Design of Automatic Machinery: Comprehensive Guide

Kevin Jogin -

Introduction

In the fast-paced world of modern manufacturing, the need for efficiency, consistency, and cost-effectiveness drives the push toward automation. Automatic machinery, with its promise of reducing labor costs, improving product quality, and increasing production speed, has become an essential component for companies striving to stay competitive in a global market. However, designing and implementing these complex systems is a challenge that requires a deep understanding of multiple engineering disciplines and a methodical approach to problem-solving.

This comprehensive guide explores the intricate process of designing automatic machinery, offering a detailed roadmap from conceptualization to implementation. Drawing from a wealth of industry experience, practical examples, and case studies, it delves into the essential steps required to create efficient and effective automated systems. Whether you're an engineer tasked with developing new automation or a manager seeking to justify the investment in such technologies, this guide provides the knowledge and tools necessary to succeed.

We begin by examining the fundamental reasons for automation and the various perspectives that influence its adoption. From there, we explore the detailed steps involved in designing automatic machinery, including analyzing human processes, brainstorming novel solutions, and applying a mechatronics strategy. Subsequent chapters cover crucial topics such as justifying automation projects, integrating industrial robots, designing workstations, and selecting appropriate actuators and sensors.

With insights into real-world applications and lessons learned from both successes and failures, this guide aims to equip you with a thorough understanding of the automation design process. By the end of this journey, you'll be well-prepared to tackle the challenges of automation, ultimately helping your organization achieve greater efficiency, quality, and competitiveness in today's demanding market.

Automation

Automation, the process of designing, building, and implementing automatic machines, plays a critical role in modern manufacturing. Understanding the motivations and implications of automation from various perspectives (manufacturing director, company CEO, stockholders, current company worker, sales representatives, consumer, environmentalist) helps in anticipating challenges and solutions.

Why Automate?

Automation aims to reduce labor, improve quality, reduce waste, increase production efficiency, and maintain onshore production. It's crucial to evaluate if a process can be economically automated or should remain manual.

Steps to Automation

Designing an automatic machine involves several key steps:

  1. Understanding Automation:
    • Definition: Automation involves creating systems operated by mechanical or electronic devices, replacing human observation and effort.
    • Approach: Avoid the "black box" approach that oversimplifies automation. Instead, use a systematic design of components and controls.
  2. Automation Design Process:
    • Look at Similar Processes: Learning from existing automation processes can provide insights and ideas for new designs.
    • Human Process Analysis: Observe how humans perform the task to identify potential automation methods.
    • Try Novel Methods: Experiment with new approaches, thinking outside the box. For example, using a vacuum for gripping or air jets for separation can provide unique solutions.
    • Apply Mechatronics Strategy: Integrate mechanical engineering, electrical engineering, controls, software, and materials to develop a comprehensive automation solution.

Justifying Automation

Automation projects need justification through cost-benefit analysis, considering factors like labor reduction, quality improvement, and flexibility. Intellectual property, such as patents and trade secrets, also plays a role in justifying and protecting automation projects.

The Automation Design Process

  1. System Specifications: Clearly define the system's requirements and constraints.
  2. Brainstorming: Generate a wide range of ideas and concepts.
  3. Machine Classification: Categorize machines by function (assembly, inspection, test, packaging) and transfer method (linear, rotary, robot-centered).
  4. Mechanisms Toolbox: Use a variety of mechanical mechanisms to achieve the desired automation tasks.

Industrial Robots

Robots are essential in automation for handling, welding, painting, dispensing, assembly, packaging, food processing, drug discovery, and machine loading/unloading. Selecting the right robot type, analyzing workspace, and understanding mechanical actuators are key steps in integrating robots into automation.

Workstations

Workstations in automation are designed with structural members, bearing devices, and drive mechanisms. Safety considerations, such as pinch points, lockout/tagout procedures, and risk assessments, are critical.

Feeders and Conveyors

Feeders (escapement feeders, vibratory bowl feeders, centripetal feeders, flexible feeders) and conveyors (segmented, timing screws, star wheels) are crucial for material handling in automation. Accumulators and pick-and-place feeders further enhance the automation process.

Actuators

Actuators (pneumatic, hydraulic, electric motors) are the driving force behind automation. Selecting the right actuator involves understanding power requirements, frictional losses, gearing, inertia, and motion profiles.

Sensors

Sensors (limit switches, optical switches, vision systems) provide feedback and control in automation. Vision systems, in particular, are valuable for inspection and quality control.

Control

Control systems (programmable logic controllers, ladder logic, other programming options) manage the operation of automation systems. Timing diagrams and case studies help in designing effective control systems.

Bringing New Automation to Market

Case studies illustrate the process of bringing new automation solutions to market, from concept to production and market acceptance. Patenting and protecting intellectual property are also discussed.

System Specifications

Writing clear and comprehensive system specifications is crucial for successful automation projects. This includes defining design specifications, creating request for quote (RFQ) documents, and evaluating proposals.

Packaging Machines

Packaging automation involves liquid filling machines, cartoning, labeling, palletizing, forming pouches, blister packs, and bags. The packaging process is crucial for many industries, making automation solutions widely applicable.

This comprehensive guide provides detailed steps and considerations for designing automatic machinery, from understanding the basics of automation to justifying projects, integrating robots, and controlling systems.