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Industrial Automation
Design, Planning and Using Technology

 Jun 98



Table of Contents
Hydraulics and Pneumatics
Hydraulics and Pneumatics Components Air Flow thru Pneumatic Valves
Hydraulic Fluids, Contamination & Filtration Noise in Fluid Power Systems
Power Transmission
Power Transmission Components Establishing Predictive Maintenance
Failure Analysis of Gears & Bearings Select Servo Technology & Application
Motion Control and Sensors
Motion Control and Sensor Components Selecting Electronic Sensors
Electronic Interfacing  and Controls Selecting Controller for Application

Software Solutions and Applications in Industrial Automation
MES ...these topics are still under construction in detail. Please excuse.... SCADA
MMI (you can see some of the work on this section by entering here.) QA/QC



Hydraulic and Pneumatic Components

Accumulators (bladder, piston)Actuators (rotory)  Adapters  Amplifiers  Bearings (composite) Clamping Systems Compressors (air)  Connectors Control Panels (electrical)  Controllers & Positioners Couplers (hydraulic)  Cylinder Tubing (composite)  Cyliners (hydraulic, multi-power, pneumatic)  Drives (electronic)  Filters (hydraulic, all types)  Filtration (carts & systems)  Fittings (hydraulic, all types)  Gages (instrumentation) Grippers (parrallel)  Headers  Heat Exchangers  Hoses (hydraulic, pneumatic)  Hydraulic Flanges Hydraulic Fluids  Industrial Nuts   Intensifiers Junction Blocks  Manifolds & Subplates  Motors (air) Motors (brushless, motor parts, hydraulic)  Nozzles O-Rings Orifices Packings Plugs (protectors and expansion) Positioners Power Units/Packs Presses (air) Pressure Transmitters Protectors (cable, hoses, thread, cable) Pumps (air operated, hydraulic, vacuum)  Regulators (pressure) Reservoirs Restrictors Seals (sealing systems, seal kits, packing) Sensors Shock AbsorbersSilencersStrainers Switchs (all types) Test EquipmentThreadlock Adhesives  Transducers & Transmitters  Tubing & Shafting (metal, plastic)Valves (ball, cartridge, check, directional control, electro-pneumatic, flow control, pilot, pneumatic, pressure control, proportional, servo, solenoid)Wear Rings



Hydraulic Fluids, Contamination and Filtration

Always to be considered are the properties and characteristics of the fluids handled:  water-, petroleum-, systhetic-, and/or vegetable-based.  Must be able to compare performance and application of each.  Must understand selection criteria.
The detrimental effects of contaminants on hydraulic fluid, components, systems, and performance must be understood.  Must know different types and forms of contaminants and their sources.  Must understand fluid sample analysis to determine degree and nature of contamination as a step toward improving fluid cleanliness.
Fluid filtration as an integral step toward cleanliness in fluids.  Important are: filter placement within a system (suction, pressure, and return lines, plus off-line filtration), advantages and disadvantages of each type of filter media, filter construction, and filter ratings and performance. Must understand selection criteria for best fit.



Air Flow throught Pneumatic Valves

Three important areas to an understanding of pneumatic systems:

Gas Dynamics - must understand general gas laws, standard conditions for air, how to run calulations, and gas behavior during compression and expansion.

Flow Rates - must understand the flow of incompressible fluids (liquids), the flow of compressed air, the SCFM concept, and be know how to run calculations.

Valve Pressure Drop - must understand liquid and air valve coefficients, air valve selection, tables to simplify calculations, and know how to run calculations.



Noise in Fluid Power Systems

Different types of noise (airborne, structure-borne, and fluid-borne). Need an understanding of sound pressure, sound level, decibels, the A scale, and harmonics.  The sources of noise may be pumps, motors, and/or valves.  Must know noise control - controlling noise at the source, source isolation, increasing the natural frequency of transmitters, and streamlining and insulating noise sources from their surroundings.



Power Transmission Components

Ballscrews  Bearings (all types)  Belting  Brakes & Clutches  Breathers  Bushings (ball) Chains (roller) Collars Connections (hub & shaft) Controls (motor) Conveyors & Components  Couplers & Couplings Drives (all types) Drum Motors  Encoders  Ends (rod) Expansion Chambers Gears (gear boxes, gear heads) Gib Liners Guides (linear motion) Inverters Isolation Mounts Linear Motion ProductsLinkages & Connecting Rods Locknuts  Lubrication Systems  Motor Controls Motorized Pulleys Motors (brushless DC, electric-all types, gear, induction)  Pulleys Reducers (speed) Relief Vents (pressure/vacuum) SealsSplines Sprockets (all types) Starters (solid state)Switches Tables (positioning)  Timing Devices  Torque Transmission Wear Strips  Winches



Failure Analysis of Gears and Bearings

To prevent additional failures, it is often necessary to understand why something failed.  You need to be able to recognize the various types of failures, normal operating stresses, effects of inadequate lubrication, momentary overloads, and fatique loads. Futhermore, attention should be paid to setting up a failure analysis program.



Establishing a Successful Predictive Maintenance Program (RCM!)

Many decision makers consider predictive maintenance programs too complex and costly. In some cases, this is true.  You must consider the phases, from planning initial concepts and developing cost-benefit analysis to carrying the project to maturity.  You need to understand how a mature program operates and the methods to ensure they meet realistic criteria.



Selecting Servo Technolgy and Applications Correctly

With the wide variety of servos available, it is tempting to select whatever is familiar.  However, that type may not offer the optimum performance or economy.  The application information needed to make decisions must be developed.  An understanding of ac, dc, and vector servo drive technologies with emphasis on adjustment procedures, manual and auto-tuning, and the economic factors must be in place.



Motion Control and Sensor Componenents

Actuators (linear) Amplifiers (servo)  Blocks (terminal) Blowers Controllers Dampers (inertia) Data Acquisition Distributed Control Systems Drivers (step motors)Fans Slides (components & systems) Motors (DC brushless, compact gear, stepper)Measuring Systems Relays Sensors (capacitive, fibre optic, inductive, magnetic, photoelectric, pressure, ultrasonic) Signal Conditioning Software (various and for step motors)  Switches



Electronic Interfacing and Controls

Must have an understanding of analog electrohydraulic controls and basic control loops (with regard to speed control and load disturbances), ability to select sensors relative to speed, torque, pressure, and flow measurements.  Must know control valves with emphasis on proportional and servo-quality proportional valves, and PID control, including control algorithms and proportional, integral, and theoretical derivative control action.



Selecting Electronic Sensors

Must understand the functions and advantages of transducers and how to integrate them into systems.

Types of Transducers - pressure, linear-displacement, rotary, temperature, and other special types.
Application Considerations - electrical interfacing, measurement range, placement within a system, and connections.
Evaluation of selection alternatives by weighing variables to reach an intelligent decision.



Selecting the Right Controller for the Application

Motion control applications vary widely in speed, positioning, coordination, and other parameters.  There is an equally wide choice of control options on the market, from the simple operator's devices to programmable logic controllers and industrial computers.  You must understand how to match a controller to an application's performance and economic constraints.



Selecting Software Solutions / Applications

Pros and Cons of each type of software solutions /applications for consideration. A competitive evaluation of vendors' products and capabilities is part of project assessment and an integral responsibility of the Project Management Executive.

Assessments begin with an evaluation of the type of application, since there are over 100 categories for specifying an MES (Manufacturing Execution System).



Evaluation Areas for Project Management Assessment

System Information
Plant Management
Resource Management
Finite Scheduling
Maintenance Management
Manufacturing / Process

Engineering Management

Process / Manufacturing Simulation
Manufacturability Analysis
Engineering Process Development Tools
Computer-Aided Process Planning & Documentation
Electronic Documentation Management, Delivery
Process Management
SCADA / Supervisory / Cell Control
Recipe and NC Program Management
Computer-Aided Operator Support
Data Collection, Information Management
Man Machine Interface
Quality Management
Quality Documentation
Supplier Management
Process Controls
Inspection and Testing
Laboratory Information Management (LIM)
Non-conformance and Corrective Action
Statistical Analysis
Product Handling and Servicing
Cost of Quality
System Interfaces
System Information
System Information
Manufacturing Environment Intended
Installing Base for System
System Pricing
Platform Options
Client/Server or Distributed Architecture Options
System Environment
Primary Software Language / Software Tools
Network Capability
System Operational Environment
Operating Area
International Language
Input Devices Support
System Interface Options
Electronic Data Interface (EDI)
Data Input Format
Data Export Format
Other Electronic Data Interfaces
Supplier Information
Supplier Information
Total Personnel for MES
Quantity of Personnel Dedicated to following:
Support, Analysis, and Implementation Services


Remember, do it right... or you will be very unhappy!

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