Advanced Manufacturing Systems and Automation Types

Posted on Jan 17, 2026 in Design and Engineering

Types of Automation in Production Systems

Automation of production systems can be classified into three basic types: Fixed automation, Programmable automation, and Flexible automation. This section compares these types, discussing the advantages and limitations of each.

1. Fixed Automation (Hard Automation)

Fixed automation refers to the use of special-purpose equipment to automate a fixed sequence of processing or assembly operations. Each operation in the sequence is usually simple, involving perhaps a plain linear or rotational motion or an uncomplicated combination of two. It is relatively difficult to accommodate changes in the product design, hence the name hard automation.

Advantages of Fixed Automation:

Low unit cost due to high volume.
Automated material handling.
High production rate.

Disadvantages of Fixed Automation:

High initial investment.
Relatively inflexible in accommodating product changes.

2. Programmable Automation (Soft Automation)

In programmable automation, the production equipment is designed with the capability to change the sequence of operations to accommodate different product configurations. The operation sequence is controlled by a program, which is a set of coded instructions that can be read and interpreted by the system. New programs can be prepared and entered into the equipment to produce new products.

Examples: Numerical controlled machine tools, industrial robots, and programmable logic controllers (PLCs).

Advantages of Programmable Automation:

Flexible to deal with design variations.
Suitable for batch production.

Disadvantages of Programmable Automation:

High investment in general-purpose equipment.
Lower production rate than fixed automation.

3. Flexible Automation

Flexible automation is an extension of programmable automation. A flexible automation system can produce a variety of parts with virtually no time lost for changeovers from one part style to the next. There is no lost production time while reprogramming the system and altering the physical setup.

Advantages of Flexible Automation:

Continuous production of variable mixtures of products.
Flexible to deal with product design variation.

Disadvantages of Flexible Automation:

Medium production rate.
High investment cost.
High unit cost relative to fixed automation.

Hardwired Control Systems and PLC Comparison

Principles of Hardwired Control Systems

Hardwired control systems use physical electrical wiring to implement control logic. The control logic is created using electromechanical devices such as relays, contactors, timers, limit switches, and sensors. Each function of the control system is performed by a dedicated electrical circuit. Logic operations such as AND, OR, NOT, latch, and interlock are achieved through combinations of wired relay contacts and coils. The system does not use software; it is a hardware-based control method.

Components of Hardwired Control Systems

Power Supply: Provides electrical power to all control elements.
Relays and Contactors: Perform switching, interlocking, and control functions.
Timers: Provide time-delay functions for sequencing operations.
Limit Switches and Sensors: Detect machine position, presence, or movement.
Push Buttons and Selector Switches: Allow manual start/stop or mode selection.
Wiring and Terminal Blocks: Interconnect all components to form the control circuit.
Output Actuators: Motors, solenoids, valves, or lamps controlled through the relay logic.

Working Mechanism

The operator initiates the system through a switch or push button.
Input devices (sensors, limit switches) send signals to relays.
The relays energize or de-energize based on the wiring logic.
Relay contacts open or close to create logical sequences and control the machine steps.
The final outputs (motors, solenoids, valves) operate according to the completed electrical logic path.

Limitations of Hardwired Control Systems

Very inflexible: any change requires manual rewiring.
Complex systems require large numbers of relays and wires.
Troubleshooting is time-consuming due to physical circuits.
High maintenance because electromechanical relays wear out.
Limited logic capability compared to digital systems.
Bulky panels and large installation space needed.

Advantages of Hardwired Control Systems

Simple and easy to understand for basic operations.
No programming knowledge required.
Works even in harsh electrical environments (less sensitive to noise).
Low cost for very simple control tasks.

Advantages of PLC-Based Control Systems

Highly flexible: logic changes require only software modification.
More compact, reducing wiring and panel size.
High reliability and long life with minimal mechanical wear.

Hardwired Systems vs. PLCs: Key Differences

Modification: Hardwired systems are difficult to modify; PLCs change instantly through programming.
Size: Hardwired systems are bulky; PLC systems are compact.
Maintenance: Hardwired systems require more maintenance; PLCs require minimal maintenance.
Speed/Complexity: Hardwired control is slow for complex processes; PLCs handle complex logic with ease.
Cost (Long-Term): Hardwired systems have higher long-term cost due to maintenance and downtime; PLCs reduce downtime significantly.

Transducers and Sensors: Principles and Types

Transducers and sensors are essential components in measurement and control systems. They convert physical quantities into signals that can be measured or recorded. While these terms are often used interchangeably, there is a subtle difference:

Sensor: A device that detects changes in physical conditions or variables and generates an output (usually an electrical signal) in response.
Transducer: A device that converts one form of energy into another. All sensors are transducers, but not all transducers are sensors.

Fundamental Principles

Detection: Sensors detect physical changes in the environment (e.g., temperature, pressure, light) and respond by generating an output signal.
Conversion: Transducers convert the detected physical quantity into a usable signal, often electrical. This conversion can be direct or through intermediate steps.
Output: The output signal can be analog (continuous) or digital (discrete). Analog signals vary continuously with the physical quantity, while digital signals are in discrete steps.
Calibration: Sensors and transducers must be calibrated to ensure accuracy.

Types of Transducers and Their Applications

Temperature Transducers: Thermocouples, Resistance Temperature Detectors (RTDs), Thermistors.
Pressure Transducers: Strain Gauge Pressure Transducers.
Displacement Transducers.
Flow Transducers: Turbine Flow Meters.
Force and Torque Transducers: Strain Gauge Load Cells.
Light Transducers: Photodiodes, Photovoltaic Cells.

Fluid Power Systems and Actuator Comparison

Fluid Power Systems Defined

Fluid power systems use fluids (liquids or gases) to transmit power in the form of fluid pressure to perform work. These systems are widely used in various industrial applications for actuating mechanisms and controlling machinery. Fluid power systems are generally categorized into two types:

Hydraulic Systems: Use liquids, typically oil.
Pneumatic Systems: Use gases, typically air.

Actuators

Actuators are mechanical devices that convert energy into motion. This involves a control command that signals a change in a physical system, which then generates force to accomplish a task. The commanding signal can be human-operated or automatically controlled, while the energy source varies. There are three different actuator types: hydraulic, pneumatic, and electric.

(Note: The comparison of merits and demerits of hydraulic, pneumatic, and electric actuators, and their influence on industrial choice, is implied by the question but not detailed in the provided text.)

Key Elements of a CIM System

Computer Integrated Manufacturing (CIM) is a comprehensive approach to manufacturing that integrates various technologies to control the entire production process. It is a method of manufacturing in which the entire production process is controlled by computers. There are nine major elements of a CIM system:

Marketing: The marketing division identifies the need for a product.
Product Design: The design department establishes the initial database for production using activities such as geometric modeling and Computer-Aided Design (CAD), considering product requirements and concepts.
Planning: The planning department takes the database established by design and enriches it with production data and information to create a plan to manufacture the product.
Purchase: Responsible for placing purchase orders, follow-up, ensuring vendor quality, receiving items, arranging inspection, and supplying items to stores or arranging timely delivery based on the production schedule.
Manufacturing Engineering: The activity of carrying out the actual production of the product.
Factory Automation Hardware: Factory automation equipment further enriches the database with equipment and process data, resident either in the operator or the equipment, to carry out the production process.
Warehousing: The function involving storage and retrieval of raw materials, components, and finished goods, as well as shipment of items.
Finance: Deals with resources pertaining to money, including planning investment, working capital, and cash flow control.
Information Management: Perhaps one of the crucial tasks in CIM. This involves master production scheduling, database management, communication, manufacturing systems integration, and management information systems.

Industrial Applications of Vision-Controlled Robotics

Vision-controlled robotic systems, also known as machine vision systems, integrate image capture and processing with robotic control. These systems use cameras, sensors, and advanced algorithms to enable robots to “see” and interpret their environment. This capability significantly enhances the flexibility, accuracy, and efficiency of industrial processes. Below are detailed descriptions of various industrial applications:

Automated Inspection and Quality Control: Vision-controlled robots are extensively used for inspecting products and parts to ensure they meet quality standards. These systems can detect defects, measure dimensions, and verify the presence and alignment of components.
Assembly Line Automation: Vision-guided robots enhance the flexibility and precision of assembly operations. They can identify and pick parts, orient them correctly, and assemble them with high accuracy.
Pick and Place Operations: Vision-controlled robots are used for picking up objects from a conveyor belt or other locations and placing them in a designated area. The vision system identifies the objects’ location, orientation, and sometimes their type.
Welding and Cutting: Vision systems guide robots in welding and cutting operations, ensuring precise and accurate execution of tasks. They help in identifying the exact location and orientation of the parts to be welded or cut.
Palletizing and Depalletizing: Vision-guided robots automate the process of stacking and unstacking products on pallets. They can handle various sizes and shapes of products, improving efficiency and reducing manual labor.
Bin Picking: Vision-controlled robots perform random bin picking by identifying and retrieving parts from a bin or a container. This task involves complex image processing to recognize and determine the position and orientation of objects.
Painting and Coating: Vision-guided robots are used for painting and coating applications. They ensure even coverage and precision, reducing wastage and improving finish quality.

Evaluating Robots for Welding Capabilities

Selecting a welding robot involves evaluating multiple factors to ensure it meets the specific needs of the application. Considerations such as compatibility with the welding process, payload capacity, reach, accuracy, speed, ease of programming, durability, and integration capabilities are all critical.

Below is a list of these factors along with suitable explanations:

Welding Process Compatibility: Different welding processes (e.g., MIG, TIG, arc welding, laser welding) have specific requirements. Ensure the robot is compatible with the welding process used in your application, including the necessary attachments and power sources.
Payload Capacity: The robot must have a sufficient payload capacity to handle the welding torch, cables, and any additional equipment. An inadequate payload capacity can lead to reduced precision and potential damage to the robot.
Reach and Work Envelope: The robot’s reach and work envelope should match the dimensions of the welding workspace and parts to be welded. A robot with insufficient reach may not be able to access all required weld points.
Accuracy and Repeatability: High accuracy and repeatability are crucial for consistent weld quality. Robots with better precision can maintain consistent welding paths, reducing defects and rework.
Speed: The welding speed of the robot should match the production requirements. High-speed robots can increase throughput but must still maintain weld quality.
Programming and Control Systems: User-friendly programming interfaces and advanced control systems can simplify the setup and adjustment of welding parameters. Look for robots that support offline programming and simulation for efficient planning.
Durability and Maintenance Requirements: Welding environments can be harsh, with exposure to heat, spatter, and fumes. Choose a robot designed for durability in such conditions and consider the ease of maintenance and availability of spare parts.
Integration with Existing Systems: Ensure the robot can be integrated with existing welding equipment, fixtures, and control systems. Compatibility with current systems can reduce costs and streamline implementation.
Sensor Integration: Advanced welding robots often use sensors for seam tracking, adaptive welding, and quality control.

Industry 4.0 and the Smart Factory Significance

What is Industry 4.0?

Industry 4.0, also known as the Fourth Industrial Revolution, represents a new phase in industrial development that focuses heavily on interconnectivity, automation, machine learning, and real-time data. It encompasses the integration of the Internet of Things (IoT), cloud computing, and cognitive computing. Industry 4.0 creates what is often referred to as a “smart factory.”

The concept of Industry 4.0 includes various advanced technologies that allow industries to become more flexible, responsive, and efficient. Industry 4.0 is characterized by:

Interconnectivity: Machines, devices, sensors, and people are connected and communicate with each other via the Internet of Things (IoT).
Information Transparency: Systems create a virtual copy of the physical world through sensor data, allowing for greater transparency and better decision-making.
Technical Assistance: Systems assist humans in decision-making and problem-solving, and even help with tasks that are too difficult or unsafe for humans.
Decentralized Decision-Making: Cyber-physical systems make decisions on their own and perform tasks autonomously.

Significance of Smart Factories in Industry 4.0

Smart factories are the cornerstone of Industry 4.0. They are highly digitized and connected production facilities that rely on smart manufacturing. Smart factories leverage advanced technologies to improve processes, enhance productivity, and create flexible manufacturing systems that can quickly respond to changes in demand and supply.

The significance of smart factories includes:

Enhanced Efficiency and Productivity: Smart factories optimize production processes through real-time monitoring and data analysis. This allows for immediate adjustments and improvements, minimizing downtime and maximizing output.
Flexibility and Customization: Unlike traditional manufacturing setups, smart factories can easily adapt to changes in product design and customer demand. This flexibility enables mass customization, where personalized products can be produced at scale.
Reduced Operational Costs: By automating routine tasks and optimizing resource usage, smart factories reduce operational costs. Predictive maintenance and efficient energy management contribute significantly to cost savings.
Improved Quality Control: Continuous monitoring and real-time data analytics ensure that any deviations in quality are detected immediately. This leads to higher product quality and reduces the incidence of defects.
Data-Driven Decision Making: The vast amounts of data generated in smart factories are analyzed using advanced analytics and machine learning algorithms. This data-driven approach facilitates better decision-making and strategic planning.
Worker Safety and Enhanced Working Conditions: Automation and robotics take over hazardous and repetitive tasks, reducing the risk of workplace injuries. Smart factories also ensure better working conditions by creating more ergonomic and safe environments.
Sustainability: Smart factories contribute to sustainability by optimizing resource use, reducing waste, and improving energy efficiency. They support green manufacturing practices and help in achieving sustainability goals.
Supply Chain Integration: Smart factories are integrated with the broader supply chain. This connectivity allows for seamless coordination with suppliers, distributors, and customers, improving overall supply chain efficiency.