Automation Lecture Notes PDF

Automation Föreläsning 1 - Production systems Automations is often an integrated part of a production chain Automation Is a consequence of desire to increase ○ Productivity ○ Quality ○ Freeing (frigöra) resources, to perform other tasks Automation levels trough con...

Automation Föreläsning 1 - Production systems Automations is often an integrated part of a production chain Automation Is a consequence of desire to increase ○ Productivity ○ Quality ○ Freeing (frigöra) resources, to perform other tasks Automation levels trough continuous improvements ○ Rarely through new groundbreaking technology New technology improvements are for example: ○ Combustion engine ○ Electricity ○ Electronics ○ Digitalisation ○ Manufacturing techniques such as 3D-printing When is business effective? → When it creates value for the customer Value creating production for… Customers Co-workers Owners Society Production as a system Process objects are: ○ Machines ○ People ○ Tools ○ Products Production rate Time-in-system Production systems  Method chosen for manufacture Governed by ○ Costs ○ Lead times ○ Quantity Functional workshop Similar but customized machines Flexible production A lot of transport and difficult to handle with large volumes Production line Short lead times, low costs, large volumes Reduced flexibility Process monitoring SCADA - Supervisory control and data acquisition ○ Current status - visualization ○ Alarm, log book ○ Shows trends ○ Handbook, expert systems ○ Communication and synchronization with other workstations Operator workplace: Three main functions 1. Current state 2. Trends and history 3. Alarms and events Response time and hierarchical level Manufacturing approaches Automation Flexible manufacturing Quality programs Integration Lean production Japanese methods Kaizen - continuous improvements JIT - Just-in-time Muda - No waste Open and transparent, self-control Right the first time No errors LEAN-manufacturing The 7+1 wastes 1. Waiting - e.g. idle or defective equipment 2. Overproduction 3. Inventory - e.g. wares spare parts 4. Defects 5. Transports 6. Over processing 7. Movement - e.g. searching 8. (+1) Unused creativity or expertise Factory in a box 1. Mobility a. Manufacturing in several locations b. Manufacturing by subcontractor c. Technology upgrade 2. Flexibility a. Up-scaling b. Down-scaling c. Generally d. Non-type-bound tools 3. Speed a. Ready for immediate use Föreläsning 2 - General automation (Automation in production) Automation Processes MAterial handling, transports Information Management Decisions Control/inspection Purpose of automation Why? ○ Create value - when the business creates value for the customer Automation is about ○ Mechatronics ○ Signal-/information flows - and can be further divided into ○ Manufacturing automation ○ Service automation Motivation Keyword: Value-making Trend is towards increased automation → machines replacing humans Swedish industry is at the front - though not alone or first ○ Poland has invested a lot during the past two decades Development Application Automation is a great financial risk-taking ○ Projects often delay both timewise and costly (increased costs) Why automate? Working environment - humans can avoid unsafe tasks, humans avoids doing repetitive jobs Productivity improves Salary costs are cut out Labor shortages reduces Product quality increases - the human factor/error is excluded Lead times are reduces PIA - Products in action Resource utilization - increased effectiveness Why not automate? Resistance from workers Expensive to train and educate staff Initial investment costs of automation are high Management of the improvements - organizational “re-engineering” Examples of automation Supply Water Electricity Raw amterials AC Transport Carts (AGV) Conveyor belts Process Punching Moving Cutting Analyzing Burning processes Manufacturing Storage/inventory Automatic machine tools to form parts - CNC (computer numerical control) Industry robots Automatic material handling Feedback and operational information Expectations of automation Energy, material and time savings Quality improvements Reduced amount of “rubbish/bad” environment → improved Improved traceability Increased availability and security Fast respond to market changes Fast contact with the management and finance departments Concerns - But also opportunities Automation can result in: Jobs disappear Jobs may be partially reduced Several jobs can be combined into one Automation and its history Piecemeal production → Batch production → Mass production → Craftsmanship → Manufacturing industry Mechanization and automation Started with the industrial revolution ○ Change from human/animal work to usage of machines Mechanization ○ For example: An operator is required to manage the opening of locks + Automation - “Watts fly ball governor” removed the need for an operator Mechanization The use of machines replaces man or animal power Is based on ○ Task specialization ○ Connection to specified need Was more powerful, compact and faster ○ Ex. farming - tractor vs horses Mechanization - organization Close relation to the management Functional groups with specialized activities Formal hierarchical communication for coordinating Detailed descriptions of rights, obligations and practices for each individual job Process-oriented structure When does mechanization work? Gves straightforward information Creates a “stable climate” that makes overproduction work When production of same thing is repetitive When high precision is required Disadvantages with mechanization Its difficult to manage many and rapid changes in the market Could lead to internal conflicts between unit goals and organizational goals May lead to dehumanizing effects for personnel at low levels in the hierarchy ○ Less of work/jobs ○ Repetitive (boring and mundane) tasks everyday Principles of automation Mechanization Continuous process ○ Specialist can move between different workplaces but still work with similar jobs (e.g. repairmen, machinists, plumbing) ○ Innovations ○ Mass production technology No/little human intervention Remote control Automatic control ○ Control/feedback Machine is controlled by sensors ○ Machines are equipped with sensors, transducers and built-in logic for decision-making Start, stop, perform movements Counting Memory Identify dimensions/distances Adjust/identify temperatures Light Sound Pressure Rationalization ○ Improvements of each process step in order to contribute the most of a process step to the final product Ex: mounting adjustment ○ Logical evaluation of performance/evaluation Save energy, resources, time and reduce waste Modular products Products that fit several models of a part Managing automation Leaders need to receive information that is ○ Accurate - correct information and essential ○ Complete ○ Relevant  ○ In time In order to make good decisions Additional requirements for successful information are ○ Management of data flows - including information ○ Availability and security of procedures Industrial revolutions Industry 1.0 ○ Beginning of industrial revolution, mechanization of manufacturing by introducing steam and water power Industry 2.0 ○ With electrical power, assembly lines enables mass production Industry 3.0 ○ Automated production with implemented electronics, programmable logic controllers (PLC), IT systems and robotics Industry 4.0 ○ Smart factory is introduced, autonomous decision-making if cyber physical systems using machine learning and Big data analysis. Interoperability through Internet of Things and cloud technology Types of automation Fixed automation - Hard automated Custom built/custom equipment for a special order if process or assembly High initial costs are often required Inflexible type of production ○ For example: Three-million power contacts or one million shoelaces Programmable automation - Adjustable automation Equipment is designed to be able to cope with certain production changes (product group), through conversion or reprogramming. Is suitable for “batch” manufacturing Does not handle changes to new product-manufacturing without major changes required Flexible automation - (hardest) Process equipment can handle many different products and parts Relatively short changeover time between different products Has a flexible manufacturing system that can be used for multiple combinations of products according to any schedule Specially adapted products can be made Summarized ○ 3 types of automations ○ 5 types of automations Product complexity Product variety Product volume Production rate Manufacturing system Workshop types and assembly lines Fixed position manufacturing - All personnel works at the same station Process manufacturing - Quantity manufacturing Line layout - Focuses mainly on: - Production flow - Product standardization - Tempo work/Fast production Overview of workshop type Functional workshop - Focuses mainly on - Machine utilization - Work arrangement - The processes - Work measurement Complexity for automated manufacturing Assembly complexity Complex production systems are affected by ○ Variety of product ○ Instructions ○ Components in assembly ○ Tools required ○ Customer/assembly demands ○ Value chain disturbances Production complexity Objective complexity How complex a system is independent of who studies it Objective complexity can be both static and dynamic Subjective complexity Production systems are experienced as complex depending on who studies them Ex. assembly of cars despite few and similar parts TRaining and experience Stress level, personnel personality Improved through increased responsibility Complexity index (CXI) is a subjective survey method Gives an index of how complex the work at a workstation is Indicates where areas for improvement exist How an employee perceives work at a station Station design Work variance Change work and instructions But not Full picture  Whether it is good or bad to work at the station Complemented by other analyzes Survey response are tallied and categorized What is the CXI for the station? What areas contributed to the value of CXI? What comments were made? Self learning systems (AI) With the help of result data, the process can adjust itself for improvement - also called machinelearning ○ Ex - smart homes Generative algorithms ○ Developed in the computer game industry Dynamic automation strategies Dynamo++ ○ Developed since the 2000s A method for mapping production-sections for possible automation solutions Divided into four sequences ○ Current status - collection of data and information ○ Between current and future systems ○ Analysis of planned implementation - Time/resources ○ Follow-up (some time after implementation) level of automation (physical) 1. Muscle power alone 2. Static hand tools 3. Flexible tools 4. PNeumatic or electric tools 5. Technical aids - operator does not perform the task 6. Technical aids but more flexible 7. The technical aid performs the task and is switched between different products - autonomous LEvel of automation - Cognitive 1. The workers own experience 2. The worker receives information about what is to be carried out 3. The worker receives information about how the task is to be performed 4. Technology calls for verification by worker 5. Technology calls the installers attention - e.g. status updates 6. The technology takes over the task performed by the worker - automatic distance measurement and braking 7. The task is solved completely automatically - decision making by the technology Solution combinations Organisation Industrial automation Advantages ○ Salary costs are reduced ○ Efficiency of production increases ○ Machines can do the same thing repeatedly without getting tired ○ Unhealthy jobs (like spray painting) can be replaced by robots Automation is received both positively and negatively, however, automation has brought more advantages than disadvantages How is automation introduced Change can come up mainly by: 1. Political/strategic decisions to get more advanced production a. Product standardization 2. As a result of technical or administrative developments… a. Adjustment period b. Reached degree of technological potential Organisation - technology evaluation A disappropriate amount of time spent evaluating, technical aspects compared to the potential impact on the organization Ways to deal with this: Adapt the technology to fit the structure of the organization Change organization by technology Maintain an already existing structure of organization and technology by modifying processes. Organization - Introduce technology In order to introduce technology to an organization, knowledge of the organizational structure is required. Technological changes follow with development(changes in the production and organizational. Technology companies Successful companies are good at what is not technology ○ F.e. customers, employees, collaborators etc… Automation - always relevant There's often concerns in the media about robotization. In an interview, the Swedish prime minister believes that investment in automation is necessary in global competition. We must be able to produce the best goods and service that can be offered We should not be afraid of new technology, we should be afraid of the old technology Global phenomena - difficult to go back Ex: USA and election promises by Donald Trump ○ To not further implement automation, rather develop and giving back jobs to workers, implemented grants did have the opposite effect Personnel Automation effects on jobs Within organizations there are certain agreements for employees that must be taken into account - F.E. heavy industry ○ Labor rights and unions are prioritized ○ Sometimes, when major changes are needed, it can be easier to create something entirely new using modern technology than to try to modify or update old, complex systems. The workers perspective Will it be more jobs or re-allocations? Which type of jobs? Additional tasks? Will the union change their requirements? Automation will lead to redistribution of work, responsibilities and work environment - along with education (which is internally within large companies) Difference between work and surveillance/administration becomes blurry Automation - the staff Healthy Work environment Reduced risk of injury Decoupling - opportunity to work with different tasks ○ The process - “Automatic process” ○ Material supply - Buffers and magazines ○ Keywords: Participation Commitment Attitudes Technical knowledge Individuals must be able to manage computers to cope with governance and massive amounts of data Literacy and social skills are supplemented with “Technological literacy” literacy = läskunnighet Often easier to train/educate young people or those with formal education More extensive training programs for others Training for automation - organizationally Requires a newer way of thinking Training to manage automatic systems is linked to training for technical staff Management decisions are vital when they affect maintenance and operation. They can only be made by someone who knows the plant immediately as a technical system. To trains staff When is training needed? When the nature of the task changes Technical or functional knowledge is low Technological revolutions require training and re-education, especially for the elderly TRaining is lifelong - we can no longer count on having the same job/tasks forever Training forms On-the-job training Vestibule training Apprenticeship Computer-assisted instruction (CAI) Net-based training Behaviour modification Job rotation Case studies, business games, in-basket training, role playing Current trends Prevention of accidents MTO - Man, Technology, Organization Man ○ IS often “lazy” but also smart and effective ○ If security fail safe mechanism (or procedure) felt as a hinder, they will be “manipulated” to be able to perform the work more efficiently Machine/Technology ○ Sensors, work routines (F.e. checklists), mechanical obstacles ○ Must protect workers and equipment from damage Organization ○ Create awareness about security ○ Keep track of statues, laws and regulations  ○ Shall create a healthy but in the meantime efficient environment Arbetsmiljöverket ○ Rules ○ Frameworks, etc… Föreläsning 3 - Industry robots What can robots do? Work that is dangerous for humans ○ Ex. Decontaminating robot - cleaning main circulating pump housing in the nuclear power plant Repetitive work that is boring, stressful and causes fatigue ○ Ex. welding robots Tasks that humans preferably avoid ○ Ex. cleaning toilets Industry robot density What is a robot? Legend robots Wheeled robots Autonomous underwater vehicles Unmanned aerial vehicle Robot history The word was coined by a czech aotuher Robota in czech means tireless “workers” or “servants” A robot is a reprogrammable, multi-functional manipulator designed to move:  ○ Materials ○ Parts ○ Tools ○ Special devices Through varying motions in order to perform varying tasks Robot laws The first robot UNIMATE - created in 1954, the first programmable robot designed by george devol, who coined the term “universal automation”, later shortened to Unimation. This will be the name of the first robot manufacturing company (1962). First electric robot ASEA (now ABB) bought robots from American Unimate, for its production. CEO Curt Nicolin was interested in manufacturing them under license, but the contract went to electrolux. It was then decided that ASEA would develop its own robot TRavelling to industrial fares, they learned that electric drives were becoming more powerful and saw potential of using them in robots, instead of pneumatics and hydraulics 1978 The Puma (programmable universal machine for assembly) robot is developed by with design support from general motors 1980s  The robotics industry experiences rapid growth. Many organizations are starting to introduce courses in robotics. These later spread to mechanical and computer science courses. ○ Adepts SCARA robot ○ Cognex in-sight robot ○ Barrett technology manipulator 1995-present New applications in small-scale robotics drive a second market for start-up companies and research 2003: NASA's mars exploration rovers have been up for a while - 10+ years. Exploring large parts of the martian surface When are robots used? Industrie that applies robots Agriculture Vehicle Barley Pleasure Healthcare - Hospital, care, surgery, research, etc Laboratories: Research, construction, etc Law & ORder: Surveillance, patrolling, etc Manufacturing Military: Mine clearance, surveillance, reconnaissance, assault, etc Mining industry Exploration Transportation: Air, ground, rail, space, etc Utilities: Gas, water, electricity Stock Typical industrial robot applications Material handling Material movement, pick and place, pallet racking Loading Processes Welding Painting Cut, polish Mounting Inspection What can robots do? Industrial robots Material handling ○ Material-handling manipulator Material movement Machine loading and/or unloading Spot welding ○ Spot-welding manipulator Continuous welding Spray painting Mounting ○ Montage manipulator Inspection/review Robots in space Robots in dangerous environments TROV in antarctica under the sea HAZBOT operating in atmospheres containing combustible gases Robots in medicine/healthcare Robot assistant for microsurgery Robots in home Sony SDR-3X amusement robot  Sony Aido Robots in the future? AI - artificial intelligence Carts Humanoids Kismet How does an industrial robot work? Robots in automation Why are robots an important part of automation? ○ Reprogrammable - can connect to other computer systems ○ Can be equipped with different tools ○ Can be equipped with different “givare” - ○ Can manage repetitive, often heavy and dangerous tasks faster than humans Ciretarias for an industrial robot An arm that can physically move and rotate the workpiece A wrist that can rotate the workpiece around at least one axis of motion - orientation space A hand that can grasp and release a workpiece Manual control and programming option Memory that can record data/positions Automatic control for previously learned tasks Movement speed faster than a human Sufficient load capacity Functional safety Sensors to identify and react to their surroundings Low price Industrial robots Important and reliable part of industrial automation From the beginning only in the engineering industry, mainly the automotive industry During the s990s, commodity-producing companies changed. Shorter production life-cycles mean that the robots flexibility brings benefits ○ Faster setup times Knowledge base for robot construction Typical knowledge-base for the design and operation of robotics systems ○ Dynamic system modeling and analysis ○ Feedback control ○ Sensors and signal conditioning ○ Actuators and power electronics ○ Hardware/computer interfacing  ○ Computer programming Research areas: Mathematics Physics Biology Machinery Electronics Computer science The parts of the robot The base of a robot: Fixed or mobile Robot manipulators used in manufacturing are usually fixed - i.e. they cannot move Mobile bases are typically platforms with wheeös or tracks. Some robot bases may have legs for locomotion How to mechanically move segments Drive system Electric ○ Uses electric motors to control individual joints ○ In modern robots this drive system is used Hydraulic - liquid ○ Uses hydraulic piston and vacuum pump control systems ○ Strong with good lifting capacity Pneumatic - air ○ Limited to small robots and simple movements Often combinations ○ End pieces often pneumatic Pneumatic systems for robot movement Robot anatomy Manipulator consists of joints and link ○ Joints provide relative movement ○ Links hold the joints ○ Linear or rotary ○ Each joint gives a DOF ○ Most robots have 5 or 6 DOF Robot manipulator consists of two parts ○ Body and arm - to position objects in the robots workspace Manipulator joints Transverse movement ○ Linear joint - type L ○ Orthogonal type - type O  Rotating movement ○ Rotary joint - type R ○ Swivel joint - type T ○ “Revolver” joint - type V Joint notation scheme Uses the symbols ○ L, O, R, T, V To indicate joint types that the manipulator consists of Separates body-arm assembly from ankle assembly with colon (:) ○ Ex. TLR:TR Some common body-arm configurations… Polarcoordinate Notation: TLR ○ Consists of a sliding arm L maneuvered relative to the body, which can rotate about a vertical axis T and a horizontal axis R Cylindrical Consists of a vertical column, relative to an arm that moves up or down The arm can be moved in or out to the column Cartesian coordinates Notation LOO Consists of three sliding joints, two orthogonal Other names: rectilinear robot, x-y-z robot, Gentry robot Articulated arm Notation TRR  Common SCARA Notation VRO Selectively compliant assembly robot arm (SCARA) ○ Similar to articulated arm, except that the vertical axes are used for shoulder and elbow joints, which is compatible in the horizontal direction for vertical insertion tasks Advantages & disadvantages of the arm-configurations Parallel kinematic robots Ankle configurations The ankle assembly sits at the end of the arm The final contact is located at the end of the ankle The ankle can orient the end contact Body and arm determine positioning of end contact Two or three DOF ○ Roll - rulla ○ Pitch - svänga ○ Yaw - gira Extra axes - possible addition Linear table Rotating table Rotating and leaning fixtures How to control a robot Robot control system Limited sequence control ○ Pick and place, mechanical stop positions Playback with point-to-point control ○ Records the duty cycle as a series of points, then “plays back” the sequence during program execution Playback with continuous control ○ More memory capacity and/or interpolation function beyond points Intelligent control ○ Uses intelligence-like behaviour, i.e. reacts to sensors, make decisions, communicates Robot control system End tools The tools a robot can “hold” to perform tasks Mainly two types ○ Grippers To hold and manage objects during the work cycle ○ Tools To perform a process, e.g. paint or weld Work areas Singularities Motion in cartesian space, converted to positions, angular or linear velocities for the respective link arm actuators A singularity is a condition where the positions of a robots link arms are such that no solution exist to convert the robots motion in cartesian space into angular motions for each link arm. ○ Workspace limiting singularities: elbow singularity occurs when an arm is fully extended ○ Internal singularities: occur when two or more axes are aligned with each other When a robot has reached a singularity, one or more DOF in cartesian space are lost. This means that there are one or more directions in cartesian space i which it is impossible to move the robot regardless of the angular velocities chosen Examples of special applications Welding Advantages ○ Consistent quality of welds ○ Repeatability ○ Cheaper on large series ○ Fewer mistakes that lead to scrap parts ○ Better profitability ○ Faster Disadvantages ○ Expensive one-time cost ○ Susceptible to downtime ○ Requires large series ○ Requires good fixtures Milling Föreläsning 4 - Industry robots 2 Robot programming “Leadthrough” or “Teach in” ○ The duty cycle is taught to the robot by moving the manipulator through the motion cycle and at the same time entering program joints into the control memory for later playback Simulation and offline-programming ○ The program is prepared on some external computer and then loaded into the robot controller for execution without management methods Programming language for robots ○ Usually text, lin-by-line programming for commands to the control “Leadthrough” or “Teach in” Powered leadthrough ○ Common for point-to -point robots ○ Uses handheld controls Manual leadthrough - new ○ Good for robots with continuous trajectories ○ Human programmer physically moves the manipulator Advantages  ○ Easy to learn ○ Logical way of programming ○ No computer programming required ○ In workspace programming - every position are immediately visible Disadvantages ○ Shutdown while programming is in progress ○ Limited program logic possibilities ○ Not compatible with monitoring/control Robot programming Text-based programming languages ○ Improved sensor capabilities ○ Extended output possibilities for control and external equipment ○ Program logic ○ Calculations and data processing ○ Communication with monitoring computers ○ Robot simulation Coordinate systems Different robots have different axes To be aware of when programming robots Logical “stupidity” Singularity points Point accuracy Track tracing/tracking - bannoggrannhet Acceleration Elbow room - svängrum Robotcell Robot safety Also found in OSHA mnual Occupational injuries (sometimes fatal) can occur when working with robots  ○ OBS! MTO Types of injuries that may occur ○ Collision or strike by robot arm ○ A body part gets stuck or crushed between the robot arm or other surrounding equipment ○ Mechanical faults due to equipment is released too soon, the robot breaks or reacts unexpectedly to some input Robot controlled welding cell This robot performs arc welding at one workstation while the other workstations changes parts to weld Moving robots - AGV - Automatic guided vehicle In other names: ○ Carrier ○ PDV ○ FLV ○ Autotruck More flexible than conveyors (transportband) I.e. operation and battery Suitable for partly automated organizations Mainly for transportation, but could also ease the work for welding robots in a weld cell Follows roads and signals ○ Ex.. wires, magnetic tape, light, optically readable lines AGV in docks E.g.s hamburgs container terminal Complicated calculations where many hundreds of AGVs work together ○ Collision problems ○ Coordination problems ○ Timing AGV - laser controlled Can navigate without pre programmed route Will replace manually operated forklifts AGV equipped with a robotic arm can, in addition to transport, also handle unloading/loading and assembly on site New upcoming industry robots Two armed robots - YUMI Two armed robot with high precision and safety for assembly of smaller components, such as electronics. DOF = 14, 7 per arm- Lifting capacity = 0.5kg per arm Mentions YUMI Motoman Yaskawa Kuka Development of other types of robots For amusement Industry Help in home Social Restaurants Alot of other areas Working robots Boston dynamics - industry/military Atlas Spotmini Handle Bio Inspired robots to correspond with biological features such as squid arms Android Robot made to resemble humans Also called humanoid robot- in short hubbot Humanoida robotar yadayada