It is a procedure in which the control and management functions performed by a person are transferred to instruments and devices. Due to this, labor productivity and product quality are significantly increased. In addition, a reduction in the share of workers involved in various industrial sectors is ensured. Let us further consider what automation and automation of production processes are.

History reference

Independently functioning devices - the prototypes of modern automatic systems - began to appear in antiquity. However, until the 18th century, handicraft and semi-handicraft activities were widespread. In this regard, such "self-acting" devices have not received practical application. At the end of the 18th - beginning of the 19th centuries. there was a sharp jump in volumes and levels of production. Industrial Revolution created the prerequisites for improving the methods and tools of labor, adapting equipment to replace a person.

Mechanization and automation of production processes

The changes that caused affected primarily wood and metalworking, spinning, weaving mills and factories. Mechanization and automation were actively studied by K. Marx. He saw in them fundamentally new directions of progress. He pointed to the transition from the use of individual machines to the automation of their complex. Marx said that the conscious functions of control and management should be assigned to a person. The worker stands next to the production process and regulates it. The main achievements of that time were the inventions of the Russian scientist Polzunov and the English innovator Watt. First created automatic regulator to feed the steam boiler, and the second - the centrifugal speed controller of the steam engine. Remained manual for quite a long time. Before the introduction of automation, the replacement of physical labor was carried out through the mechanization of auxiliary and main processes.

Situation today

On the present stage development of mankind, automation systems for production processes are based on the use of computers and various software. They contribute to reducing the degree of participation of people in activities or completely exclude it. The tasks of automating production processes include improving the quality of operations, reducing the time they require, reducing costs, increasing the accuracy and stability of actions.

Basic principles

Today, automation of production processes has been introduced into many industries. Regardless of the scope and volume of activities of companies, almost every company uses software devices. There are various levels of automation of production processes. However, the same principles apply to any of them. They provide conditions for the efficient execution of operations and formulate general rules for managing them. The principles in accordance with which the automation of production processes is carried out include:

1. Consistency. All actions within the operation must be combined with each other, go in a certain sequence. In the event of a mismatch, a violation of the process is likely.
2. Integration. The automated operation must fit into the overall environment of the enterprise. At one stage or another, integration is carried out in different ways, but the essence of this principle is unchanged. Automation of production processes in enterprises should ensure the interaction of the operation with the external environment.
3. Performance independence. An automated operation must be carried out independently. Human participation in it is not provided, or it should be minimal (only control). The employee must not interfere with the operation if it is carried out in accordance with the established requirements.

These principles are specified in accordance with the level of automation of a particular process. Additional proportions, specializations, and so on are established for operations.

Automation levels

They are usually classified according to the nature of the management of the company. It, in turn, can be:

1. strategic.
2. Tactical.
3. operational.

Accordingly, there is:

1. The lower level of automation (executive). Here management refers to regularly performed operations. Automation of production processes is focused on the performance of operational functions, maintaining the set parameters, maintaining the specified operating modes.
2. tactical level. This provides a distribution of functions between operations. Examples include production or service planning, document or resource management, and so on.
3. strategic level. It manages the entire company. Automation of production processes for strategic purposes provides a solution to predictive and analytical issues. It is necessary to maintain the activities of the highest administrative level. This level of automation provides strategic and financial management.

Classification

Automation is provided through the use of various systems (OLAP, CRM, ERP, etc.). All of them are divided into three main types:

1. Immutable. In these systems, the sequence of actions is set in accordance with the configuration of the equipment or process conditions. It cannot be changed during the operation.
2. Programmable. They can change the sequence depending on the configuration of the process and the given program. The choice of this or that chain of actions is carried out by means of a special set of tools. They are read and interpreted by the system.
3. Self-tuning (flexible). Such systems can select the desired actions in the course of work. Changes to the configuration of the operation occur in accordance with the information about the course of the operation.

All these types can be used at all levels separately or in combination.

Operation types

In every economic sector there are organizations that produce products or provide services. They can be divided into three categories according to "remoteness" in the resource processing chain:

1. Mining or manufacturing - agricultural, oil and gas companies, for example.
2. Organizations processing natural raw materials. In the manufacture of products, they use materials mined or created by companies from the first category. These include, for example, enterprises in the electronics, automotive industry, power plants, and so on.
3. service companies. Among them are banks, medical, educational institutions, catering establishments, etc.

For each group, operations related to the provision of services or the release of products can be distinguished. These include processes:

1. Management. These processes provide interaction within the enterprise and contribute to the formation of company relations with interested participants in the turnover. The latter, in particular, include supervisory authorities, suppliers, consumers. The group of business processes includes, for example, marketing and sales, interaction with customers, financial, personnel, material planning, and so on.
2. Analysis and control. This category is associated with the collection and generalization of information about the execution of operations. In particular, such processes include operational management, quality control, inventory assessment, etc.
3. Design and development. These operations are associated with the collection and preparation of initial information, project implementation, control and analysis of the results.
4. production. This group includes operations related to the direct release of products. These include, among other things, demand and capacity planning, logistics, and maintenance.

Most of these processes are now automated.

Strategy

It should be noted that the automation of production processes is complex and labor intensive. To achieve your goals, you need to be guided by a certain strategy. It contributes to improving the quality of operations performed and obtaining the desired results from the activity. Competent automation of production processes in mechanical engineering is of particular importance today. The strategic plan can be summarized as follows:

Advantages

Mechanization and automation of various processes can significantly improve the quality of goods and production management. Other benefits include:

1. Increasing the speed of repetitive operations. By reducing the degree of human involvement, the same actions can be carried out faster. Automated systems provide greater accuracy and maintain performance regardless of the length of the shift.
2. Improving the quality of work. By reducing the degree of participation of people, the impact is reduced or eliminated. human factor. This significantly limits the variations in the execution of operations, which, in turn, prevents many errors and improves the quality and stability of work.
3. Increased control accuracy. Usage information technologies allows you to save and take into account in the future a larger amount of information about the operation than with manual control.
4. Accelerated decision making in typical situations. This improves the performance of the operation and prevents inconsistencies in the next steps.
5. Parallel execution of actions. make it possible to carry out several operations at the same time without compromising the accuracy and quality of work. This speeds up the activity and improves the quality of the results.

disadvantages

Despite the obvious advantages, automation may not always be appropriate. That is why a comprehensive analysis and optimization is necessary before its implementation. After that, it may turn out that automation is not required or will be unprofitable in an economic sense. Manual control and execution of processes may become more preferable in the following cases:

Conclusion

Mechanization and automation are undoubtedly of great importance for production area. AT modern world fewer operations are performed manually. However, even today in a number of industries one cannot do without such work. Automation is especially effective on large enterprises where products for the mass consumer are produced. So, for example, in automobile factories, a minimum number of people participate in operations. At the same time, they, as a rule, exercise control over the course of the process, without participating in it directly. Modernization of the industry is currently very active. Automation of production processes and production is considered today the most effective way improving the quality of products and increasing the volume of its output.

Solving automation problems

Question 3 Production and technological processes automated production

tracking system

tracking system- automatic system in which the output value reproduces with a certain accuracy the input value, the nature of the change of which is not known in advance.

Tracking systems are used for various purposes. Completely different physical quantities can be considered as the output quantity of a servo system. One of the most widely used types of servo systems are systems for controlling the position of objects. Such systems can be considered as further development and the improvement of systems for remote transmission of angular or linear movements, in which the controlled variable is usually the angle of rotation of the object.

The comparison element (Fig. 1, d) from the master element connected to the input shaft of the servo system receives the input value α BX. The value of the processing angle a OUT comes here from the control object associated with the output shaft of the system. As a result of comparing these values, a mismatch appears at the output of the comparison element θ = α IN - a OUT.

The mismatch signal from the output of the comparison element is fed to the converter (PR), in which the angle θ is converted into a voltage proportional to it U 0 - an error signal.

However, in the vast majority of cases, the power of the error signal is insufficient to actuate the executive engine (M). Therefore, an amplifier is connected between the converter and the actuator, which provides the necessary amplification of the error signal in terms of power. The amplified voltage from the output of the amplifier is supplied to M, which drives the control object, and the displacement a OUT of the latter is transmitted to the receiving element of the measuring circuit, i.e. to the comparison element.

Adaptive system

An adaptive (self-adapting) system is an automatic control system in which the way the control part operates is automatically changed to implement in some sense the best control. Depending on the task and methods for solving it, various control laws are possible, therefore, adaptive systems are divided into the following types:

§ adaptive systems of functional regulation, where the control action is a function of some parameter, for example, feed - function of one of the cutting force components, cutting speed- power function;

§ adaptive systems of limit (extreme) regulation, which ensure the maintenance of the limit value of one or more parameters in the object;

§ adaptive systems of optimal p regulation that takes into account a combination of many factors using a complex optimality criterion.

In accordance with this criterion, the adjustable parameters and values ​​are changed, for example, maintaining the processing mode in the machine that ensures maximum productivity and the lowest cost of processing is determined by the task optimal values parameters (speeds of cutting forces, temperature, etc.), on which the productivity and cost of the machining process depend.

Technological operation

Technological operation call the finished part of the technological process, performed at one workplace. It should be borne in mind that the workplace is an elementary unit of the structure of the enterprise, where the performers of work serving technological equipment, for a limited time tooling and objects of labor. For example, the processing of a stepped shaft can be performed in the following sequence: in the first operation, the ends are cut and the auxiliary bases are centered, in the second, they are turned outer surface, on the third - these surfaces are polished.

Typical technological operation call a technological operation characterized by the unity of the content and sequence of technological transitions for a group of products with the same design and technological features.

A group technological operation is a technological operation of joint production of a group of products with different design, but common technological features.

Types of technological operations

The technological process can be built on the principle of concentrated or differentiated technological operations.

a - sequential; b - parallel; c - parallel-sequential operations

Figure 3.2 - Main types of concentration

Concentrated process operation- an operation that includes a large number of technological transitions. As a rule, it has a multi-tool setting. The limit of concentration of operations is the complete processing of the part in one operation.

A differentiated operation is an operation, consisting of the minimum number of transitions. The limit of differentiation is the execution of a technological operation, consisting of one technological transition.

The advantages of differentiation of operations are as follows: relatively simple and cheap equipment is used, the simplicity and slight complexity of their adjustment, and the possibility of using higher processing modes is created.

Disadvantages of the principle of differentiation of operations: the production line is lengthening, the amount of equipment and production space required is increasing, the number of workers is increasing, a large number of installations.

Technological transition

Technological transition called the completed part of the technological operation, performed by the same means of technological equipment with constant technological modes and installation. If the tool was changed during the turning of the roller, then the processing of the same surface of the workpiece with this tool will be a new technological transition. But the tool change itself is an auxiliary transition.

Auxiliary transition call the completed part of the technological operation, consisting of human actions and (or) equipment, which are not accompanied by a change in the properties of the object of labor, but are necessary to complete the technological transition. Transitions can be combined in time due to the simultaneous processing of several surfaces, i.e. they can be carried out sequentially (roughing, semi-finishing, finishing turning of a stepped shaft or drilling four holes with one drill), parallel (turning a stepped shaft with several cutters or drilling four holes at once four drills) or parallel-sequential (after turning the stepped shaft simultaneously with several cutters, simultaneous chamfering with several chamfering cutters or drilling four holes in series with two drills).

setup- part of the technological operation, performed with unchanged fixing of the workpieces being processed or the assembled assembly unit. Turning parts to any angle is a new setting. If the roller is first turned in a three-jaw chuck with one setting, and then it is turned over and turned, then this will require two settings in one operation (figure 3.4).

Figure 3.4 - Scheme of the first (a) and second (b) installation

Position

The workpiece installed and fixed on the rotary table, subjected to drilling, reaming and countersinking, has one setup, but with the rotation of the table it will take a new position.

position called a fixed position occupied by a rigidly fixed workpiece or an assembled assembly unit together with a fixture relative to a tool or a fixed part of the equipment when performing a certain part of the operation. On multi-spindle machines and semi-automatic machines, the workpiece, with one of its fixings, occupies different positions relative to the machine. The workpiece is moved to a new position along with the clamping device.

When developing technological process processing of workpieces, it is preferable to replace setups with positions, since each additional setup introduces its own processing errors.

In the conditions of automated production under operation should be understood as a complete part of the technological process, performed continuously on an automatic line, which consists of several units of technological equipment connected by automatically operating transport and loading devices. In addition to the main technological operations, the TP includes a number of auxiliary operations necessary for its implementation (transport, control, marking, etc.).

According to the layout

By type of transport, automatic lines are distinguished:

a) with through transportation of the workpiece between machines (used in the processing of body workpieces);

b) with lateral transportation (used in the processing of crankshafts, sleeves, etc.);

c) with top transportation (used in the processing of shafts, gears, flanges, etc.);

d) with combined transportation;

e) with rotary transportation used in rotary AL, in which all technological operations are carried out with continuous transportation of workpieces and tools.

According to the degree of flexibility:

a) synchronous or rigid;

b) non-synchronous or flexible.

AT synchronous automatic lines workpieces are moved at synchronized time intervals. The processing time at the working position is equal to or a multiple of the cycle. A tact is a time interval through which a product of a certain type is periodically produced. Such lines are used in large-scale and mass production.

AT non-synchronous automatic lines machined parts are moved as soon as the operation is ready. Since the processing time for each position is different, intermediate accumulators are needed. These lines are used in serial and pilot production.

Question 26 Auxiliary devices of transport and storage subsystems: pallets, pallets, pushers. devices for turning and orienting parts, devices for dividing flows (appointments, designs, scope)

Flow dividers.

Are applied to division of flows in the branching automatic lines (fig. 1.). They are divided according to the principle of movement of dampers: swinging, reciprocating and rotating.

The division is carried out through:

Swinging dampers rotating under the action of the workpiece itself (Fig. 1., a);

With the help of reciprocating dampers (Fig. 1., b, c);

They are used in the case when it becomes necessary to divide the total flow into several independent flows between the same type of machines. Are established between the mechanism of orientation and the store or between the store and a feeder. The designs are varied and depend on the shape and size of the parts and on the design of the accumulators and feeders.

Rice. 1. Dividers of streams: a. - with frequent dampers; b.c - with the help of reciprocating dampers.

orienting devices.

In many cases in automated production, the workpiece or part must be fed into working area or on transport systems or grippers or turning devices, etc. in an oriented position. For this, they are used various designs orienting devices in the form of gates, sectors with reciprocating or oscillating movements, rotating disks, spade mechanisms, bushing tubes, etc. Schemes of orienting devices are shown in fig. 2.and 3.

The orientation of parts is also possible during their transportation. In this case, the asymmetry of the shape of the parts and the location of the center of gravity are used. The way of orientation can be passive and active.

Passive orienting devices received wide use during vibration transportation of parts. The common principle of their action is that incorrectly oriented parts are dropped from the transport device and returned to the beginning of the stream, and then only correctly oriented parts follow.

Active orienting devices give parts a complex position in space, regardless of their initial position when they enter the orienting device. The principle of forced change is also used when reorientation is necessary. For simple parts of small sizes - simple orienting devices are used, for children. complex shapes or heavy - orienting devices such as tilters or universal rotary devices. Sometimes a magnetic field is used.

Orientable blanks are conditionally divided into:

Blanks of a simple shape, oriented with the help of cutouts in the trays, bevels, cutters;

Workpieces with a displaced center of gravity, which are oriented at once or when rotated while passing through a slot or cutout in the tray;

Symmetrical and asymmetric workpieces, which are oriented in the event of a failure in the special. tray window (stencil orientation).

Workpieces oriented with the help of special devices.

Flat blanks such as circles, rings (Fig. 2.,a) with d>h, are oriented with the help of a spiral tray, the working surface of which is inclined along the radius towards the center of the bunker under b=3-5 0 to ensure the reset of the second layer of blanks. Tray collar m<h.

Caps with d ³ h are oriented in a passive way with the help of a cutout with a tongue (Fig. 2., b).

Workpieces oriented bottom down pass along the tongue without tipping over, because the tongue provides sufficient support to keep the workpiece stable. Workpieces located with the hole down are pressed on the tongue, lose balance and fall into the hopper.

Cylinders with l> d are oriented in a passive way (Fig. 2., c) to dump incorrectly oriented workpieces, a bevel is installed under the tray, located at a height of 1.1 d from the surface of the tray.

To orient the stepped disks, a passive method is used (Fig. 2.,d) using the shape features. Workpieces located with a large diameter down freely pass by the ejector and move further along the tray.

Rice. 2. Schemes of orienting devices.

Workpieces with a large diameter upwards are collided by the ejector from the tray into the bunker.

Workpieces such as rods with heads (Fig. 2., e) are actively oriented using a slot made on a straight section of the tray.

For the active orientation of the rollers with a ledge (Fig. 3., a), a shift in the center of gravity is used.

For the orientation of thin workpieces in the form of brackets, triangles, sectors, a passive method is used (Fig. 3., b). For T-shaped plates - the active method (Fig. 3., c).

If it is necessary to reorient the workpieces during the manufacturing process, the active orientation method is used.

Rice. 3. Schemes of orienting devices.

Rotary devices.

Used in machine tools to move a workpiece or tool to a position. These are multi-position tables and drums, blocks of multi-spindle machines, turrets, disk magazines and dividing devices (Fig. 4.).

Rotary devices are subject to requirements for accuracy of rotation by a given angular value, accuracy and rigidity of fixation in the working position, rotation in the minimum time, with restrictions on the resulting dynamic loads.

The accuracy of rotary devices should be evaluated from a probabilistic standpoint. By accuracy here we understand the accuracy of angular positioning; characterized by the current rotation angle error. AT best systems control of automatic rotary devices, to minimize errors, commands are given with an appropriate lead. The accuracy of modern CNC rotary machines is 3..6 arc seconds.

Performance is characterized average speed turning w cf– up to 1.0 s -1 . Universality is determined by the possible range of the number of divisions, which in modern automatic turntables is equal to 2...20000 and higher.

As a drive for rotary devices, stepper motors are used (Fig. 4, a), which make it possible to obtain wide versatility in the range of divisions, to dock with CNC or computer control systems. Rotary devices with a hydraulic drive (Fig. 4, b) and with a Maltese mechanism (Fig. 4, c) are widely used in machine tools and turrets with a constant fixed angle of rotation.

Rice. 4 Schemes of rotary devices.

Such schemes are used with the periodic switching on of the kinematic chain by various couplings (Fig. 4, c, d), and ratchet mechanisms (Fig. 4, f)

A transport package is an enlarged cargo unit, formed from piece cargo in containers and without it, using various ways and packaging means, which retains its shape in the process of circulation and provides the possibility of complex mechanization of loading and unloading and warehouse operations.

One of the main means of packaging are pallets(flat, rack and box).

Pallets for flexible automated production are selected in accordance with the same methodological principles that are outlined above in relation to the creation of mechanized and automated warehouses of any type.

All pallets can be classified:

By appointment - transport and technological (cassettes, satellites);

By type of transported cargo - universal(for a wide range of goods) and special (for certain goods);

By design (flat, rack, box, one-and two-style, one-and two-way);

By material (metal - steel or light alloys, wood, plastic, cardboard, composite using particle boards and other materials)

By duration of use (single use, reusable);

By area of ​​application (intra-warehouse pallets, for intra-factory transportation, for external long-distance transportation);

By size (150 x 200; 200 x 300; 300 x 400; 400 x 600; 600 x 800; 800 x 800; 800 x 1000; 800 x 1200; 1600 x 1000; 1600 x 1200).

Reusable pallets are part of the transport and storage equipment of the GAP, site, workshop, enterprise. Single-use pallets can be considered as a kind of transport packaging of goods.

A feature of special technological pallets for HAP is that certain loads (blanks, semi-finished products, parts) are placed on them in a fixed position, and sometimes they are fixed in advance, as, for example, on satellite pallets of multi-operational drilling-milling-boring machines, and served on them the details on the machine directly to the processing area.

Cassette trays and satellite trays are made stamped, welded, cast, and they can serve independent device to form a cargo transport and storage unit, or they are stacked on standard pallets.

Transport and storage pallets are universal in terms of the type of goods placed in them and can be metal or plastic, and by design they are flat, rack and box.

The movements of parts such as bodies of revolution in HPS are most often carried out using the simplest transport pallets without attaching products to them. Such pallets simultaneously perform
transportation and warehousing functions.

There are three varieties of them:

1) single pallets that move singly and cannot be stacked in multiple tiers;

2) retractable pallets installed in special containers, with the possibility of extension-latches;

3) multi-tiered pallets that can be placed near the RM one on top of the other, in stacks.

It is promising to create universal multi-subject pallets based on universal modules. Such pallets consist of a frame that provides the possibility of processing products of various shapes on various RMs, inserts that are used to install special elements that serve to accommodate workpieces (parts); the shape and dimensions of these elements are determined by the shape and dimensions of the blanks (parts).

Carrier frame (welded steel structure) has the dimensions of Euro pallets (1200 x 800 mm), although smaller dimensions can be used. With a smooth footprint, the frame can be floor-mounted or moved on rollers or by chain conveyors. Protective tubes located across or along the frame protect products from damage during transport. In the corners of the frame, supports are welded for stacking products in several tiers. The distances between the tiers can be changed using the inserted measuring rods.

The following criteria can be used to select pallets: compliance with the dimensions of euro pallets; weight of products and pallets; the number of products placed on the pallet (depends on the size and shape of the products); minimum piece processing time of one product; the required time of unmanned operation of the GPS.

For products with relatively small dimensions and long time processing, when the stock of products on one or two pallets is sufficient to ensure the stable operation of the FMS, use single pallets;
- for large-sized products with a short processing time, use sliding and multi-tiered pallets with additional devices for manipulating them.

Such pallets include pallets with fasteners mounted on them or special transport pallets. The time needed to change pallets can be significantly reduced by moving the clamping-detachment of workpieces from the work area to an additional interchangeable pallet carrier that ensures that they are quickly returned to the work area.

The most common are machine (included in the GPM), transport and auxiliary pallets.

Most often, pallets are used in the GPS, which simultaneously serve both for basing and fixing parts, and for transporting and manipulating them. This ensures the flexibility of the transport subsystem, since, on the one hand, all pallets have a unified work surface, and on the other hand, the tables of the transport and manipulation system are adapted to use pallets of a particular type.

In the case of using machine pallets included in the GPM, the workpiece is attached to them outside the working area, in parallel with the processing of another part. After that, it moves to the working area, where it is automatically fixed for processing.

Questions for the exam

Question 1 The purpose and objectives of automation of production processes. Types of automation of production processes

The main goals of process automation are:
-- increasing the efficiency of the production process;
-- Increasing the safety of the production process.

The goals are achieved by solving the following tasks of process automation:
-- improving the quality of regulation;
-- increasing the equipment readiness factor;
-- improvement of labor ergonomics of process operators;
-- storage of information about the course of the technological process and emergency situations.

The term "automation" refers to a set of methodological, technical and software tools that ensure the measurement process without direct human participation. The goals of automation are presented in Table. one.

Table 1

Automation Goals
Scientific	Technical	Economic	Social
1. Increasing the efficiency and quality of scientific results due to a more complete study of models 2. Increasing the accuracy and reliability of research results by optimizing the experiment. 3. Obtaining qualitatively new scientific results that are impossible without a computer.	1. Improving the quality of products due to the repeatability of operations, increasing the number of measurements and obtaining more complete data on the properties of products. 2. Increasing the accuracy of products by obtaining more complete data on aging processes and their precursors.	1. Saving labor resources by replacing human labor with machine labor. 2. Reducing costs in industry by reducing the complexity of work. 3. Increasing labor productivity based on the optimal distribution of work between man and machine and the elimination of incomplete loading during occasional maintenance of the facility.	1. Increasing the intellectual potential by entrusting routine operations to the machine. 2. Elimination of cases of employment of personnel of operations in undesirable conditions. 3. Freeing a person from hard physical labor and using the saved time to meet spiritual needs.

Automation tasks are:

Elimination or minimization of the "human factor" in the performance of functions by a system or device;

Achieving the specified quality indicators in the implementation of automated functions.

Solving automation problems technological process is carried out through the introduction modern methods and automation tools. As a result of automation of the technological process, an automated process control system is created.

Automation of production processes is the main direction in which manufacturing is currently moving forward around the world. Everything that was previously performed by man himself, his functions, not only physical, but also intellectual, are gradually moving to technology, which itself performs technological cycles and exercises control over them. Now this is the general direction modern technologies. The role of a person in many industries is already reduced to only a controller for an automatic controller.

In general, the concept of "process control" is understood as a set of operations necessary to start, stop the process, as well as maintain or change physical quantities (process indicators) in the required direction. Individual machines, units, devices, devices, complexes of machines and devices that need to be controlled, which carry out technological processes, are called control objects or controlled objects in automation. Managed objects are very diverse in their purpose.

Automation of technological processes- replacement of the physical labor of a person spent on controlling mechanisms and machines by the operation of special devices that provide this control (regulation of various parameters, obtaining a given productivity and product quality without human intervention).

Automation of production processes allows many times to increase labor productivity, improve its safety, environmental friendliness, improve product quality and more rational use of production resources, including human potential.

Any technological process is created and carried out for a specific purpose. Manufacture of final products, or to obtain an intermediate result. So the purpose of automated production can be sorting, transporting, packaging products. Automation of production can be complete, complex and partial.

Partial automation occurs when one operation or a separate production cycle is carried out in automatic mode. In this case, limited human participation is allowed. Most often, partial automation occurs when the process is too fast for the person himself to fully participate in it, while rather primitive mechanical devices driven by electrical equipment do an excellent job with it.

Partial automation, as a rule, is applied on already operating equipment, is an addition to it. However, it is most effective when included in common system automation initially - immediately developed, manufactured and installed as an integral part of it.

Integrated automation should cover a separate large production site, it can be a separate workshop, power plant. In this case, all production operates in the mode of a single interconnected automated complex. Complex automation of production processes is not always advisable. Its scope is modern highly developed production, which uses extremelyreliable equipment.

The breakdown of one of the machines or units immediately stops the entire production cycle. Such production should have self-regulation and self-organization, which is carried out according to a previously created program. At the same time, a person takes part in the production process only as a permanent controller, monitoring the state of the entire system and its individual parts, intervenes in production for start-up and in the event of emergency situations, or the threat of such an occurrence.

The highest level of automation of production processes - full automation. With it, the system itself carries out not only the production process, but also full control over him who is holding automatic systems management. Full automation makes sense in cost-effective, sustainable production with established processes with a constant mode of operation.

All possible deviations from the norm must be foreseen in advance, and systems of protection against them should be developed. Also, full automation is necessary for work that may threaten human life, health, or are carried out in places inaccessible to him - under water, in an aggressive environment, in space.

Each system consists of components that perform specific functions. In an automated system, sensors take readings and transmit them to make a decision on system control, the command is already executed by the drive. Most often this electrical equipment, since it is with the help of electric current it is better to follow commands.

It is necessary to separate the automated control system and automatic. At automated control system the sensors transmit readings to the remote control to the operator, and he, having already made a decision, transmits a command to the executive equipment. At automatic system- the signal is already analyzed by electronic devices, they, having made a decision, give a command to the executing devices.

Human participation in automatic systems is still necessary, albeit as a controller. He has the ability to intervene in the process at any time, correct it or stop it.

So, the temperature sensor may fail and give incorrect readings. Electronics in this case, will perceive its data as reliable, without questioning them.

The human mind is many times greater than the capabilities of electronic devices, although it is inferior to them in terms of response speed. The operator can recognize that the sensor is faulty, assess the risks, and simply turn it off without interrupting the process. At the same time, he must be completely sure that this will not lead to an accident. To make a decision, he is helped by experience and intuition, inaccessible to machines.

Such targeted intervention in automatic systems does not carry serious risks if the decision is made by a professional. However, turning off all automation and switching the system to manual control mode is fraught with serious consequences due to the fact that a person cannot quickly respond to a change in the situation.

A classic example is the accident at the Chernobyl nuclear power plant, which became the largest man-made disaster of the last century. It occurred precisely because of the shutdown of the automatic mode, when the already developed programs for the prevention of emergency situations could not influence the development of the situation in the reactor of the station.

Automation of individual processes began in industry as early as the nineteenth century. Suffice it to recall Watt's automatic centrifugal regulator for steam engines. But only with the beginning of the industrial use of electricity became possible a wider automation of not individual processes, but entire technological cycles. This is due to the fact that before that, mechanical force was transmitted to machine tools using transmissions and drives.

The centralized production of electricity and its use in industry, by and large, began only in the twentieth century - before the First World War, when each machine was equipped with its own electric motor. It was this circumstance that made it possible to mechanize not only the production process itself on the machine, but also mechanize its control. This was the first step towards creating automatic machines. The first samples of which appeared already in the early 1930s. Then the term "automated production" itself arose.

In Russia, back then in the USSR, the first steps in this direction were taken in the 30s and 40s of the last century. For the first time, automatic machines were used in the production of bearing parts. Then came the world's first fully automated production of pistons for tractor engines.

Technological cycles were combined into a single automated process that began with the loading of raw materials and ended with the packaging of finished parts. This became possible due to the widespread use of modern electrical equipment at that time, various relays, remote switches, and, of course, drives.

And only the appearance of the first electronic computers made it possible to reach a new level of automation. Now the technological process has ceased to be considered as just a set of individual operations that must be performed in a certain sequence to obtain a result. Now the whole process has become one.

Currently, automatic control systems not only lead the production process, but also control it, monitor the occurrence of emergency and emergency situations. They start and stop technological equipment, monitor overloads, practice actions in case of accidents.

Recently, automatic control systems make it quite easy to rebuild equipment for the production of new products. This is already a whole system, consisting of separate automatic multi-mode systems connected to a central computer, which links them into a single network and issues tasks for execution.

Each subsystem is a separate computer with its own software designed to perform their own tasks. It's already flexible production modules. They are called flexible because they can be reconfigured to other technological processes and thereby expand production, versify it.

The pinnacle of automated production are. Automation has permeated production from top to bottom. Automatic transport line for the delivery of raw materials for production. Automated management and design. Human experience and intelligence is used only where it cannot be replaced by electronics.

All questions

Basic principles of automation of production processes

Automation of production processes has remained the general line of development and modernization in the field of industrial production for many decades.

The concept of "automation" suggests that machines, instruments and machine tools, in addition to the actual production function, are transferred to the management and control functions that were previously performed by a person. Modern development technology allows you to automate not only physical, but also intellectual work, if it is based on formal processes.

Over the past 7 decades, factory automation has come a long way, which fits in 3 stages:

1. automatic control systems (ACS) and automatic control systems (ACS)
2. process automation systems (ACS)
3. automated process control systems (APCS)

At the present level, automation of production control systems is a multi-level scheme of interaction between people and machines based on automatic data collection systems and complex computing systems that are constantly being improved.

In the current economic conditions, at the forefront are industrial enterprises, which respond flexibly to changing conditions, can produce a diverse range of products, quickly adjust the production of products according to new standards, accurately meet the deadlines and volumes of orders, while offering a competitive price and maintaining quality at a high level. Without modern means and production automation systems to meet these requirements is almost impossible.

Main goals and benefits of enterprise automation in modern conditions:

• reduction in the number of workers and service personnel, especially in non-prestigious, "dirty", "hot", harmful, physically difficult areas of production
• improvement of product quality;
• increase in productivity (growth in output);
• creation of rhythmic production with the possibility of precise planning;
• improving production efficiency, including more rational use raw materials, reducing losses, increasing the speed of production, improving energy efficiency,
• improvement of environmental friendliness and production safety indicators, including reduction of harmful emissions into the atmosphere, reduction of injury rate, etc.
• improving the quality of management at the enterprise, the coordinated work of all levels of the production system.

Thus, the costs of automation of production and enterprises will certainly pay off, provided there is a demand for manufactured products.

To achieve these goals, it is necessary to solve the following tasks for automation of production processes:

• introduction of modern automation tools (equipment, programs, control and monitoring systems, etc.)
• introduction of modern automation methods (principles of building automation systems)

As a result, the quality of regulation, the convenience of the operator, and the availability of equipment are improved. In addition, it simplifies the receipt, processing and storage of information about production processes and equipment operation, as well as quality control.

Characteristics of APCS

Automated process control systems free a person from the functions of control and management. Here, a machine, a line or a whole production complex with the help of own system communications independently collect, register, process and transmit information using various sensors, instrumentation and processor modules. A person only needs to set the parameters to perform the work.

For example, this is how the Soyer automated fastener welding system works:

The same information collection devices can detect deviations from the specified norms, give a signal to eliminate the violation, or in some cases correct it on their own.

Flexible enterprise automation systems

The leading modern trend in the automation of production and enterprises is the use of flexible automated technologies (GAP) and flexible production systems (FPS). Among characteristic features such complexes:

1. Technological flexibility: acceleration and deceleration of productivity while maintaining the coherence of all elements of the system, the possibility of automatic tool change, etc.
2. Economic flexibility: quickly rebuild the system to new requirements of the nomenclature without unnecessary production costs, without replacing equipment.
3. The structure of the GPS involves industrial robots, manipulators, means of transportation, processor, including microprocessor control systems.
4. The creation of a GPS involves the complex automation of an enterprise or production. At the same time, the production line, workshop or enterprise work in a single automated complex, which includes, in addition to the main production, design, transportation, storage of finished products.

Elements of production automation

1. Machine tools with numerical program management(CNC);
2. Industrial robots and robotic complexes;
3. Flexible production systems(GPS);
4. Computer-aided design systems;
5. Automatic storage systems;
6. Computer quality control systems;
7. Automated system of technological planning of production.

In the following video, you can see how Kuka industrial welding robots perform automated welding:

Means of automation of production from Vector-groups

Vector-Group is a professional supplier of industrial equipment from the world's leading manufacturers. In our catalog you will find equipment for the automation of industries and engineering plants, welding industries, industries related to metalworking and other areas.

Automation equipment includes:

— industrial robots Kuka (Germany) - allow you to automate the processes of welding, cutting, material processing, manipulation, assembly, palletizing, and other processes.

– systems for automatic welding of fasteners Soyer (Germany),

– automatic transportation systems and load grippers DESTACO (USA).

The company offers assistance in the selection, supply of equipment, provides service. You can order both a standard production solution and a solution designed for specific individual requirements.

For all questions regarding our equipment, the specifics of its operation, cost, as well as any other questions, please contact our specialists.

ORGANIZATION OF AUTOMATED PRODUCTION

INTRODUCTION

At present, automation of production is one of the main factors of the modern scientific and technological revolution, which opens up opportunities for mankind to transform nature, create huge material wealth, and increase human creative abilities.

The development of automation is characterized by a number of major achievements. One of the first was Henry Ford's introduction of assembly lines into the manufacturing process. Industrial robots and personal computers have made a significant revolution in the automation of production. All this pushed our society to the path of a new automated control of the production process.

Currently, for the effective functioning of the enterprise, automation is introduced everywhere, it becomes an integral part of the entire production process. And this is quite justified and profitable, because costs are reduced and product quality is improved.

Automated production is a system of machines, equipment, Vehicle, which ensures the strictly coordinated in time execution of all stages of manufacturing products, starting from the receipt of initial blanks and ending with the control (testing) of the finished product and the release of products at regular intervals.

The purpose of this work is to consider the basic principles of automated production management, as well as to determine the effectiveness of automated control systems.

INTRODUCTION OF AUTOMATION IN PRODUCTION

The essence of automated production, its composition, applicability, performance

Automation of production is a process in which the functions of production management and control, previously performed by a person, are transferred to instruments and automatic devices. Automation is the basis for the development of modern industry, the general direction of scientific and technological progress. The purpose of production automation is to increase labor efficiency, improve the quality of products, to create conditions for the optimal use of all production resources.

Automated production arose in some industries (for example, in the chemical and food industries) already at the beginning of the 20th century. mainly in such production areas where technology cannot be organized differently at all.

The stages of development of production automation are determined by the development of means of production, electronic computers, scientific methods of technology and organization of production.

At the first stage, automatic lines and rigid automatic plants were created. The second period of development of automation is characterized by the emergence of electronic control, the creation of machine tools with numerical control (hereinafter CNC), machining centers and automatic lines. The prerequisite for the development of production automation in the third stage was the new CNC capabilities based on microprocessor technology, which made it possible to create a new machine system that combined the high productivity of automatic machines with the requirements for flexibility in the production process. At a higher level of automation, automatic factories of the future equipped with artificial intelligence equipment are being created

In automated production, the operation of equipment, assemblies, apparatus, installations occurs automatically according to a given program, and the worker controls their work, eliminates deviations from the given process, and adjusts the automated equipment.

There are partial, complex and full automation.

Partial automation of production, more precisely, automation of individual production operations, is carried out in cases where process control, due to their complexity or transience, is practically inaccessible to a person and when simple automatic devices effectively replace it. As a rule, operating production equipment is partially automated. With the improvement of automation tools and the expansion of their scope, it was found that partial automation is most effective when production equipment is designed immediately as automated.

With integrated automation of production, a site, workshop, plant, power plant function as a single interconnected automated complex. Integrated automation of production covers all the main production functions of an enterprise, economy, service; it is expedient only with highly developed production based on perfect technology and progressive management methods using reliable production equipment operating according to a given or self-organizing program, while human functions are limited to general control and management of the complex.

Full automation of production is the highest level of automation, which provides for the transfer of all management and control functions of complex automated production to automatic control systems. It is carried out when automated production is profitable, stable, its modes are practically unchanged, and possible deviations can be taken into account in advance, as well as in conditions that are inaccessible or dangerous to human life and health.

The basis of the compressor systems of machines are automatic lines (hereinafter AL). Automatic lines are a system of coordinated and automatically controlled machines (assemblies), vehicles and control mechanisms located along the technological process, with the help of which parts are processed or products are assembled, backlogs are accumulated, waste is removed according to a predetermined technological process. The role of the worker on the AL is reduced to monitoring the operation of the line, adjusting individual mechanisms, and sometimes feeding the workpiece to the first operation and removing the finished product from the last operation.

AL are used to automatically perform certain operations (stages) of the production process and depend on the type of raw materials (blanks), dimensions, weight and technological complexity of manufactured products.

The AL complex includes a transport system designed for supplying blanks from the warehouse to the stands, moving suspended technological equipment from one stand to another, for transporting finished products from the stands to the main line or finished product warehouse.

Depending on the method of ensuring rhythm, synchronous (rigid) AL are distinguished, which are characterized by rigid inter-unit communication and a single cycle of machine operation, and non-synchronous (flexible) AL with flexible inter-unit communication. Each machine in this case is equipped with an individual store-accumulator of operational backlogs.

The structural layout of the AL depends on the volume of production and the nature of the technological process. There are lines of parallel and sequential action, single-thread, multi-thread, mixed (with branching flow) (Fig. 1.1.1).

Rice. 1.1.1 Structural layout of automatic lines: a - single-flow sequential action; b - single-threaded parallel action; c - multithreaded; g - mixed (with a branching stream); 1 - working units: 2 - switchgears.

Parallel action ALs are used to perform one operation when its duration significantly exceeds the required rate of release. The processed product is automatically distributed (from a store or a bunker) to the line units and, after processing by receiving devices, is collected and sent to subsequent operations. Multi-threaded ALs are a system of ALs of parallel action, designed to perform several technological operations, each of which is longer than a given output rate in duration. Several ALs of serial or parallel action can be combined into a single system. Such systems are called automatic sections, workshops or productions.

Automated sections (workshops) include automatic production lines, autonomous automatic complexes, automatic transport systems, automatic storage systems; automatic quality control systems, automatic control systems, etc.

Rice. 1.1.1 Structural composition of the automated production unit

Automatic lines are widely used in the food industry, the production of household products, in the electrical, radio engineering and chemical industries. The most widespread automatic lines are in mechanical engineering. Many of them are manufactured directly at enterprises using existing equipment.

Automatic lines for the processing of products strictly defined in shape and size are called special; when the object of production changes, such lines are replaced or redone. Specialized automatic lines for processing the same type of products in a certain range of parameters have wider operational capabilities. When changing the production object in such lines, as a rule, only reconfigure individual units and change their modes of operation; the main technological equipment in most cases can be used for the manufacture of new products of the same type. Special and specialized automatic lines are mainly used in mass production.

In serial production, automatic lines must be versatile and provide the ability to quickly change over for the manufacture of various products of the same type. Such automatic lines are called universal quick-adjustable, or group. The somewhat lower productivity of universal automatic lines compared to special ones is compensated by their quick readjustment for the production of a wide range of products.

Efficiency of functioning of automated production

When carrying out work at a particular enterprise in order to switch to automated production, the question arises of assessing capital costs for the introduction of automation tools and determining the effectiveness of these costs. To do this, it is necessary to establish the cost structure for the creation of automated production and the procedure for determining the effectiveness of these costs.

Comparison of costs and results in the creation of automated production is part of the general problem considered in the theory of economic efficiency of capital investments.

The technical level of modern production makes it possible to automate almost any technological operation. However, automation will not always be cost-effective. Automation of production can be carried out using various equipment, various means of automation, transport and control devices, any layout of technological equipment, etc. Therefore, it is necessary to choose the right options for automating production and give a comprehensive assessment of their economic efficiency.

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