Automation involves the creation and use of automatic machines. While it has the potential to boost domestic manufacturing, it can also cause concern due to the possibility of replacing human workers. Engineers may envision the use of intelligent machines to efficiently produce large quantities of goods at a lower cost, but for those currently employed in the industry, the prospect of being replaced by machines can be unsettling.
There are a number of benefits that can be gained from automating a manufacturing process. Some of these reasons include:
Reducing labor;
Avoiding labor’s sick days, lunch breaks, being late for work;
Improving quality;
Reducing waste;
Enabling production of multiple shifts and weekends;
Increasing repeatability and quality;
Increasing Workman’s Compensation claims and expenses;
Keeping production onshore.
As can be seen, there are many factors to consider and the responsibility for automating a process often falls to an engineer or engineering team. In some cases, there may already be ready-made solutions available on the market that can be purchased and implemented. However, there may also be instances where an engineer must design and build an automated system from scratch. This may be necessary if there are no existing solutions that meet the specific needs of the company or if it is more cost-effective to create a customized solution.
The process of designing a new machine, similar to designing any other product, typically involves several steps. These steps can vary depending on the specific needs and goals of the project, but there are generally six key steps that are followed:
Define the problem or need that the machine will address.
Research and gather information about the intended use of the machine, including any relevant specifications or requirements.
Brainstorm and generate ideas for potential solutions.
Given the pressure to quickly bring a product to market and the possibility of receiving an expediting fee from production customers in a strong economy, automation design engineers may face significant challenges. In order to effectively address these challenges, it is important to break down the task into smaller parts, thoroughly understand the customer's needs and constraints, use visual tools to document the automation process, prototype and simulate the design, and seek out resources and expertise as needed. By following these steps, the automation design engineer can successfully navigate the demands of a fast-paced market and deliver an effective automation solution.
Look at similar automation processes and machines.
Look at how a human does the process.
Attempt novel things in seemingly random acts of creativity.
Apply a Mechatronics strategy.
Let us now look at each of these.
Similar Automation Processes and/or Machines most likely already exist!
Needless to say, engineers should avoid reinventing the wheel as it is unnecessary financial and time investment both of which are limited resources for us. Engineer should do a quick market analysis and see what is out there to meet their automation needs. The experience of observing how others have solved problems can be valuable. With each new plant visit, the author is continually amazed by how cross-pollination of ideas from unrelated fields can lead to multidisciplinary design solutions. This is one of the benefits of gaining more experience and perspective over time. Additionally, trade shows can be a good place to see automation machines in operation, but they are not always readily available to view online. Many automation companies do have websites with information, but not all of them have video clips of their machines. In order to get a better understanding of the capabilities of a specific machine, it may be necessary to request a video from the company or speak with one of their application engineers. However, it is important to be wary of marketing claims and to verify the suitability of the machine for your automation needs. If the machine is not the right fit and the concept is not patented, you may need to consider designing and building a custom machine using some of the strategies outlined in this article.
Observe humans performing the task, but be open to novel ideas!
Watching a human perform a task can be both helpful and limiting when it comes to automation. On the one hand, observing how a person performs a task can provide valuable insights into the skills and techniques involved. On the other hand, the way that a human performs a task may not always be feasible or cost-effective to automate. In these cases, it may be necessary to find a new approach to the process in order to achieve success. It's important to keep an open mind and not get too biased by the current method of doing things. For example, Mr. Clay Cooper (personal communication, 1996) found a creative solution to automating the process of tying bows for gift boxes and chocolates, by looking at the task in a different way than previous engineers who had tried and failed to replicate the human worker's movements.
One day while stuck at an airport with a long layover, a man named Mr. Clay Cooper decided to examine the tied laces on his shoe to pass the time. He noticed that by creating three loops (as shown in Figure 2.4a) and passing the end loops through the middle loop (Figure 2.4b), he could easily create a perfect bow with minimal handling of the lace (Figure 2.4c). This process eliminated the challenge of making the first loop and wrapping the other lace around it that many people struggle with when tying their shoelaces. To automate this process, a custom-designed mandrel (Figure 2.5) would be needed to produce the three loops. Mr. Cooper's innovative approach to tying shoelaces shows how examining a task from a different perspective can lead to novel solutions.
This process can also be used to tie ribbon for packages. While the resulting bow is not as structurally strong as a traditional bow tied with both ends of the lace or ribbon, it is still strong enough for a package and looks just as nice. Additionally, it may be easier to unwrap the package since the bow can remain in place after sliding out the other end. To automate this process, a mandrel with movable parts would be needed to ensure that the grippers can grab the ribbon consistently. However, the process becomes much more feasible when broken down into simpler steps rather than attempting to replicate the difficult and complex task of tying a shoelace.
Try new things
The human hand and eye are remarkably skilled at performing tasks, and researchers continue to try to replicate these abilities in automation. However, current methods are often not cost-effective. As a result, it may be necessary to use simpler, less dexterous fingers or manipulate products in a different way in order to achieve the desired results. For example, using six or eight actuated fingers to place a pocket on a shirt front may be more reliable than relying on a single human hand. In addition to considering different approaches to tasks, it is also important to consider the range of physical principles that can be applied in automation, such as using vacuum or static charge to grip materials. By thinking outside of the box and considering a wide range of possibilities, it is possible to find creative and effective solutions to automation challenges.
Mr. Clay Cooper at American Dixie Group faced a challenge in automating the process of separating paper baking cups from a stack (Cooper, 1994). These cups are used for some brands of cupcakes and muffins and are made from a thin, heat-resistant paper that is stamped with a die to create fluted sides. Usually, 25 cups are stamped at once and then stacked with other groups of similar size. While a person might peel off a single cup from the top or bottom of the stack for use in a single muffin pan at home, this approach is not practical for high-volume baking. Mr. Cooper sought a new solution and found that using a suction cup on the inside of the top cup in the stack was effective, but it caused the bottom surface to pucker and the performance was not consistent. He therefore developed a test device made from PVC pipe with drilled holes and duct tape that he attached to a shop vacuum. This device was able to grip the inside of the top cup without deformations, but occasionally a second or third cup would come along due to the cups' edges becoming attached to each other during the stamping process.
Apply a Mechatronics Strategy
The Mechatronics approach to engineering has been perceived by some as a new development of the 1990s (Craig, 1992; Derby, 1992). Others view it as simply a rebranding of Systems Engineering (Groover, 2001). Regardless of one's perspective, it is widely accepted that a comprehensive systems approach is essential for the successful design and construction of automation systems. As seen in Fig. 2.9, there is the total integration of:
Mechanical Engineering;
Electrical Engineering;
Controls;
Software;
Materials and Components.
To achieve optimal results in custom automation projects, it is important to consider all available technologies and use them creatively in an integrated manner. This may seem obvious, but in some cases, mechanical functions are fully designed, manufactured, and assembled before the controls team has an opportunity to review the machine. This can lead to significant difficulties when the controls team is tasked with adding sensors and a controller to make the machine operational. When the process is straightforward, this approach may still be successful, but it is generally a recipe for problems. These types of projects tend to take longer to debug and often require costly rework and redesign, which can impact profits and disrupt schedules.
It is generally not feasible for a single engineer to handle the Mechatronics or Systems Engineering approach for complex automation projects. Even when the task is relatively simple, it is unlikely that one person would have the expertise and time required to bring the resulting automated product to market. There are simply not enough hours in the day for one person to acquire all of the necessary knowledge, especially when more experienced team members are available to assist.
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Case Study 3
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