Many times in Manufacturing Automation parlance when people say “Automation” they mean only “Pick and Place” kind of automation using Robots , end effectors / grippers, conveyors, scissor lift, tilt / turn devices with continuous position and trajectory control or “point to point” movements.
BUT basically there are three distinct applications of Automation:
1. Material Handling Automation
2. Process Parameter Control Automation
3. Data Automation for Industry 4.0
Further there are two distinct types of Automation viz.,
A. “As-Programmed” Automation – where the sequence, movements, process parameters and commands are pre decided / pre-set through software OR hardwired logic.
B. Adaptive Automation – where the sequence, movements, process parameters and commands are varied according to existing conditions “on the fly” to produce the desired end result. This could also include adaptive access and collision avoidance.
Above all, there are immense possibilities of integration of all of above along with intelligence of Simulations in Virtual World …this would be the next-gen FULL PROCESS AUTOMATION
ILLUSTRATIVE EXAMPLE:
- If you have a Robot doing TIG / MIG ( blind ) welding – it is “as programmed” automation
- You add a “weld Positioner” to move / index / tilt the job in coordination with Robot trajectory – it in “integrated “as programmed” automation
- You add a feedback of weld quality through current measurement, arc length , melting rate / deposition rate , thermography, vision system etc. – if it adaptively changes the process parameters for a uniform, consistent weld quality irrespective of welder skill – it is PROCESS INTEGRATED ADAPTIVE AUTOMATION
- It could acquire data such as distortions in welding and compensate for the same through work-holding device and optimizing weld sequence and parameters for optimal results in line with Simulation – it would be NEXT-GEN PROCESS INTEGRATED ADAPTIVE AUTOMATION
- One could add Industry 4.0 requirements for overall weld shop performance monitoring including the cycle times, cost, consumptions, productivity etc., it would be NEXT-GEN FULL PROCESS INTEGRATED ADAPTIVE AUTOMATION
In principle similar approach could be there for any type of manufacturing process be it: assembly, machining, EDM / ECM, Laser Cutting-Welding- Hardening, Additive Manufacturing , metal forming, sheet forming and composites.
AVINASH KHARE