Industrial Automation: Hands On

Industrial Automation: Hands On

Authors: Frank Lamb

Published: June 2013

eISBN: 9780071816472 007181647X | ISBN: 9780071816458

Cover

About the Author

Title Page

Copyright Page

Contents

Preface

1 Automation and Manufacturing

1.1 Automation

1.1.1 Advantages

1.1.2 Disadvantages

1.1.3 The Factory and Manufacturing

1.1.4 The Manufacturing Environment

2 Important Concepts

2.1 Analog and Digital

2.1.1 Scaling

2.2 Input and Output (Data)

2.2.1 Discrete I/O

2.2.2 Analog I/O

2.2.3 Communications

2.2.4 Other Types of I/O

2.3 Numbering Systems

2.3.1 Binary and BOOL

2.3.2 Decimal

2.3.3 Hexadecimal and Octal

2.3.4 Floating Point and REAL

2.3.5 Bytes and Words

2.3.6 ASCII

2.4 Electrical Power

2.4.1 Frequency

2.4.2 Voltage, Current, and Resistance

2.4.3 Power

2.4.4 Phase and Voltages

2.4.5 Inductance and Capacitance

2.4.6 Solid-State Devices

2.4.7 Integrated Circuits

2.5 Pneumatics and Hydraulics

2.5.1 Pneumatics

2.5.2 Hydraulics

2.5.3 Pneumatic-Hydraulic Comparison

2.6 Continuous, Synchronous, and Asynchronous Processes

2.6.1 Continuous Processes

2.6.2 Asynchronous Processes

2.6.3 Synchronous Processes

2.7 Documentation and File Formats

2.7.1 Drafting and CAD

2.7.2 Other Design Packages and Standards

2.7.3 Image File Formats

2.8 Safety

2.8.1 Hazard Analysis

2.8.2 Emergency Stops

2.8.3 Physical Guarding

2.8.4 Lockout/Tagout

2.8.5 Design Mitigation

2.8.6 Guard Devices

2.8.7 Software

2.8.8 Intrinsic Safety

2.9 Overall Equipment Effectiveness

2.9.1 Availability

2.9.2 Performance

2.9.3 Quality

2.9.4 Calculating OEE

2.10 Electrostatic Discharge

3 Components and Hardware

3.1 Controllers

3.1.1 Computers

3.1.2 Distributed Control Systems (DCSs)

3.1.3 Programmable Logic Controllers (PLCs)

3.1.4 Embedded Controllers and Systems

3.2 Operator Interfaces

3.2.1 Text-Based Interfaces

3.2.2 Graphical Interfaces

3.2.3 Touch screens

3.3 Sensors

3.3.1 Discrete Devices

3.3.2 Analog

3.3.3 Special Purpose Sensors

3.4 Power Control, Distribution, and Discrete Controls

3.4.1 Disconnects, Circuit Breakers, and Fusing

3.4.2 Distribution and Terminal Blocks

3.4.3 Transformers and Power Supplies

3.4.4 Relays, Contactors, and Starters

3.4.5 Timers and Counters

3.4.6 Push Buttons, Pilot Lights, and Discrete Controls

3.4.7 Cabling and Wiring

3.5 Actuators and Movement

3.5.1 Pneumatic and Hydraulic Actuators and Valves

3.5.2 Electric Actuators

3.5.3 Motion Control

3.6 AC and DC Motors

3.6.1 AC Motors

3.6.2 DC Motors

3.6.3 Linear Motors

3.6.4 Servomotors and Stepper Motors

3.6.5 Variable Frequency Drives

3.7 Mechanisms and Machine Elements

3.7.1 Cam-Driven Devices

3.7.2 Ratchet and Pawl Systems

3.7.3 Gearing and Gear Reduction

3.7.4 Bearings and Pulleys

3.7.5 Servomechanisms

3.7.6 Ball Screws and Belt-Driven Linear Actuators

3.7.7 Linkages and Couplings

3.7.8 Clutches and Brakes

3.8 Structure and Framing

3.8.1 Steel Framing

3.8.2 Aluminum Extrusion

3.8.3 Piping and Other Structural Systems

3.8.4 Electrical Enclosures and Ratings

4 Machine Systems

4.1 Conveyors

4.1.1 Belt Conveyors

4.1.2 Roller Conveyors

4.1.3 Chain and Mat Conveyors

4.1.4 Vibrating Conveyors

4.1.5 Pneumatic Conveyors

4.1.6 Accessories

4.2 Indexers and Synchronous Machines

4.2.1 Rotary Cam Indexers

4.2.2 Synchronous Chassis Pallet Indexers

4.2.3 Walking Beams

4.2.4 Pick-and-Place

4.3 Part Feeders

4.3.1 Vibratory Bowls and Feeders

4.3.2 Step and Rotary Feeders

4.3.3 Escapements and Parts Handling

4.4 Robots and Robotics

4.4.1 Articulated Robots

4.4.2 SCARA Robots

4.4.3 Cartesian Robots

4.4.4 Parallel Robots

4.4.5 Robot Basics and Terminology

4.4.6 Robot Coordinate Systems

5 Process Systems and Automated Machinery

5.1 Chemical Processing

5.2 Food and Beverage Processing

5.3 Packaging

5.4 Web Handling and Converting

5.5 Metal, Plastic, Ceramic, and Glass Processing

5.5.1 Metals

5.5.2 Plastics

5.5.3 Ceramics and Glass

5.6 Assembly Machines

5.6.1 Part Handling

5.6.2 Fastening and Joining

5.6.3 Other Assembly Operations

5.7 Inspection and Test Machines

5.7.1 Gauging and Measurement

5.7.2 Leak and Flow Testing

5.7.3 Other Testing Methods

6 Software

6.1 Programming Software

6.1.1 Programming Concepts

6.1.2 Programming Methodologies

6.1.3 Languages

6.2 Design Software

6.3 Analysis Software

6.4 Office Software

6.5 SCADA and Data Acquisition

6.6 Databases and Database Programming

6.7 Enterprise Software

7 Occupations and Trades

7.1 Engineering

7.1.1 Mechanical

7.1.2 Electrical and Controls

7.1.3 Industrial and Manufacturing Engineering

7.1.4 Chemical and Chemical Process Engineers

7.1.5 Other Engineering Disciplines and Job Titles

7.2 Trades

7.2.1 Mechanical

7.2.2 Electrical

8 Industrial and Factory Business Systems

8.1 Automation-Related Businesses

8.1.1 Manufacturers

8.1.2 OEMs

8.1.3 Manufacturers’ Representatives

8.1.4 Distributors

8.1.5 Machine Builders

8.1.6 Systems Integrators

8.1.7 Consultants

8.2 Departments and Functions

8.2.1 Management

8.2.2 Sales and Marketing

8.2.3 Engineering and Design

8.2.4 Maintenance

8.2.5 Manufacturing and Production

8.2.6 Finance and Human Resources

8.2.7 Quality

8.2.8 Information Technology

8.3 Lean Manufacturing

8.3.1 Kanban and “Pull”

8.3.2 Kaizen

8.3.3 Poka-Yoke

8.3.4 Tools and Terms

8.4 Systemization

8.4.1 Job and Task Descriptions

8.4.2 Communications

8.4.3 Hiring and Training

8.4.4 Engineering and Project Notebooks

9 Machine and System Design

9.1 Requirements

9.1.1 Speed

9.1.2 Improvements

9.1.3 Cost

9.1.4 Requirements Documentation

9.2 Quoting

9.2.1 Quote Request

9.2.2 Quote Analysis

9.2.3 The Decision

9.3 Procurement

9.3.1 Terms

9.4 Design

9.4.1 Mechanical

9.4.2 Electrical and Controls

9.4.3 Software and Integration

9.5 Fabrication

9.5.1 Structural

9.5.2 Mechanical

9.5.3 Electrical

9.5.4 Assembly

9.6 Start-up and Debug

9.6.1 Mechanical and Pneumatics

9.6.2 Packaging Integration

9.6.3 Controls

9.7 FAT and SAT

9.7.1 Factory Acceptance

9.7.2 Site Acceptance

9.8 Installation

9.8.1 Shipping

9.8.2 Contract Millwright and Electrician

9.9 Support

9.9.1 The First Three Months

9.9.2 Warranty

10 Applications

10.1 Binder-Processing Machine

10.2 Crystal Measurement

10.3 SmartBench

10.4 Sagger Load Station

10.5 Tray Handlers

10.6 Cotton Classing System

A: ASCII Table

B: Ampacity

C: Motor Sizing

D: NEMA Enclosure Tables

E: Manufacturers, Machine Builders, and Integrators

F: Thermocouples

Bibliography

Index