The Art of Manufacturing: Overcome control challenges for increasing efficiency in manufacturing using real-world examples

Description

Demystify automation and solve control-related problems with the help of real-world products and case studies put together by two industrial automation experts Key FeaturesReal life applications and case studies of automation curated from authors rich experienceOvercome tricky automation and control issues in the manufacturing processImplement automation in manufacturing for higher efficiency and productivity in the industryBook Description Engineering disciplines focus mainly on programming control systems, while the challenges they overcome or their industry applications largely go uncovered, leaving a huge gap between the theory and industry practices. This leads to engineers learning about subjects without actually understanding their purpose and entering the industry needing months of training. The Art of Manufacturing cuts across pedantic theory and reaches practical applications. You'll begin your learning journey by starting from the product and moving backward to the manufacturing landscape, factories, machines, and finally to the automation and control challenges faced in manufacturing. The book builds on the authors' valuable on-field experience, providing a detailed view of the manufacturing of real-world products, while simultaneously providing various analogies and references to daily tasks. As you advance through the chapters, you'll work on interesting control problems and find out how to overcome them in applications. The concluding chapters offer you a sneak peek into the future of automation and factories. By the end of this book, you'll be able to relate a real-world product with an associated control challenge and discover ways to overcome these challenges. What you will learnUnderstand the role of machines, factories, and plants in manufacturing a productExplore the manufacturing landscape and its continuous evolutionUse practical applications to mitigate control challenges in manufacturingResolve implementation challenges of various applications in a machineDiscover how humans and automation work together in factoriesFind out how to solve the same control challenge in different waysDiscover links between Industry 3.0, Industry 4.0, digitalization, and lean manufacturingWho this book is for The book will interest an inquisitive student of engineering (electrical, electronics, mechatronics, E&TC) who wishes to explore beyond the classroom textbook content. It will also serve as a teacher's handbook helping the lecturer bring the flair of industry into the classroom. Moreover, it will be useful for a practicing engineer, with cross-disciplinary knowledge that is needed to manufacture any real product. You must have basic knowledge of electronics, electrical, and mechatronics (engineering). Table of ContentsProduct Information DocumentAutomation Is a Part of our Daily LivesThe Art of Temperature ControlTension Control: Managing Material TensionLevel Control – Controlling the Level of Liquid to Avoid Drying Up or Spilling OverMotion Control: Control, Synchronization, and Interpolation of Axes for Accuracy and PrecisionMaterial Dispensing ControlThe Interplay of Humans-Machines-AutomationAutomation – Dramatically Helping Avoid Human InterventionAutomation Can Build a Super-Organism with AwarenessWhat's Next? Cover Title Page Copyright Foreword Contributors Table of Contents Preface Part 1: Introduction to the Manufacturing Landscape and Innovative Automation in Everyday Life Chapter 1: Automation Is a Part of Our Daily Lives Understanding our daily rituals and the products we use Probing how consumer demands and needs are drivers Analyzing the elements of a factory – production lines and machines Continuous process versus discrete process Mass/batch production versus customized production Inside a factory Analyzing the elements of automation – components and structures Control, automation, and data technologies Automation components Summary Chapter 2: The Art of Temperature Control Highlighting the need for temperature control The challenge and need for temperature control The control challenge An overview of an application (plastic) Overview of another application (pharma) Overcoming the control challenge Summary Chapter 3: Tension Control – Managing Material Tension The need for tension control Control challenge An overview of an application An overview of textile applications An overview of newspaper printing Overcoming the control challenge (tension control) Ways to measure tension Varying the tension Summary Chapter 4: Level Control – Controlling the Level of Liquid to Avoid Drying Up or Spilling Over The need for level control Challenge and the need for level control Control challenge Overview of applications Overview of the automotive application Overcoming the control challenge of level control Overview of a boiler application Summary Chapter 5: Motion Control – Control, Synchronization, and Interpolation of Axes for Accuracy and Precision The need for motion control Control challenges (motion control) Overview of an application Overcoming the control challenge (motion control) Summary Chapter 6: Material Dispensing Control The need for quantity control Control challenge (quantity control – weight or volume) Overview of an application Overcoming the control challenge (quantity control – weight or volume) Summary Part 2: Automation and Humans Chapter 7: The Interplay of Humans-Machines-Automation Humans and machines The need for interaction with machines Interaction while in operation Interaction while the machine is constructed Interaction at the design and testing stages Interaction at the supply chain and procurement stages Programming platforms and programming languages IEC 61131-3 languages Various formats of the application software Data from the process – values, alarms, and events Elementary operator interface – switches, dials, and meters Supervisory control Plantwide information Digital dashboards SCADA systems DCSs Advanced functions Mobile first – control from anywhere Summary Chapter 8: Automation – Dramatically Helping Avoid Human Intervention The need to reduce human intervention The control challenge in designing machines without supervision Application examples Continuous processes No-second-chance missions A high cost of error How the control challenge is solved Stored program controllers Maintenance techniques Systems with redundancy Fail-safe configurations Graceful degradation Lights-out factory Almost-human machines Summary Chapter 9: Automation Can Build a Super-Organism with Awareness A blueprint of automation with awareness Automation as a super-organism Automation and awareness Technological advances to help realize the blueprint Controller chips are getting smaller and faster Internet of things – controllers can talk to each other Pervasive computing Cloud and infinite processing power Augmented reality Data analytics Pattern recognition Classification Machine learning Robotics Applications where such automation can be deployed Quality control Supply and logistics coordination Safety Smart factory Autonomous vehicles Challenges ahead Summary Chapter 10: What’s Next? The question Need for the question Can we simply extrapolate? Is it too much of a good thing? When do we call a stop to it? What are the challenges? Improving functional capability Improving interaction Which functionalities are to be avoided? Improving security How could automation address the challenges? Quantum computing Low power consumption Context awareness Unobtrusive functioning More modes of command input: vocal, visual, mental Updates on the fly Security Solving human problems Summary Index About Packt Other Books You May Enjoy