What is Automation?
Automation describes a wide range of technologies that reduce human intervention in processes. Human intervention is reduced by predetermining decision criteria, sub process relationships, and related actions — and embodying those predeterminations in machines.
Automation includes the use of various equipment and control systems such as machinery, processes in factories, boilers, and heat-treating ovens, switching on telephone networks, steering, and stabilization of ships, aircraft, and other applications and vehicles with reduced human intervention.
Automation covers applications ranging from a household thermostat controlling a boiler to a large industrial control system with tens of thousands of input measurements and output control signals.
Advantages of Automation
Improved Worker Safety
Automated cells remove workers from dangerous tasks, safeguarding them against hazards.
Lower Operating Costs
Robots can perform the work of several people, streamlining processes and reducing waste.
Reduced Lead Times
Automation keeps processes in-house, improving control and reducing lead times.
Increased Output
Robots work 24/7 at constant speed, increasing production potential.
Consistent Quality
Automated cells perform with less variability, ensuring consistent product quality.
Better Planning
Consistent production allows for reliable timing and cost predictions.
Predictable Project Margins
Consistent production by robots enables shops to reliably predict timing and costs, permitting tighter margins on projects.
Reduce Need for Outsourcing
Automated cells concentrate capacity, allowing shops to produce parts in-house that were previously outsourced.
Easy Integration
Complete systems—hardware, software, and controls—are delivered production-ready, enabling immediate productivity.
Maximize Labor
As the workforce shrinks, automation provides a real and viable solution to meet ongoing labor demands.
Types of automation.
Automation systems are classed into three different types of automation:
- Fixed automation
- Programmable automation
- Flexible automation
Fixed Automation
Fixed automation refers to the use of special-purpose machines to perform a specific task only. These types of automatic machines are made to perform single or at the most two tasks. Fixed automation is capable of manufacturing a particular product style, so any changes in the product design or process means changing the automation system which in turn is quite difficult. These machines that are used to automate the task are custom-built according to the manufacturing process. As Fixed automation is employed for doing a particular process it becomes difficult for fixed automation to adapt to new changes in the process. Fixed automation is initially expensive, however, in the long run with high production rates, it becomes economical. Therefore, fixed automation is best suited for mass production.
Examples of fixed automation include automated assembly lines in automobile manufacturing industries, material handling conveyor systems, machining transfer lines, chemical manufacturing systems etc.
Advantages of Fixed Automation are:
- • Fixed automation has high production rates.
- • Manufacturing cost per unit is lower.
- • Uniform quality output.
Limitations of Fixed automation are:
- • High Initial investment is required.
- • Difficult to adapt to changes.
Programmable automation:
Programmable automation refers to the production equipment 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 introduced into the equipment to produce new products. Unlike Fixed production which is suitable for mass production, Programmable automation is suitable for batch production. In programmable automation, for each new style of product the machinery must be reprogrammed. As the systems are being reprogrammed there is a span of non productive time.
Examples of programmable automation include NC controlled machine tools, industrial robots, CNC machines Programmable logic controllers (PLC) etc.
Advantages of Programmable Automation are:
- • Programmable automation is best suited for batch production.
- • There is flexibilty to accomodate product change.
Limitations of Programmable automation are:
- Initial cost is high.
- Lower production level as compared to fixed automation.
- Reprogramming is time consuming.
Flexible automation:
Flexible automation is an extended part of programmable automation. A flexible automated system is one that is capable of producing a variety of products (or parts) with virtually no time lost when changes are made from one product to the next. There is no production time lost while reprogramming the system and altering the physical setup (tooling, fixtures, and machine setting). Consequently, the system can produce various combinations and schedules of products instead of requiring that they be made in separate batches.
Examples of flexible automation include robotic arms that can be reprogrammed to do a variety of tasks like drilling, welding, spray painting etc.
Advantages of Flexible Automation are:
- • No time is lost while changes are made.
- • Easier to adapt to changes in product.
- • It is faster than programmable automation as no time is past in making the changes.
Limitations of Flexible automation are:
- Higher cost of equipment/machinery.
- Manufacturing cost per unit is higher.
Pump Automation
Pump Automation control systems provide real-time control and protection of your centrifugal pumps while also providing valuable process insight. By protecting against unplanned pump failure due to process upsets, we can keep your process running longer and eliminate unplanned repair activities. By Right-Sizing your pumps to your system, we can reduce not only your energy consumption but the wear and tear on your process system. Automation of pumps will give oil companies accurate data on sales and control over any adulteration. The petrol pump is one of the next scenes for automation in India. In a move to curb fuel adulteration and to face the competition from the private sector, the state-owned oil marketing companies are implementing an end-to-end automation of the fuel delivery network. The automation covers various aspects of the outlets, including level gauges in underground tanks and gauges to check quality parameters of the fuel. Every time fuel is dispensed, a bill, giving details of the date, time, quantity of the purchase, the pump and the attendant who delivered the product, will be generated automatically. Automation of pumps will give oil companies accurate data on sales and control over any adulteration, which might happen at the retail end. These benefits will also flow to the customer.
Some of the pumping applications that are typically automated include:
- Batching & dispensing
- Heating and Cooling
- Dosing & Metering
- Dewatering
- Multiphase Pumping
- Recirculation
- Transfer
- Unloading
These advanced pumps offer alternatives for building automation systems, including water supply, sewage and drainage, and air conditioning and heating pumps.
These advanced pumps offer incredible alternatives for developing building automation systems. Given the advances in automation technology, there are many different interaction techniques used in developing these automated systems.
Water supply pumps – Water intake varies by type of structure including educational institutions, hotels, factories, medical centers, and many others that often need versatile systems which meet certain individual requirements. These specialty pumps usually offer efficient stress enhancing, rainwater and domestic water utilization, fire extinguishing water, and even raw water intake to ensure reliable drinking water is delivered to all floors and areas of a building, even to high-lying faucets.
Sewage and drainage pumps – Waste water selection and transportation play a critical role in both conserving resources and protecting the environment. However, ongoing difficulties can interfere with working conditions for pumping systems and require new and innovative solutions to improve procedures. These pumps are designed to effortlessly collect and transport wastewater and other media and drain it through standard or pressurized drainage.
Air conditioning and heating pumps – In order to manage the environment accurately and maintain the heat range, air flow, and moisture, a building may have different heating and cooling needs based on its purpose, from medical to manufacturing. These types of pumps often are high-efficiency, have lifting units for condensates, and come with advanced controls and pump regulators.
PUMP AUTOMATION SYSTEM
Home Automation
A home automation system combines hardware and software via a wireless network to control your home electronics and appliances through one device. These devices can be controlled remotely, even when you're not at home.
Types of Home Automation
- Lights
- Doors
- House Alarm
- Thermostat
- Appliances
- Garage
- Watering Systems
- Energy Savers
Factory Automation
Factory automation is the implementation of technology and systems to automate a manufacturing process with the ultimate goal of increasing productivity and reducing costs. The level of automation may be anything from single operation automations to end-to-end automation where there is no human involvement. Factory automation can be implemented at any point in the manufacturing process from material quantity control, to production and assembly and finally to packaging and dispatch.
Types of Factory Automation
- Minimal Automation: There may be a little automation in this, but on the whole the process is manual. Examples are quality inspection, manual product assembly etc. This relies on training, expertise and human judgments for the process.
- Single automated machines: Use of single machines that are designed to automate a single repetitive process like inspection, cutting, packaging etc. The parts may be manually inserted and positioned into the equipment.
- Automated Production lines: Automated production lines typically combine material transfer on a conveyor system with a series of dedicated workstations each designed to fulfill a particular purpose in the production cycle. The sequence is fully defined and the level of operator involvement depends on the amount of automation. In a fully automated line operators are needed only for supervision, monitoring, adjustment and maintenance of the equipment.
- Fully automated (end-to-end): The ultimate solution is the end-to-end automated factory where there are no operators and the factories can run 24 hours per day 365 days per year. These factories may even include self-adjustment and quality measurement of products.
Benefits of Factory Automation
- Improved Productivity: One of the main drivers of factory automation must be improved productivity. The advantages of potential 24/7/365 production and streamlined processes cannot be underestimated.
- Improved Quality: Repeated tasks that are continually monitored and adjusted and reduced human error.
- Improved Consistency: Similar to the improved quality, the repeatability of an automated process makes the results more predictable and reduces any variations that are related to different operators and other human factors.
- Reduced Waste: Improved planning with automated production and the improved repeatability leads to reduced waste.
- Safer Working Conditions: Automating dangerous processes and built-in shut-down coupled with less operator involvement leads to a safer working environment and considerable risk reduction.
- Cost Saving: This is the main driver and is a combination of all the above. Increased productivity, reduced down-time, reduced training costs and elimination of accidents leads to significantly improved profitability after the initial outlay of automating the system.