..

- - - - - -

cHAPTER 4 Automation

f n the computer age, productivity in a manu-
facturing organization has been greatly increased
by refinements in the methods of operations
rather than development of new manufacturing
processes. Our ability to acquire data in real
time and to analyze and to act on the informa-
tion ei ther directly or indirectly through the
actions of devices has contributed significantly to
the efficiency of an operation. Automation in
manufacturing is a loosely defined term implying
applications of machines, controls, and com-
puters to increase productivity. Factory automa-
tion might include many facets. In a broad sense,
it may comprise four distinct but closely inter-
related parts: ( 1) the manufacturing system, (2)
material handling, (3) sensing equipment, and (4)
the control system.
We will study types of manufacturing
systems and material handling in later chapters.
Here we will introduce aspects of automation,
including: (1) sensory techniques, (2) bar codes,
(3) radio frequency identification systems, (4)
machine vision, (5) programmable logic control-
lers, (6) numerically controlled machines, and (7)
robots and their applications. Illustrative exam-
ples are given, where feasible, to show a spec-
trum of applications.

Sensing Methods
Sensing equipment plays a role similar to that of the physical senses. It
observes what is happening and transmits the information to the control
unit. Sensing techniques employ photoelectric cells, infrared cells, high-
frequency electronic devices, and units making use of isotopes, X rays,
ultrasonics, and resonance. Sensing devices offer many advantages. Speeds
of operation are many times faster than the maximum sensing that is pos-
sible by humans. There is no human-fatigue problem, and absolute accu-
racy of inspection is assured within machine limits. Observations can also
be made in places that are inaccessible or unsafe for human beings.
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CHAPTER 4 Automation

figure 4.1
Barcode
BARCODE
_ Quict zone .1
Sean light
·------1..-1 •

Digital pulses
V ~~~~, ,.... ..... _ __,

V"'"'

Binary code: V.n... corresponds to J

V'"'" corresponds to O
(This example reprcsents O123 in 1 2 of S symbology .)

1
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The btnary values O and 1 are represente tn d · bar codes in different :i ~
forms. In sorne systems, the Os are designated as white spaces and ls, as
black bars. In sorne other systems, Os appear as narrow bars or spaces and
1s are shown as wide bars or spaces.
A bar code is translated into machine language by using a bar code
reader. In sorne readers, a beam of red light projected by the reader is
manually swept over the bar code. Other bar code readers use oscillating J
mirrors to reftect a beam of light onto the bar code. The frequency of oscil-
lation is so high that the beam appears as a band of light to the human
operator. The light is absorbed by the dark bars and reflected by the light
background of the spaces. The intensity and duration of the reftections is
detected by a phototransducer within the bar code reader that produces ·-
voltage pulses. These pulses are then converted by an analog-to-digital con-
verter so that the computer receives digital 0/1 signals. The 0/1 digit 1
signals provide values in the format necessary for a computer to int at
h · l F. 4 ·¡¡ erpre '
or process, t e stgna . tgure .1 1 ustrates a voltage pulse gene t d b
h. h . h ra e y a
converter. Ftgure 4.2 1 ustrates the schematic diagram of th h d ·
· 1 d · h.
software tnvo ve tn t ts process. e ar ware and

Bar Code Symbologies

Many different bar code systems are in use in ¡ d
.. gives a brief summary of available codes and tnh ~stry today. Table 4.1
e1r char t · ·
example, Universal Product Code (UPC) and its ac eristtcs. For
European article numbering system (EAN) counte~part in Europe, the
. , are matnly us d . .
bustness. The bar codes on grocery items are 1-0 UPC e tn retad
• d 3 · · .
code, 3 of 9, orco e 9, ts used tn tndustry, the De ar code A
· very popular
in . ~any others governmental applications t P tment of Defense, and
. 1
. n er1eaved 2 of 5, or 1 2/5, is •

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