Automation Principles and Strategies

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??????????????????????????? ??????????Automation
Principles and Strategies

• The USA Principles
• 1997 APICS American Production and Inventory
  Control Society.
• Understand the existing process
• Simplify the Process
• Automate the Process

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1.Understand the existing process

• ??????????????? ?????????????????
  ???????????????????
• ??????? input
• ??????????????????????????? ???????????? input
  ??? Output

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1.Understand the existing process

• ??????????????? ?????????????????
  ???????????????????
• ??????????????? (function)???????????????????
• ??????????????????????????????????????????
• ??????????????? ??????(upstream) ??????????
  (downstream)?????????????? ???????????????????????
  ???????????????????????????

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1.Understand the existing process

• ??????????????? ?????????????????
  ???????????????????
• ????????????????
• ??????????? (work study)
• ???????????? SWOT
• ???????????????????????????? (input parameter
  output variable)

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2. Simplify the process

• ????????????????????????????????????
  ?????????????????????????????????? ????
  ?????????? ECCS ??????????
• EEliminate all unnecessary work
  ????????????????????????????
• C Combine operation or element
  ?????????????????????????????????
• C Change the sequence of operation
  ?????????????????????
• SSimplify the necessary operation
  ?????????????????????????

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Ten Strategies for Automation

• Groover ??? ????? ??????? 10 ?????????????????????
  ?????????? ??????
• Specialization of Operation ??????????????????????
  ????????????????????? ????????????????????????????
  ?????????????
• Combined Operations ?????????????????????????
  ???????????????????????????/???????? (work
  station) ????????????????
• Simultaneous Operations ???????????????? ????
  ???????? 2-3 ?????????????????????????????????????
  ??????

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Ten Strategies for Automation

• 4. Integration of operation ????????????? ??????
  ??????????????????????????????????????????????????
  ?? ???????????????????????????????????????????????
  ????
• 5.Increased Flexibility ?????????????????
  ??????????????????????????????????????????????????
  ? job shop ???????????????????????????????????????
  ??????????????????????????????????
• 6. Improved material handling and Storage
  ??????????????????????????? ??????????????????????
  ??????

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Ten Strategies for Automation

• 7. On-line inspection ???????????????????????
  ??????????????????????????? ??????????????????????
  ?????????
• 8. Process control and optimization
  ?????????????????????????? ???????????????????
• 9. Plant Operation Control ??????????????????????
  ???????? ?????????????????????????????????????????
  ?????????????? ???? ??????????????????????????????
  ???????????????????
• 10. Computer-integrated manufacturing
  ?????????????????????? ????????????????????????
  ???????????????????? ??? ?????????????????????????
  ???????????????

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Automation Migration Strategy

• ??????????????????????????????????
  ???????????????????? 3 ???????
• Phase I manual production
• ?????????????????????????? ?????????????
  ??????????????????????????? ???????????????????
• Phase II Automated production
• ?????????????????????????????????????????
  ????????????????????????????????
  ???????????????????????????????
• Phase III Automated integrated production
• ??????????????????????????????????????????
  ???????????????????????????? ????????????????????
  ??????????????? ?????????????????????

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Levels of Automation
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Basic Elements of an Automated System

• ?????????? 3 ??????????? ??????
• Power ???????????????????????????????????????
• A Program of Instructions ????????????????
• A Control system ?????????????????????

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Power

• Power for the process ????
• ???????? gt ??????? ???????? Thermal
• ??????? ??? gt ???????????? mechanical
• ???????????
• ?????

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Power

• Power for automation ??????????????????????????
• ??????????? controller unit ??????????????????????
  ????/??????? ?????????????????? ?????????????????
  ???????? ????????????????????????????
• Power ???????????????????????????
  ??????????????????????????????????????????????????
  ?????????? ???? ?????? ??????? ???????????????????
  ?????? (actuators)
• ??????????????????????????? (Data acquisition and
  Information processing) ?????????????????????????
  ??????????????????????????????????????????????????
  ????

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Program of Instructions

• ?????????????????????????????????????????????
  ???????????????????????????????????????????????
• Work Cycle Programs ?????????????????????????
  ???? Loop
• ???????? ???? ?????????????????????
  ??????????????????
• 1. ???? ???????????? ??????????????
• 2. Timer ?????????????? ?????
• 3. ???????? ????????????????????
• - ???????????????????????? ?????????
  ??????????
• - ??????????????????????

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Control System

• ?????????? ???????????????????????????????????
• ???????? ???? Close Loop ??? Open Loop

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Control System

• Close Loop ???? ???????????? feedback control
  system ??????????????????????????????(output
  variable) ???????????????? input parameter
  ??????????????????????????????????????????????????
  ?????????????(output)?????????????????????????inpu
  t

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Control System
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Control System

• Open Loop
• ????????????????????????? ????????????????????????
  ????
• ?????????????????????????????? ???????????????????
  ?? ????????????????????????????????? ???
  ??????????????????????????????????????????

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Advanced Automation Functions

• ??????????????????????????????????
• ????????????????????????????Safety Monitoring
  ?????????????? ?????????? ?????????????????????
  ?? ???????????????????????????????????????????
• 2. ??????????????? ????????????? Maintenance and
  Repair Diagnosis ?????? ?????????????
  ?????????????????????? ???????????????????????????
  ???
• 3.?????????????????????????????? error detection
  recovery ????????????????????????? ????????

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??????????????????????????

• ?????????????? Actuators
• ???? Measuring Sensor
• ???? ?????? Control
• LOGIC COTROL
• Numerical Control

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?????????????? Actuators

• ???????
• DC motor, Induction Motor, Stepping Motor, Servo
  Motor
• Pneumatic , Hydraulic Motor

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?????????????? Actuators

• ?????????????????????
• Hydraulic Cylinder
• Pneumatic Piston
• Linear screw/ tread
• Solenoid

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Measuring Devices Sensors

• DC tachometer
• Dynamometer/Load Cell
• Thermometer
• Voltage , Ammeter Ohmmeter
• Optical encoder
• Linear Scale
• Ultrasonic sensor
• Strain gage

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??? 1

• ?????????????????????? ???????????? 1 ???? (????
  ??????????????????????????)
• ????????????????????
• ??????????????????????????????
• ???????????????????? Actuator, Sensor
• ????????????? Control system
• Work Cycle Program