Automated Manufacturing Process and System - Research Paper Example

? Design Technology, 8th December, Automated Manufacturing process and system Introduction Engineering has made lives easier across the globe because of momentous and amazing creations that are coming up every day. The 21st century engineering operations differ conspicuously with the 1900s activities that had lots of defects. People used to work hard and not smart because works were manual oriented. Contrary, today’s equipment is made on the foundation of high level digital intelligence hence smart machines of magnificent efficacy in terms of output and time. Computer memories have been fitted in these machines to come up with Human Interface Machines. A developed nation like Sweden doesn’t depend on labor intensive force when carrying out its engineering projects. It has invested massively in designing programmed machinery that work quicker and appropriately. The degree of freedom (DOF) of such equipment is multifaceted: translational, rotary, and angular. Invention and Creation of an Automated Manufacturing System Scientists, programmers and engineers came up together with an idea of automating manufacturing processes by integrating various systems. Two chief components were drawn in to create this system namely: the computer and the machine accessories. A simple automated manufacturing system consists of the following components: A computer structure (CAD system joined to a machine management/control set-up via a transmission BUS cables), servo-mechanical motors, data cables and working heads. This simple set up has changed the world completely and can work where humans are not able to operate. A good example is the recent Gulf of Mexico oil spill where special under-sea robots were sent to seal the bust duct. Following instructions and commands from a ship above the robots worked on damaged section of the rig. If it were not for the said machines, immense damage would have been meted on the ecosystem eventually affecting the whole globe. This is what is referred to as the power of automated engineering as it leaves anybody who comes across it taken aback. Operation and Control of an Automated Manufacturing Systems An article to be worked on by an automatic process doesn’t come into contact with humans once set. At advanced levels the setting is done by the machine itself with the help of robotic arms. The heart of an automated system is the computer unit. The computer system has three main sections as described above on the composition of a Computer Aided Manufacturing System (CAMS). Engineers come up with a design they want to create on the real physical object. Some designs are intricate and a conventional draughtsman is unable to handle. A higher level of intelligence is required for such a task. Using software that have been created for design purposes such as inventor, AutoCAD, mechanical desktop, solid works etcetera, a three or two dimensional object is generated. This item is saved in the memory of the computer system in softcopy version as a file. Additionally, programmers do the vital work of designing a step by step command system that is procedural as far as the works will be concerned. The programs can be altered to ensure best results are achieved. Besides, vector analysis and dimensional controls are considered in creation of a complete automated process. This is referred to as Vector/Dimensional Automation. The sole function of the computer design system is to relay coordinate commands information to the machine control section. A special BUS or jumper cable is used to pass this information between the two units. The servos are connected to the machine control output. Therefore, an input from the Computer Design System is interpreted and analyzed here for further processing. The process of digesting this information is aided by Programmable Logic Circuits (PLCs) (Hugh 2007). They are logical circuits that work on information sequentially. After examination, an output is dispatched to the servos for execution. The servo control is Polar oriented in X, Y and Z directions. The last part of the whole set up to actualize this file coordinate information is the working head. They may be multi-provided meaning that the machine is synchronous depending on the program files that have been inputted on the Computer Aided Design system. This implies that one machine can perform many tasks simultaneously. However, the number of functions carried out by the machine is commensurate to the memory properties of the computer. A powerful memory in terms of speed and size would work well with multi-work headed machines. These working heads are sometime referred to as robotic arms and the whole unit a robot. They resemble human hands right from the picking the work pieces, setting and operation. Others are translational, rotary and angular. They move in predetermined directions and patterns. BUS/JUMPER CABLES Fig.1.A schematic diagram of a typical Automated Manufacturing System (William 2008) Merits of Automated Manufacturing systems and Processes A lot of good things are associated with an automated process. One of the outstanding features of neo-engineering activities is an increase in throughput and productivity. There are minimal breakdowns that lead defective goods. There is no allowance for an error in the design of highly-intelligent machines. Precision is a key factor to be considered. Another advantage of using these machines is an increased quality as compared to manual and semi-automatic equipment. In case the current production situation doesn’t appear bright as far as quality of output is concerned, there are increased chances of better quality with time. Consistency of processed products is maintained looking from robustness perspective. Special robotic machines are capable of working in very dangerous situation where human beings can’t. For instance, underwater, space, fire, nuclear plants etc. Automated machines are capable of performing chores that are beyond human capability in terms of environment, space, weight and size. Large objects meant for space exploration, ships, aero-industry, nuclear amenities are huge for human handling. Division of Labor: The people who have been replaced by these machines have a good time of investing their minds on other productive work hence are not bound around old manual or semi-automatic machines. A country that has embraced automatic technology, boasts of highly skilled and intelligent citizenry. Those brains are an important asset to the country. Other nations are likely to hire or even poach such expatriates considering what is brought on the table. There is a very fast economic growth associated with automation as witnessed by Japanese and Germans in 1900s. Demerits of Automated Manufacturing Systems and Processes A computer system is limited in terms of level of intelligence. This may result in gross errors if the work it is supposed to handle is big and complex. More commands will call for higher speed and a bigger size computer memory space. These machines are susceptible to insecurity dangers too because of viral attacks. The installed programs are vulnerable to interruption and infection from unwanted software commonly referred to as viruses. Secondly, the cost involved in development and research towards may become excessive and unpredictable to a point of losses contrary to the expectation of the investors. It means automation cost exceeding the Returns on Investment (ROI) or automation cost saving measures. Finally, capital costs to initiate new automated manufacturing processes and systems are huge. However, the programme can be rolled out gradually hence spreading automation cost over time. Application of Automated Manufacturing Processes There are vast examples where automated system is used. One of the areas that CAMS has been of great help is the milling industry. Some work pieces are huge and require complex operations. Others require precision of highest degree especially in the medical and surgical field. A company that has been largely involved with computer automated milling operations is Cincinnati Milicron Company (William 2008). Spray works of objects has been made possible by use of automatically controlled spray guns. The movement pattern of the gun’s arm is predetermined to ensure uniform and repeated painting. Off-shore Oil exploration and drilling has been necessitated by automatic machines. A Central Command station situated on top of the rig is able to operate smart robots that have been designed with special materials to withstand harsh undersea environment. NASA has been a great consumer of this technology in its space exploration activities. Since some rockets launched are pilotless, remote controls have to be used in transmission and movement. Sky Scrapers have been built by utilizing machineries that use automated processes. These are just but a few areas Automated Manufacturing System and Processes have been greatly used. Conclusion Having discussed summarily the automation of a manufacturing system and/or process, it is worthy a point to note that such skills come in handy at a time like this when everything is turning digital. Relic analogue systems don’t hold water anymore today. Nations that embraced this expertise long time ago have witnessed fast economic and scientific progress in vast sectors right from farm work to space mission. These systems have been put in place to enable operations in unbearable conditions looking from human point of view. It implies that automation has made it possible to tap hidden natural resource that brings with economic progress and prowess. Old school bench operations are being phased out and replaced by faster, efficient and precise processes. Consequentially, safety is guaranteed where high degree of accuracy is inevitable for instance aero-industry. The components of an airplane’s engine need utmost attention when being worked on. The same applies to hospital equipment such as radiograph and CT scanning machines applied in identification and analysis of internal body parts. A country like Japan has automated its surgery procedures where robots carry out delicate incision tasks that human beings cannot handle. Nations that are making use of this system of automatic machinery help increase the competence edge of their labor force. There is a probability of such expatriates being sought after by other nations who desperately need such services. Automated Manufacturing Machines exported to client countries need company of engineers who created them especially during commissioning. As a result the users have to part with some commissioning fee that is remitted to the country of origin. This skilled labor force becomes an asset to their nation. However, research and development of curriculums that entail automated manufacturing processes with a huge initial cost. The last but not least thing to highlight about AM systems and processes is that they are environmentally friendly and have reduced green house gases (GHG) effect by large amount. Their power consumption is much less compared to old systems that used high amperage and voltage ratings. Regular upgrading of robotic machines consequentially leads to a cleaner and better working and living environment. Thus adopting Automated Manufacturing Systems and processes leads to a better world on social, economical, environmental and professional frontier. Work cited Masters, William. E. Computer Automated Manufacturing Processes and Systems. Los Angeles: Dogwood Easley, 2010. Groove, Mikell. P. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems. 4th. Ed. Canteburry: John Wiley & Sons, 2010. Zhiwu, L & MengChu, Z. Deadlock Resolution in Automated Manufacturing Sytems. London: Springer-Verlag, 2009. Philip, M. Automation, Production Systems and Computer Integrated Manufacturing Systems. New Jersey: Prentice Hall, 2007. Hugh, J. Automatic Manufacturing Sytems with PLCs. London: Oxford University Press, 2010. Jose, B. & Helder, A. Informatics in Control, Automation and Robotics. Dordrecht: Springer, 2006. Read More