Stages and means of production automation

The forerunner of automation was the complex mechanization of production, during which the physical functions of a person in the production process were performed using manual mechanisms. At the same time, the labor of a person was physically facilitated, and the control of mechanisms became his main activity. Mechanization is aimed at facilitating the conditions of human labor and increasing its productivity.

As mechanization develops, the task of fully or partially automating the control of mechanisms arises. As a result of solving this problem, technological machines are created that are capable of performing production functions to a greater or lesser extent without human intervention. The emergence and spread of technological machines laid the foundation for the automation of production.

In the development of automation, a number of successive stages can be distinguished, each of which is characterized by the emergence of new automation tools and the expansion of the composition of production automation objects. On an enlarged basis, in relation to industrial production, the following main stages of automation can be distinguished.

1. Mass production automation. In the mass production of industrial products, the task of increasing labor productivity is particularly acute. Here, significant costs for automation tools are possible, since being related to a unit of production (with a large number of units of production), they lead to an acceptable increase in its price.

As a result, it becomes expedient to create and use in the production of specialized and special technological machines. Each such machine is designed for a single technological operation or a limited set of technological operations in the production of a particular product. The task of restructuring the machine for the production of other products is either set to a limited extent, or not set at all.

The main goal of automation is to obtain maximum productivity. The technological process of manufacturing a product is divided into simple operations of short duration, which can be performed in parallel on different technological machines.

Production lines are created from technological machines in accordance with the sequence of technological operations of the product manufacturing process. A further increase in the level of automation is achieved by automating inter-operational transport and intermediate storage (inter-operational stores of semi-finished products). The result of such complex automation of the technological process is the creation of automatic lines.

The automatic line implements in automatic mode the technological process of manufacturing a certain product. An automatic line to achieve the highest productivity is built from special and specialized equipment. The creation and implementation of an automatic line requires a lot of time and material costs, therefore, such lines are cost-effective only in mass production of products, when the same product in unchanged form is produced continuously in large quantities over a number of years. Automatic lines have limited opportunities for changeover to the manufacture of other products, or such opportunities are not provided at all.

Since the use of automatic lines and cyclic technological machines is limited to mass and large-scale production, the volumes of automated production based on them are correspondingly limited. According to various estimates, the volume of mass and large-scale production is from 15 to 20% of the total production, and this share tends to decrease. Consequently, the level of production automation with the help of automatic lines and cycle machines can be no more than 15–20%. In reality, this level is even lower.

Cyclic technological machines and automatic lines are among the means of "hard" automation. With their help, it is possible to achieve very high labor productivity, but the scope of such tools is limited, and only on their basis, full automation of production is impossible.

2. Automation of the main processing operations of multi-product production. Multiproduct production involves the manufacture of various products in batches of a limited volume in a limited time. The range of products and volumes of batches can vary widely: from single items to batches of medium-scale production.

In multi-product production, technological equipment should be largely universal and provide readjustment and restructuring for the manufacture of various products (within the technological capabilities of the equipment). In the case of automated production, such readjustment and restructuring should be carried out automatically with a minimum amount of manual operations or with their complete elimination.

Fulfillment of the listed conditions defines "flexible" automation. The basic principle of flexible automation is the principle of programmatic control of technological equipment. The operating cycle of the technological machine is then set by a control program containing a coded description of the sequence of cycle elements using certain symbols. The control program is developed separately from the controlled equipment and is drawn up on some machine carrier, which allows it to be read by the automatic control device of the technological machine.

For the first time, this principle (which arose and improved during computer control) was implemented for the automation of metal-cutting machine tools. Machine tools with numerical control (CNC) appeared and began to be widely distributed. The first models of CNC machines, due to insufficient perfection, required, when changing the working cycle, not only the replacement of the control program, but also some manual operations for readjustment. Such machines turned out to be effective when processing batches of the same type of parts with a volume of at least 50–100 pieces. As CNC principles and technical solutions improved, this limit was constantly reduced, and at present CNC machines are effective even in individual production.

Initially, CNC machines were created for certain types of machining. Subsequently, multi-operational CNC machines with automatic change of the processing tool (machining centers) became widespread.

CNC machines allow you to automate the process of processing parts and are flexible, because they can be reconfigured to process parts of a different shape by replacing the control program. This circumstance makes it possible, for example, to automate the process of changeover of the machine and, consequently, increases the level of production automation.

The principle of CNC, due to its efficiency, has become widespread for other technological equipment, which made it possible to provide flexible automation of various technological operations. CNC equipment is primarily used in mechanical engineering, instrument making and metalworking. However, its use is not limited to the listed industries.

The main disadvantage of CNC equipment is the lack of automation of auxiliary operations and the need for manual maintenance of the equipment. This circumstance leads to a decrease in the equipment utilization factor to the level of 40–60%.

3. Industrial robotics. Automation of the main operations of technological processes has led to an increase in the contradiction between the level of their automation and the level of automation of auxiliary operations (primarily the loading and unloading of automated equipment). As a means of eliminating this contradiction, the concept of a program-controlled tunable automaton was proposed for performing auxiliary operations for servicing automated equipment.

Such machines appeared in the sixties of the last century and were called industrial robots (IR). The first developments of industrial robots were focused on replacing a person when loading workpieces into technological machines and unloading processed products. On the basis of the technological machine and the robot serving it, robotic technological complexes (RTC) are created, which are complexly automated technological cells.

With the help of the RTK, it becomes possible to comprehensively automate individual technological operations or a limited set of technological operations in a multi-product production. The first RTKs using simple CR with cycle control were effective in medium-scale production. With the improvement of PR (CNC robots, adaptive robots, intelligent robots), their flexibility and the possibility of effective use in small-scale and individual production are increasing.

Industrial robots are constantly improving. In the process of improvement, the technical characteristics of robots are improved, their functionality is expanding, and the scope of application is expanding. Currently, the bulk of manufactured PR is focused on the performance of technological operations: welding, painting, assembly and some other basic technological operations. Along with such robots, loading and unloading robots continue to be used, transport robots, etc. have appeared.

4. Automation of management. Management in any production requires solving a large amount of tasks for collecting and processing information, making decisions and monitoring their execution. Significant human resources are attracted to solve management problems. The quality of solving managerial problems largely determines the result of production.

The possibility of automation of management appeared with the development and widespread use of computers, when computers became available for use by individual enterprises. It became possible to automate (with the help of a computer and appropriate software) the processes of collecting and processing information necessary for making managerial decisions and monitoring the progress of production. With the use of computers, problems of production planning, problems of material support, problems of accounting for labor and wages, as well as a number of other problems of production management, began to be solved.

The solution of such problems was not strictly tied in time to production processes and could be carried out in the "machine" time of the computer, i.e. during such a time period as is required for the execution of the relevant computer program. Characteristic for this stage of automation was the creation of centralized computing centers in production for solving control problems. Communication between computers and production was mainly carried out using operational personnel.

Such centralized systems are called automated production control systems (APCS). The automated control system provides a solution to the problems of organizational and dispatching production management. The main effect of the introduction of automated control systems is to reduce the time required for making management decisions, increase the efficiency of management and its quality, as well as reduce the management personnel involved in routine information processing.

A significant amount of management in production falls on the tasks of operational and technical management of production equipment and technological processes. To automate the solution of these problems, it is necessary to provide a direct connection between the control computer and control objects. In addition, the tasks of operational and technical management must be solved in real time of the controlled process.

Therefore, along with automated control systems, automated process control systems (APCS) appeared, which provide automated solutions for the tasks of operational, technical, dispatching and organizational management of individual technological processes of production. The integration of automated process control systems with an automated technological complex ensures the implementation of the concept of unmanned technology in production.

5. Automation of engineering work. Production requires the cost of highly skilled labor of specialists - engineers. Engineers develop new products, conduct research and testing, develop new processes and upgrade old ones. Without engineering labor, the progress of production is impossible. The cost of paying engineering labor in production costs is a significant share (by the standards of industrialized countries).

The desire to increase the efficiency of engineering work, reduce the material and time costs for designing new or modernized products, for research, for preparing production has led to the emergence of appropriate automated systems. The basis of such systems was the use of computers, since engineering work is intellectual work. Typical engineering problems are heuristic problems based on a significant amount of routine work.

Routine work (obtaining reference information, processing results, drawing up drawings and text documents, etc.) in most cases lends itself to algorithmization (description in the form of a deterministic sequence of simple operations) and, therefore, they can be automated using a computer. In principle, any process that can be algorithmized can be automated.

The means of automation of engineering work are computer-based software and hardware complexes: design automation systems (CAD), automated systems for scientific research (ASNI), automated systems for technological preparation of production (ASTPP). The first two systems are used by designers and researchers to develop new or upgrade existing products. The result of their work are technical and working projects of new products.

To implement these projects, it is necessary to prepare the production of the designed products. This task is assigned to specialists-technologists who design new technological processes or modernize existing ones. To automate the work of technologists (those works that lend themselves to algorithmization), ASTPP are intended. The use of ASTPP allows you to increase the efficiency of production preparation, reduce material and time costs for this process, improve the quality of results and reduce human labor costs.

6. Integration of automated production systems into a single flexible automated production (FAP). Integration is the sharing and interaction of the above automation systems to achieve the ultimate goal of production. At the same time, automation systems for human intellectual functions (design, management, research, technology development) use common databases, which ensures a direct exchange of information between them.

In GAP, the main principle of equipment and process management is computer software control, which ensures the restructuring of production for the production of new or upgraded products by software (replacement of control programs) in an automated mode. As a result, production acquires the property of flexibility and implements the concept of flexible technology. Integrated automation of human labor makes it possible to reduce the share of human labor in the GAP by 20 times compared to traditional production. Such production implements the concept of unmanned technology.

Under the conditions of HAP, both physical and intellectual functions of a person are automated. Computers are the main means for automating intellectual functions. Therefore, HAP is often referred to as integrated and computerized production.

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Automated production processes are those processes in which the main work on the manufacture of products is fully automated, and the auxiliary ones are fully or partially automated. The functions of the worker are reduced to monitoring and controlling the operation of automatic machines, loading raw materials and unloading finished products.

The complex automated production process is described by the following equations.

Automated production processes are understood as those in which the main work on the manufacture of products is fully automated, and the auxiliary ones are fully or partially automated.

Automated production processes are understood as those in which the main work on the manufacture of products is fully automated, and the auxiliary ones are fully or partially automated. The functions of the worker are reduced to monitoring and controlling the operation of automatic machines, loading raw materials and unloading finished products.

Automated production processes are understood as those in which the main work on the manufacture of products is fully automated, and the auxiliary ones are fully or partially automated. The functions of the worker are reduced to monitoring and controlling the operation of automatic machines, loading raw materials and unloading finished products.

This approach to automated production processes has many advantages. The fact that they are cheap and pay off quickly makes it very easy to push them through the upper management. One of the most striking managerial arguments against the introduction of large automatic plants is that the demand for a product can change before the automatic plant designed for it is put into operation.

The most important stage in the creation of an automated production process is the choice of the most appropriate variant of the technological process.

Optimal technological options for the manufacture of finished products should serve as the basis for an automated production process. The name Mechanical engineering technology is currently incorrectly attributed to existing courses and educational specialties, which are, in essence, cutting.

At modern industrial enterprises, in metallurgical, chemical, oil refining and other industries with automated production processes, measuring equipment is used mainly to control production processes (their parameters), combined with automatic regulation and control, and control the quality of products. Although the control of the production process, carried out through one or another of its parameters, has a different goal than the measurement of individual quantities, namely, checking the degree (within the established limits) of the fulfillment of the specified modes (parameters), nevertheless, the control process has much in common with the measurement as in technique, as well as in equipment. An example is measuring transducers that convert all kinds of non-electrical quantities into electrical ones and are widely used both in measurements and in control. In addition, in devices used for control, in some cases, it is measurements that are carried out if, for example, it is required to know the numerical values ​​of the controlled parameter and its changes over time.

In many cases, when conducting various kinds of scientific experimental research, testing new types of equipment, as well as when controlling automated production processes, documentary registration of the values ​​of controlled non-electric quantities over time is used. In these cases, instead of an indicator device, a device is used that registers (records) the electrical signals arriving at its input. The most widely used magnetic and oscillographic records of electrical signals.

Since automation contains the possibility of improving technical and economic indicators, when developing a control algorithm, it is necessary to strive to ensure that the automated production process proceeds optimally. This means that, ceteris paribus, the productivity of the equipment should be maximum, the quality of the products obtained should be high, energy costs should be minimal and, as a result, the cost of finished products should be low.

Each unit should, if possible, have the smallest dimensions, weight and cost; the design of the converter must be technologically advanced, allow the use of automated production processes in its manufacture and provide favorable conditions for operation.

Before, when production processes were not automated, and technology was largely based on the experience and skills of people, when the means of measuring technology were not as developed as they are now, attempts to clearly comprehend to find the most reasonable optimal solutions, and even more so attempts to build optimal systems, were pointless. Now the issues of building scientifically based and automated production processes are becoming relevant. Consequently, the role of the optimum problem, the problem of choosing the single most rational solution, increases.

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. The modern development of technology makes it possible to automate not only physical, but also intellectual labor, 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, industrial enterprises are at the forefront, which respond flexibly to changing conditions, can produce a variety 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. It is practically impossible to meet these requirements without modern means and systems of production automation.

Main goals and benefits of enterprise automation in modern conditions:

• reduction in the number of workers and maintenance 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 of 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 methods of automation (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, using its own communication system, independently collects, registers, processes and transmits information using all kinds of 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 the characteristic features of such complexes:

1. Technological flexibility: acceleration and deceleration of productivity while maintaining the coordination 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 operate in a single automated complex, which includes, in addition to the main production, design, transportation, and storage of finished products.

Elements of production automation

1. Machine tools with numerical control (CNC);
2. Industrial robots and robotic complexes;
3. Flexible production systems (FMS);
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.

Automation of production

processes

1.1. Fundamentals, terminology and directions of AMS.

One of the main directions of human activity is the improvement of production processes in order to facilitate hard physical labor and increase the efficiency of the process as a whole - this direction can be realized through the automation of production processes.

So, the purpose of the APP is:

- productivity increase;

- quality improvement;

- improvement of working conditions.

The goal raises questions about what and how to automate, the feasibility and necessity of automation, and other tasks.

As you know, the technological process consists of three main parts:

- working cycle, - the main tech. process;

- idling, - auxiliary operations;

- transport and storage operations.

Main tech. process is closely related to AIDS. Consider AIDS:

C is the automation of working and idle moves of all machine mechanisms (automatic main movement, feeds and auxiliary operations).

P - automation of installation, fixing parts on the machine. I - AMS requirements for the tool.

D - technological requirements of the AMS for the part. Besides,

Auxiliary operations are the automation of loading, unloading, installation, orientation, fixing, transportation, accumulation and control of the part. From all of the above, it can be seen that the AMS has an integrated approach and, not

solving one problem, we can not achieve the desired effect. Automation is a direction in the development of production, characterized by

liberation of a person not only from muscular efforts to perform certain movements, but also from the operational control of the mechanisms that perform these movements.

Automation can be partial or complete.

Partial automation- automation of a part of the operation for managing the production process, provided that the rest of all operations are performed automatically (human control and control).

An example would be autom. line (AL), consisting of several automatic machines and having an automatic interoperational transport system. The line is controlled by one processor.

Full automation- characterized by the automatic performance of all functions for the implementation of the production process without direct human intervention in the operation of the equipment. The duties of a person include setting up a machine or group of machines, turning it on and controlling it.

Example: automatic section or workshop.

1.2. Organizational and technical features of automation.

Analyzing the trend and history of the development of automation prod. processes, four main stages can be noted, at which tasks of various complexity were solved.

These are: 1. Automation of the working cycle, creation of automatic and semi-automatic machines.

2. Automation of machine systems, creation of AL, complexes and modules.

3. Production automation complexes processes with the creation of automatic workshops and factories.

4. Creation of flexible automated production with automation of serial and small-scale production, engineering and managerial work.

1 At the first stage, universal equipment was modernized. As you know, the processing time of one product is determined by the formula:

T \u003d t P + tX

Thus, to increase the productivity of the equipment, the time tР and tХ was reduced and tР and tХ were combined, which means that if the machine, in addition to working moves (tР), can independently perform idle strokes (tХ), then it is an automatic machine.

It should be borne in mind that idle moves should be understood not only as the movement of individual machine components without processing, but also loading, orientation of the part, and their fixation. However, as practice has shown, the automation of universal machines has its limits in terms of productivity, i.e. the growth of labor productivity did not exceed 60%. Therefore, in the future, special automatic machines began to be created using new principles:

Multi-tool and multi-position automata were used in production lines, which was the highest form of the first stage of automation (see Table 1 for a block diagram).

Structural diagram of machine No. 1

Automatic (bar)

2 At the second stage, an AL is created (structural diagram see Table 2).

AL is called - an automatic system of machines located in the technological

logical sequence, united by means of transportation, control, automatically performing a set of operations except for control and adjustment.

The creation of AL required the solution of more complex problems. So one of them - - Creation of an automatic system for inter-machine transportation of workpieces, taking into account the unequal rhythm of the machines (the time for the operation is different); as well as non-coincidence in time of their downtime due to emerging problems. The machine-to-machine transportation system should include not only conveyors, but also automatic storage magazines to create the consumption of inter-operational reserves, control devices and blocking of the machine system. At the same time, it is necessary not only to harmonize the working cycles of individual machines, as well as transporting mechanisms, but also locks in case of various problems (breakdowns, out-of-field dimensions).

tolerance, etc.).

At the second stage of automation, the problem is also solved: creation of automated control tools, including active control with the adjustment of the machine.

The economic effect is achieved not only by increasing productivity and a significant reduction in manual labor costs due to the automation of machine-to-machine transportation, control, and chip removal.

Structural diagram of AL tab. #2

3 The third stage of automation is the complex automation of production processes - the creation of automatic workshops and factories.

Automatic shop or factory called a workshop or plant in which the main production processes are carried out on the AL.

Here, the tasks of automation of inter-line and inter-shop transportation, storage, cleaning and processing of chips, dispatch control and production management are solved (the structure of the auto shop, see the diagram, Fig. 3).

The structure of the automatic workshop table. No. 3

Automatic

Here, the elements that perform working moves are already AL with their technological rotary machines, transportation, control mechanisms, etc.

In auto. shops and factories, interline transportation and accumulation of backlogs are idle moves.

The shop floor control system also performs new, more complex tasks. The most important feature of the integrated automation of production processes as a new stage in technical progress is the widespread use of computer technology, which allows solving not only the problem of control

production, but also flexible management of those. processes.

4 Flexible automated systems - as the fourth stage of automation, they represent the highest fourth stage in the development of automation of those. processes. Designed for automating processes with a replaceable production object, including for single and small-scale production.

Flexible production- a complex concept that includes a whole range of components + machine flexibility– ease of restructuring the technological elements of HAP for the production of a given set of types of parts.

Process Flexibility- the ability to produce a given set of types of parts, including from various parts, in different ways.

Flexibility by product- the ability to quickly and economically switch to the production of a new product.

+ Route flexibility– the ability to continue processing a given set of types of parts in case of failures of individual HAP technological elements.

Flexibility in volume– the ability of HAP to work economically at various production volumes.

Flexibility to expand- the possibility of expanding the GAP due to the introduction of new technological elements.

Flexibility of work - the ability to change the order of operation for each of the types in the part.

Product Flexibility- all the variety of products that GAP is capable of producing.

Determining yavl-Xia machine and route flexibility. The use of HAP gives a direct economic effect due to

freeing up staff and increasing shift work and control equipment.

Usually, in the first shift, blanks, materials, tools, those tasks, control systems, etc. are loaded, this is done with the participation of people. The second and third shifts of the GAP work independently under the supervision of a dispatcher.

Lecture #2

1.3. Feasibility studies features of automation.

When analyzing production, it is not enough to know at what stage of mechanization or automation a particular technological process is. And then the degree of automation. or mechanization (C) is determined by the level of mech. (M) and autom. (A). The assessment of the level of M and A is carried out by three main indicators:

- extent of coverage of workers fur. labor (C);

- fur level. labor in total labor costs (U T );

- fur level. and ed. productions. Processes (U P ). For fur. processing and assembly these indicators:

The percentage increase in labor productivity due to its fur. or automation:

where - index 1 corresponds to the indicators obtained before the fur. and auto.;

Index 2 after they were held; RA - the number of workers performing work using automated means;

RO - the total number of workers in the area under consideration, shop;

to - coefficient of mechanization, expressing the ratio of time mech. labor

to the total cost of time for a given working time.

P - coefficient. equipment performance, which characterizes the ratio of the labor intensity of manufacturing children. on universal equipment. with the lowest productivity, taken as the base of the labor intensity of manufacturing this part on existing equipment;

M - coefficient. Service, depending on the number of pieces of equipment serviced by one worker (when servicing equipment by several workers M< 1).

The system of three main indicators of the level of mech. and autom. production processes allows:

- assess the condition of the car production, open up reserves for increasing labor productivity;

- compare the levels of M. and A. related industries and industries;

- to compare the levels of M. and A. of the corresponding objects according to the periods of implementation and thereby determine the directions for further improvement of production processes;

- plan the level of automation.

Along with the above indicators, the criterion of the level of production automation can be used, which quantitatively characterizes the extent to which at this stage of M. and A. the possibilities of saving labor costs are used, i.e. production growth. labor:

where tPM is the complexity of manufacturing a product with full (complex) mechanization;

tNA and tPA - the complexity of manufacturing with partial and full auto.

1.4. Manufacturability of parts for automated production.

1.4.1. Features of product design in terms of automation

production.

The design of the product must ensure its manufacturability in manufacturing and assembly. The use of automation tools provides for increased attention to the design of products in terms of facilitating orientation, positioning, and mating during assembly.

Most of the means of autom. for transport and orientation of parts act by touch, i.e. they use the geometry of the parts to perform orientation and positioning.

Considering this, we can say that the choice of one or another means of autom. will be based on the analysis of the classification of production objects by geometric parameters (according to their purpose and their relative size).

One of the geometric characteristics is symmetry.

In some cases, the symmetry of the parts facilitates automation, while in others it makes it impossible. Example fig. A1, all parts on the right are symmetrical, which makes orientation unnecessary; rice. A2 - illustrates another problem. If the design features of each part is difficult to detect fur. way, the solution to the problem is to break the symmetry.

Details such as cylinders and disks are the most likely candidates for introducing asymmetric features, because without orienting signs they can take an indefinite number of positions.

Rectangular parts usually benefit from symmetry because they can have a small number of positions.

Fig A1 Orientation of parts due to symmetry.

Fig. A2 Orientation of parts due to asymmetry. a) difficult b) improved

In this case, the law of distribution of the sum of these random variables will have a Gaussian or normal distribution - fig. A5.

Mutual adhesion of parts (Fig. 3)

When loading parts into a drive or other device in bulk, the phenomenon of parts adhesion often occurs. Typical example - springs. Many parts have holes and protrusions that are not functionally related to each other and are not intended for mating. The ratio of the dimensions of these elements of the parts should exclude the possibility of the protrusion entering the hole and the adhesion of the parts. (Fig. A3).

Chapter 1. Principles of building automated production

Part 1. Fundamentals of the theory of automatic control

Automation- a branch of science and technology, covering the theory and devices of means and systems for automatic control of machines and technological processes. It arose in the 19th century with the advent of mechanized production based on spinning and weaving machines, steam engines, etc., which replaced manual labor and made it possible to increase its productivity.

Automation is always preceded by the process of complete mechanization - such a production process in which a person does not spend physical strength on performing operations.

With the development of technology, the functions of controlling processes and machines have expanded and become more complex. Man has in many cases not been able to manage mechanized production without special additional devices. This led to the emergence of automated production, in which workers are released not only from physical labor, but also from the functions of controlling machines, equipment, production processes and operations, as well as managing them.

Under the automation of production processes is understood a set of technical measures for the development of new technological processes and the creation of production based on high-performance equipment that performs all the main operations without direct human participation.

Automation contributes to a significant increase in labor productivity, improving product quality and working conditions for people.

In agriculture, food and processing industries, the control and management of temperature, humidity, pressure, speed control and movement, quality sorting, packaging and many other processes and operations are automated, ensuring their higher efficiency, labor and cost savings.

Automated production, compared to non-automated production, has certain specifics:

To be more efficient, they should cover more heterogeneous operations;

It is necessary to carefully study the technology, analyze production facilities, traffic routes and operations, ensure the reliability of the process with a given quality;

With a wide range of products and seasonality of work, technological solutions can be multivariate;

The requirements for a clear and well-coordinated work of various production services are increasing.

When designing automated production, the following principles must be observed:

1. The principle of completeness. You should strive to perform all operations within the same automated production system without intermediate transfer of semi-finished products to other departments. To implement this principle, it is necessary to ensure:

Manufacturability of the product, i.e. the minimum amount of materials, time and money should be spent on its manufacture;

Unification of methods of processing and control of the product;

Expansion of the type of equipment with increased technological capabilities for processing several types of raw materials or semi-finished products.

2. The principle of low-operational technology. The number of intermediate processing operations for raw materials and semi-finished products should be minimized, and their supply routes should be optimized.

3. The principle of less people technology. Ensuring automatic operation throughout the entire product manufacturing cycle. To do this, it is necessary to stabilize the quality of input raw materials, improve the reliability of equipment and information support of the process.

4. The principle of trouble-free technology. The control object should not require additional adjustment work after it is put into operation.

5. The principle of optimality. All control objects and production services are subject to a single criterion of optimality, for example, to produce only the highest quality products.

6. The principle of group technology. Provides production flexibility, i.e. the ability to switch from the release of one product to the release of another. The principle is based on the commonality of operations, their combinations and recipes.

Serial and small-scale production is characterized by the creation of automated systems from universal and aggregate equipment with interoperational tanks. This equipment, depending on the product being processed, can be readjusted.

For large-scale and mass production of products, automated production is created from special equipment, united by a rigid connection. In such industries, high-performance equipment is used, for example, rotary equipment for pouring liquids into bottles or bags.

For the functioning of the equipment, intermediate transport is necessary for raw materials, semi-finished products, components, and various media.

Depending on the intermediate transport, automated production can be:

With end-to-end transportation without rearrangement of raw materials, semi-finished products or media;

With a rearrangement of raw materials, semi-finished products or media;

with intermediate container.

According to the types of equipment layout (aggregation), automated production is distinguished:

Single-threaded;

Parallel aggregation;

Multithreaded.

In single-flow equipment is located sequentially in the course of operations. To increase the productivity of single-threaded production, the operation can be performed on the same type of equipment in parallel.

In a multi-threaded production, each thread performs similar functions, but operates independently of one another.

A feature of agricultural production and processing of products is the rapid decline in their quality, for example, after slaughtering livestock or removing fruits from trees. This requires such equipment that would have high mobility (the ability to produce a wide range of products from the same type of raw materials and process various types of raw materials on the same type of equipment).

For this, reconfigurable production systems are created that have the property of automated reconfiguration. The organizational module of such systems is a production module, an automated line, an automated section or a workshop.

production module they call a system consisting of a unit of technological equipment equipped with an automated program control device and automation of the technological process, autonomously functioning and having the ability to integrate into a higher level system (Fig. 1.1).

Figure 1.1 - The structure of the production module: 1- equipment for performing one or more operations; 2- control device; 3- loading and unloading device; 4 - transport and storage device (intermediate capacity); 5- control and measuring system.

The production module may include, for example, a drying chamber, a measuring system, a locally controlled handling and transport system, or a mixing plant with similar additional equipment.

A special case of the production module is production cell- a combination of modules with a unified system for measuring equipment operation modes, transport-accumulation and loading-unloading systems (Fig. 1.2). The production cell can be integrated into higher level systems.

Figure 1.2 - The structure of the production cell: 1- equipment for performing one or more operations; 2- receiving hopper; 3-loading and unloading device; 4- conveyor; 5- intermediate capacity; 6 - control computer; 7- control and measuring system.

Automated line- a reconfigurable system consisting of several production modules or cells, united by a single transport and storage system and an automatic process control system (APCS). The equipment of the automated line is located in the accepted sequence of technological operations. The structure of the automated line is shown in Figure 1.3.

Unlike an automated line, a reconfigurable automated section provides for the possibility of changing the sequence of using technological equipment. The line and section may have separately functioning units of technological equipment. The structure of the automated section is shown in Figure 1.4.

Figure 1.3 - The structure of the automated line: 1, 2, 3, 4 - production cells and modules; 5- transport system; 6 warehouse; 7- control computer.

Figure 1.4 - Structure of the automated section: 1,2,3 - automated lines;

4 - production cells;

5- production modules;

7- control computer.