MAR 2013

Course Notes - 16 Automation

2008-2009

What is meant by Automation? What processes in Marine Production are suitable for automation? What justification is there for automation in Marine Production? There is no universal definition of automation. One alternative is: The carrying out of a process without human intervention. This begs the questions: When does the process start and finish? What human intervention is permissible? How can the process equipment be adapted?

Components of Automation An industrial operation can be considered to have four components: processes - tools and techniques to perform tasks materials handling - transfer of materials between processes control - regulation of quantity and quality of outputs power technology - source of energy for the activities Each of these can be at any point on a scale of mechanisation: manual power-assisted hand-controlled machine automatic machine - hand activated fully automatic Examples of Automation at different stages Hand tools Power tools Roller conveyor Roller conveyor with product detection N.C. Plate cutting machine D.N.C. Plate cutting machine Panel Line Robot Applicability of Automation

Product Volume

Variety

Factors supporting flexible automation

MAR 2013

Course Notes - 16 Automation

2008-2009

Just-in-time production and smaller batch sizes Improved sensors Customised standard products but, for marine production, inhibiting factors are large workpieces, fixed position workpieces, difficult working conditions Robots Again, no universal definition is available. The Industry Association definition is: a programmable, multifunctional manipulator designed to move materials, parts, tools or specialised devices through variable, programmed motions for the performance of a variety of tasks. The key element of the above is: programmable - adaptable to alternative tasks Typical Robot Components Robot arm or body kinematic structure typically six axes to position end effector End effector the tool which allows the robot to perform a useful task Auxiliary equipment power and consumable supplies to the end effector Controller co-ordinates the various motors to maintain the end effector in the correct path, maintaining orientation and velocity Workpiece Positioner optional, to simplify control The use of robots To overcome shortages of labour absolute shortages of people shortages of skills poor image of the marine industry To improve productivity To carry out tasks in poor working conditions Cost-benefit analysis is essential (for robots, or any other item of equipment) Example Cost-benefit Analysis Conventional sub-assembly Equipment cost 50,000 one-off 5 welders 100,000 annual Welder duty cycle 30% Re-work cost 50,000 annual Robot Welding System cost 400,000 one-off Labour cost 10,000 annual Robot duty cycle 75% (Twin welding heads)

MAR 2013

Course Notes - 16 Automation Program cost Training cost

2008-2009 20,000 annual 30,000 one-off

Payback on the investment Conventional Cumulative Cost Initial cost Year 1 Year 2 Year 3 Year 4 Year 5 Ignoring maintenance, replacement, etc. Payback for Robot

Cumulative Cost for Robot

The payback from a robot investment will be very different given changes to costs. In a lower labour cost area, where the annual cost of five welders is only 50,000 Payback becomes

If the annual 50,000 cost of rework can be eliminated by other means Payback is also

If both are the case, the Payback is then

In a higher labour cost area, where the annual cost of five welders is 150,000 Payback reduces to If the duty cycle increases to 90% by better product design for production Payback reduces to Robot Types Cylindrical one rotational axis Spherical two rotational axes Revolute , through increased production rate.

MAR 2013

Course Notes - 16 Automation

2008-2009

three rotational axes Cartesian three translational axes Special Robot Characteristics Drive Types are Pneumatic, - Low power, Low accuracy, Low Cost Limited application, pick and place Hydraulic, -High power at reasonable cost, Medium accuracy, Safe Painting, spot welding, materials handling Electric, Higher cost for high power, Good accuracy Arc welding, assembly Programming and Control Commonly used programming and control methods, on-line Point to point playback Continuous path playback Recorded trajectory Off line programming is also used Robot languages Simulation packages Dealing with Workpiece Inaccuracy If a robot is programmed to follow a path, it will do so. If the workpiece is not where it is expected, then the robot will not perform the task correctly. Adaptive control is used to give precision for welding in particular. Preview sensors use inductive sensing, but are time consuming. real time sensors use micro switches for detecting collisions Vision systems are sensitive but expensive Through-arc seam tracking monitors arc current ( and voltage) to maintain arc position Workstation design considerations Workpiece presentation, location, orientation, accuracy Safety interlocks Workstation Layout robot surrounded by work e.g. machine loading robot robot passes fixed work stations mobile robot serving several longcycle machines work passes fixed robot profile cutting line work passes moving robot longer and variable cycle times (subassembly line)