Kuliah 1 - Control Technology in Discrete Production

This module deals with automation of concrete production (form and dimensions known beforehand). This
mainly concerns the technical characteristics, qualities and application of control systems and components.
Application or function level are not discussed in detail in this module. It is advisable to have worked through
module 1.1.a before starting on this module. After this module, module 2.3, "Control in continuous processes"
can be dealt with.

This module firstly gives a short survey of the historic development of automated production. We subsequently
focus on concrete or discontinuous processes and the applied control systems in these areas. Specific
characteristics and choice criteria for the different technologies in control systems are discussed. The most
important characteristics and application areas are explained. After this, we will deal with control units with their
programming properties and programming languages, in accordance with the IEC 1131 standard.

History
People have traditionally striven to increase their mental and physical capabilities. Research into natural
processes has led to the production of tools. At first they were simple tools such as ploughs, axes and
hammers, later also looms and printing presses. In the meantime, the Chinese had invented the abacus. It
was not until the seventeenth century that a mechanical adding machine was invented.

Gradually human actions and routine logic functions were taken over by machines. The development
from manual work to mechanical work did not really accelerate until the nineteenth century. The first steps
were made by invention of the steam engine. Steam engines were used to drive machines, which was the
beginning of mechanisation. Machines replaced human muscle power. Man controlled the machine and
checked its correct operation. Mechanisation continued until halfway into the twentieth century. Around this
time the first computer was invented. This marked the beginning of automation. This computer worked with
radio tubes as electronic elements. First, administrative methods were computerised, later industry was also
automated.

The invention of the first working electromotor in 1838 also contributed to mechanisation and automation. It
became possible to take motive power directly to the machine and even to parts of the machine. Shafts could
be driven separately. It was only from 1968 that relay building blocks were used in machine control systems. In
the meantime, the transistor was invented which was the start of miniaturisation of electronic control systems.
Electronic ratchet switches made their entry in 1969. In 1971 the 5 V TTL-building blocks were used and it took
until 1974 before the electronic time relay was introduced. The first bit-oriented memory programmed
control originates from 1976. From that time on industrial development went very fast.

Automation
Automation is the complete or partial take-over of human functions by machines. Automation was started by
human development and will continue for many years. Reasons for automation are:

o human failure, caused by :

o lack of knowledge and skills;
o physical and mental fatigue;
o decreased concentration;
o decreased human ability to react, caused by production increase;
o complexity in maths and thinking because approximation formulas appeared not to be accurate
enough;
 o dull, monotonous actions in conveyor belt work;
o physical strain or fatality risk during manual work.
Production processes
In industry raw materials are used to make products. We call this conversion a production process.

Figure 1 Process principle

There are many different production processes and corresponding control systems. A controller is an
installation for the systematic manipulation of processes or motion progress in machines.

Processes can be divided as follows:

o chemical processes: chemical or physical changes occur;

o production processes: changes take place through mechanical processing;
o transport processes: materials, energy and information are distributed spatially;
o monitoring processes: products are checked on specifications (quality).
Continuous process
A distinction is also made between continuous and discontinuous processes. In a continuous process the raw
material is fed and the end product continuously delivered. Examples of continuous processes are:

o petrol production;
o plastic production;
o paper production;
 o rolling steel to tin plate.
Discontinuous process
Production takes place in batches. There are waiting times between the batches. Examples of discontinuous
processes are:

o appliance assembly;
o burning, mixing and packaging coffee;
o regulation of traffic flows.
These processes are also called concrete production processes.

Control system
Introduction
Automation of aforementioned production processes makes demands on the controller. Physical quantities
have to be measured and kept constant. Also the production sequence has to be controlled.

Taking into account the characteristics described above a process and its controller can be represented as
follows:
 Figure 2. Process with controller

Sensors measure the process stages and give measuring signals. These signals are adapted to the controller
characteristics. The control unitprocesses the measuring signals and generates command signals which are
sent to the actuators after adaptation. Processing takes place according to a control program.
The actuators intervene directly in the process. In large systems several controllers interact in a network.
A control system consists of:

o sensors;
o actuators;
o control unit;
o software;
o a network.
Please refer to the Festo notes concerning characteristics and application of sensors and actuators. Here we
discuss control units further.

Control unit
A controller is a device for the systematic manipulation of the production process. In this module we focus
on digital controllers with binary signalsand commands. The control program is the total of instructions for
command and signal processing, which manipulates the function of the installation or machine in a desired,
systematic fashion. Depending on the program carrier we distinguish:

o wiring/ programmed or circuit programmed controllers (IPC)

o memory programmed controllers (MPC).
Wiring/ programmed controllers can be divided into:

o fixed programmed
o relay controllers
o controllers with digital building blocks
o reprogrammable
o punch cards or punch tapes
o cross rail system
o program switch or roller
Memory programmed controllers can be divided into:

o variably programmable
o read/write memory RAM
o exchangeable
o read only memory ((E)((E)(P)))ROM.
Choice criteria

The following criteria can be important for the choice between wiring and memory programmed control:

Criterion IPC MPC

program carrier wiring memory

program operation parallel serial

program modification possible simple

documentation circuit diagrams via other automatic via same

system system

life expectancy 30.106 operations >30.106 operations

standard manufacturing wire several devices standard hardware

repeatedly

required space relatively large small

help functions auxiliary relay flags

time functions time relay built-in

putting into operation effort depending on size simple

training staff not necessary necessary

build an program not possible possible

simultaneously

serial production reoccurring assembly once assembled

cost duplicate

fault finding complicated simple

Memory characteristics

The memories used in memory programmed controllers can be classified as follows:

Memory type Erase Programming Memory at power

 failure

RAM electrical electrical volatile

Random Access
Memory

Read/Write
Memory

ROM not possible template during non volatile

Read Only production

Memory

PROM not possible electrical non volatile

Programmable
ROM

EPROM by UV-light electrical non volatile

Erasable ROM

EEPROM electrical electrical non volatile

Electrical EPROM
 CIM WIKIPEDIA

Computer-integrated manufacturing
From Wikipedia, the free encyclopedia

This article needs additional citations for verification. Please help improve this
article by adding citations to reliable sources. Unsourced material may be challenged and
removed. (March 2010)

Manufacturing Systems Integration Program, NIST 2008.

Computer-integrated manufacturing (CIM) is the manufacturing approach of using computers to control the
entire production process.[1][2] This integration allows individual processes to exchange information with each
other and initiate actions. Through the integration of computers, manufacturing can be faster and less error-
prone, although the main advantage is the ability to create automated manufacturing processes. Typically CIM
relies onclosed-loop control processes, based on real-time input from sensors. It is also known as flexible
design and manufacturing.[citation needed]

Contents
[hide]

1 Overview
2 History
3 Computer-integrated manufacturing topics
o 3.1 Key challenges
o 3.2 Subsystems in computer-integrated manufacturing
o 3.3 CIMOSA
4 Application
5 See also
6 References
7 Further reading
8 External links

Overview[edit]
The term "computer-integrated manufacturing" is both a method of manufacturing and the name of a computer-
automated system in which individual engineering, production, marketing, and support functions of
a manufacturing enterprise are organized. In a CIM system functional areas such as design, analysis, planning,
purchasing, cost accounting, inventory control, and distribution are linked through the computer with factory
floor functions such as materials handling and management, providing direct control and monitoring of all the
operations.
As a method of manufacturing, three components distinguish CIM from other manufacturing methodologies:

Means for data storage, retrieval, manipulation and presentation;

Mechanisms for sensing state and modifying processes;
Algorithms for uniting the data processing component with the sensor/modification component.
CIM is an example of the implementation of information and communication technologies (ICTs) in
manufacturing.
CIM implies that there are at least two computers exchanging information, e.g. the controller of an arm robot
and a micro-controller of a CNC machine.
Some factors involved when considering a CIM implementation are the production volume, the experience of
the company or personnel to make the integration, the level of the integration into the product itself and the
integration of the production processes. CIM is most useful where a high level of ICT is used in the company or
facility, such as CAD/CAM systems, the availability of process planning and its data.

History[edit]
The idea of "digital manufacturing" was prominent the 1980s, when computer-integrated manufacturing was
developed and promoted by machine tool manufacturers and the Computer and Automated Systems
Association and Society of Manufacturing Engineers (CASA/SME).
"CIM is the integration of total manufacturing enterprise by using integrated systems and data
communication coupled with new managerial philosophies that improve organizational and personnel
efficiency." ERHUM

Computer-integrated manufacturing topics[edit]

CIM & production control system: Computer Integrated Manufacturing is used to describe the complete automation of a

manufacturing plant, with all processes running under computer control and digital information tying them together. [3]

Key challenges[edit]
There are three major challenges to development of a smoothly operating computer-integrated
manufacturing system:
 Integration of components from different suppliers: When different machines, such as CNC, conveyors
and robots, are using different communications protocols (In the case of AGVs, even differing lengths
of time for charging the batteries) may cause problems.

Data integrity: The higher the degree of automation, the more critical is the integrity of the data used to
control the machines. While the CIM system saves on labor of operating the machines, it requires
extra human labor in ensuring that there are proper safeguards for the data signals that are used to
control the machines.

Process control: Computers may be used to assist the human operators of the manufacturing facility,
but there must always be a competent engineer on hand to handle circumstances which could not be
foreseen by the designers of the control software.
Subsystems in computer-integrated manufacturing[edit]
A computer-integrated manufacturing system is not the same as a "lights-out" factory, which would run
completely independent of human intervention, although it is a big step in that direction. Part of the system
involves flexible manufacturing, where the factory can be quickly modified to produce different products, or
where the volume of products can be changed quickly with the aid of computers. Some or all of the
following subsystems may be found in a CIM operation:
Computer-aided techniques:

CAD (computer-aided design)

CAE (computer-aided engineering)
CAM (computer-aided manufacturing)
CAPP (computer-aided process planning)
CAQ (computer-aided quality assurance)
PPC (production planning and control)
ERP (enterprise resource planning)
A business system integrated by a common database.
Devices and equipment required:

CNC, Computer numerical controlled machine tools

DNC, Direct numerical control machine tools
PLCs, Programmable logic controllers
Robotics
Computers
Software
Controllers
Networks
Interfacing
Monitoring equipment
Technologies:

FMS, (flexible manufacturing system)

ASRS, automated storage and retrieval system
AGV, automated guided vehicle
Robotics
Automated conveyance systems
Others:
 Lean manufacturing
CIMOSA[edit]
CIMOSA (Computer Integrated Manufacturing Open System Architecture), is a 1990s European proposal
for an open systems architecture for CIM developed by the AMICE Consortium as a series
of ESPRIT projects.[4][5] The goal of CIMOSA was "to help companies to manage change and integrate their
facilities and operations to face world wide competition. It provides a consistent architectural framework for
both enterprise modeling and enterprise integration as required in CIM environments".[6]
CIMOSA provides a solution for business integration with four types of products:[7]

The CIMOSA Enterprise Modeling Framework, which provides a reference architecture for enterprise
architecture
CIMOSA IIS, a standard for physical and application integration.
CIMOSA Systems Life Cycle, is a life cycle model for CIM development and deployment.
Inputs to standardization, basics for international standard development.
CIMOSA according to Vernadat (1996), coined the term business process and introduced the process-
based approach for integrated enterprise modelingbased on a cross-boundaries approach, which opposed
to traditional function or activity-based approaches. With CIMOSA also the concept of an "Open System
Architecture" (OSA) for CIM was introduced, which was designed to be vendor-independent, and
constructed with standardised CIM modules. Here to the OSA is "described in terms of their function,
information, resource, and organizational aspects. This should be designed with structured
engineeringmethods and made operational in a modular and evolutionary architecture for operational
use".[6]

Application[edit]
There are multiple areas of usage:

In Industrial and Production engineering

In mechanical engineering
In electronic design automation (printed circuit board (PCB) and integrated circuit design data for
manufacturing)

See also[edit]
Direct numerical control
Enterprise integration
Enterprise resource planning
Flexible manufacturing system
Integrated Computer-Aided Manufacturing
Integrated manufacturing database
Manufacturing process management
Product lifecycle management

References[edit]
1. Jump up^ Kalpakjian, Serope; Schmid, Steven (2006), Manufacturing engineering and
technology (5th ed.), Prentice Hall, p. 1192, ISBN 978-7-302-12535-8.
2. Jump up^ Laplante, Phillip A. (2005), Comprehensive dictionary of electrical engineering (2nd ed.),
CRC Press, p. 136, ISBN 978-0-8493-3086-5.
3. Jump up^ Waldner, Jean-Baptiste (September 1992). Principles of Computer-Integrated
Manufacturing [1]. London: John Wiley & Sons. pp. 128p132. ISBN 0-471-93450-X.
 4. Jump up^ AMICE Consortium (1991). Open System Architecture for CIM, Research Report of
ESPRIT Project 688, Vol. 1, Springer-Verlag, 1989.
5. Jump up^ AMICE Consortium (1991), Open System Architecture, CIMOSA, AD 1.0, Architecture
Description, ESPRIT Consortium AMICE, Brussels, Belgium.
6. ^ Jump up to:a b F. Vernadat (1996). Enterprise Modeling and Integration. p.40
7. Jump up^ Richard C. Dorf, Andrew Kusiak (1994). Handbook of Design, Manufacturing, and
Automation. p.1014

Further reading[edit]
Yoram Korem, Computer Control of Manufacturing Systems, McGraw Hill, Inc. 1983, 287 pp, ISBN 0-
07-035341-7
Singh, V (1997). The Cim Debacle: Methodologies to Facilitate Software Interoperability.
Springer. ISBN 981-3083-21-2.
A. de Toni and S. Tonchia, Manufacturing Flexibility: a literature review International Journal of
Production Research, 1998, vol. 36, no. 6, 1587-617.
Jean-Baptiste Waldner (1992), Principles of Computer-Integrated Manufacturing, John Wiley &
Sons, ISBN 0-471-93450-X
Jean-Baptiste Waldner (1990), CIM, les nouvelles perspectives de la production, DUNOD-
BORDAS, ISBN 978-2-04-019820-6

External links[edit]
Wikimedia Commons has
media related to CIM.

cam-occ, a linux CAM program using OpenCASCADE

International Journal of Computer Integrated Manufacturing
Categories:
Product lifecycle management
Engineering
Production and manufacturing
Information technology management
Industrial computing
Computer-aided engineering

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This page was last modified on 23 November 2014 at 18:24.