver the individual components to the workstation.
The work handling system for the assembled entity.

Automated Assembly System

Work Transport System
Continuous transport systems uses a continuous moving conveyor that
operates at constant velocity. It can be implemented in two ways.
1.Work units are fixed to the conveyor or track.
2.Work units are removable for the conveyor.
Synchronous transport system All work units are moved simultaneously
between stations with a quick, discontinuous motion, and then positioned at
their respective stations.
Asynchronous transport system - a work unit leaves a given station when the
assigned task has been completed and the worker release the unit. Work units
move independently rather than synchronously. At any moment, some units are
moving between workstations, while others are positioned at stations.
Stationary base part system - the base part to which the other components are
added is placed in a fixed location, where it remains during the assembly work.

Automated Assembly System

There are 4 types of automated assembly system based on the physical
configuration.
1. In-Line Consist of a series of automatic workstations located along an inline transfer system. Continuous, synchronous, or asynchronous transfer
systems can be used with the in-line configuration.

Automated Assembly System

2. Dial-type Base parts are loaded onto fixtures or nests attached to the circular
dial. Normally used with continuous and synchronous motion of work units.

Automated Assembly System

3. Carousel Represent a hybrid between the circular work flow of the dial
assembly machine and straight work flow of the in-line system. Asynchronous
transfer mechanism often used to move the work units.

Automated Assembly System

4. Single Station Assembly operations are performed on a base part at a single
location. The typical operation cycle involves the placement of the base part at a
stationary position in the workstation, followed by the addition of components
to the base.

Automated Assembly System

Multi-Station vs. Single-Station

Multi-station assembly machine or line

Faster cycle rate
High production quantities

More operations possible

More components per assembly

Single-station assembly cell

Suited to robotic assembly
Intended for lower production quantities

Automated Assembly System

A workstation accomplished on or both of the following
tasks:
A part is delivered to the assembly workhead and added to the existing base

part on front of the workhead.

A fastening or joining operation is performed at the station in which parts
added at the workstation or at the previous workstations are permanently
attached to the existing base part.

Automated Assembly System

Parts Delivery System:
Hopper The container in which the components are loaded at the

workstation. A separate hopper is used for each component type and the
components are normally loaded in bulk.
Parts Feeder Removes the components for the hopper one at a time for
delivery to the assembly workhead. The hopper and parts feeder are often
combined into one operating mechanism.

Automated Assembly System

Parts Delivery System:
Selector A selector is a device that acts as a filter, permitting only parts in the

correct orientation to pass through where incorrectly orientated parts are

rejected back into the hopper.
Orientor An orientor is a device that allows properly oriented parts to pass
through, but it reorients parts that are not properly oriented initially.

Automated Assembly System

Parts Delivery System:

(a) Selector, (b) Orientor

Automated Assembly System

Parts Delivery System:

Example: Automated parts delivery

Automated Assembly System

Parts Delivery System:
Feed track A Feed track is used to move the components from the hopper and

parts feeder to the location of the assembly workhead, maintaining proper

orientation of the parts during the transfer.
Gravity type Hopper and parts feeder are located at an elevation above that of the

workhead.
Powered type uses vibrator action, air pressure, or other means to force the parts
to travel along the feed track toward the assembly workhead.
Escapement to remove components from the feed track at time intervals that are

consistent with the cycle time of the assembly workhead.

Placement device Physically places the component in the correct location at the
workstation for the assembly operation.

Automated Assembly System

Escapement and placement

(a) Horizontal and (b) vertical devices for placement of parts onto dialindexing table

Automated Assembly System

Escapement and placement

Escapement of rivet-shaped parts actuated by work carriers

Automated Assembly System

Escapement and placement

Two types of pick-and-place mechanisms

for transferring base parts from feeders to
work carriers

Automated Assembly System

Total Quality Management

1.
2.
3.

A management approach that pursues three main objectives:

Achieving customer satisfaction
Continuous improvement
Encouraging involvement of the entire work force
Quality is focused on customer satisfaction where products
are designed and manufactured with this quality focus.
External customers are those who buy the companys
products.
Internal customers are manufacturing departmental inside
the company who are received (normally unfinished product)
from others manufacturing department.
In term of working support, the engineer is the customer of
the technical staff support group.

Total Quality Management

The quality goals of a company are not established in
manufacturing, they are defined at the highest levels of
organization.
Does the company want to simply meet specifications set by the
customer?
Or, does the company want to make products that go beyond the
technical specifications?
Does it want to be known as the lowest price supplier or the
highest quality producer in its industry?
All the above questions will drive the quality goals of the
company.
High product quality is a process of continuous improvement. It is
a never-ending chase to design better products and then to
manufacture them better.

Quality Improvement in Automation

System
Any proper industrial automation will verify the presence and
position of a part after it has been placed into the
assembly. Often the equipment will incorporate in-process testing
to verify that the product is correct before sending it to the next
operation.
Another quality improvement is the elimination of piece part
rejects. A defective or out-of-tolerance part will usually not pass
through the tooling required to automatically feed and load
it. This sorting of rejects will improve the quality of the finished
goods, but it will also put pressure on the upstream operations to
control the piece part quality.
Source: The Next Step Industrial Automation - When
and What to Automate
By Tracy Witzenburg
Equipment Engineering Manager
Belcan Engineering Automation Group
Solon, OH