Industrial Automation: Hands On

369 Pages·2013·4.87 MB·English

by  Frank Lamb

Industrial Automation
About the Author
Frank Lamb has nearly 30 years of experience in the electrical and
electronics industry and 20 years of experience in controls and
automation. In 1996, he started Automation Consulting Services, Inc.,
an automation and systems integration company in Knoxville,
Tennessee, concentrating on controls and panel building. In 2002,
Automation Consulting Services began building smaller machines
on-site and working with companies to install production lines.
Mr. Lamb developed a multipurpose assembly and mistake-proofing
machine known as the “SmartBench.” His company now focuses on
automation and Lean/Six-Sigma-oriented training and consulting.
Industrial Automation
Hands-On
Frank Lamb
New York Chicago San Francisco
Lisbon London Madrid Mexico City
Milan New Delhi San Juan
Seoul Singapore Sydney Toronto
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Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
1 Automation and Manufacturing . . . . . . . . . . . . . . . . . . 1
1.1 Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Advantages . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.2 Disadvantages . . . . . . . . . . . . . . . . . . . . . . 2
1.1.3 The Factory and Manufacturing . . . . . . . 3
1.1.4 The Manufacturing Environment . . . . . 6
2 Important Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Analog and Digital . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.1 Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Input and Output (Data) . . . . . . . . . . . . . . . . . . 11
2.2.1 Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.2 Analog I/O . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.3 Communications . . . . . . . . . . . . . . . . . . . 15
2.2.4 Other Types of I/O . . . . . . . . . . . . . . . . . 21
2.3 Numbering Systems . . . . . . . . . . . . . . . . . . . . . . 22
2.3.1 Binary and BOOL . . . . . . . . . . . . . . . . . . 22
2.3.2 Decimal . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3.3 Hexadecimal and Octal . . . . . . . . . . . . . 22
2.3.4 Floating Point and REAL . . . . . . . . . . . . 24
2.3.5 Bytes and Words . . . . . . . . . . . . . . . . . . . 24
2.3.6 ASCII . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4.1 Frequency . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4.2 Voltage, Current, and Resistance . . . . . 25
2.4.3 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4.4 Phase and Voltages . . . . . . . . . . . . . . . . . 27
2.4.5 Inductance and Capacitance . . . . . . . . . 28
2.4.6 Solid-State Devices . . . . . . . . . . . . . . . . . 29
2.4.7 Integrated Circuits . . . . . . . . . . . . . . . . . 31
2.5 Pneumatics and Hydraulics . . . . . . . . . . . . . . . 32
2.5.1 Pneumatics . . . . . . . . . . . . . . . . . . . . . . . 33
2.5.2 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5.3 Pneumatic-Hydraulic Comparison . . . 35
v
vi Contents
2.6 Continuous, Synchronous, and Asynchronous
Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6.1 Continuous Processes . . . . . . . . . . . . . . 36
2.6.2 Asynchronous Processes . . . . . . . . . . . . 36
2.6.3 Synchronous Processes . . . . . . . . . . . . . 36
2.7 Documentation and File Formats . . . . . . . . . . . 36
2.7.1 Drafting and CAD . . . . . . . . . . . . . . . . . 37
2.7.2 Other Design Packages and
Standards . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.7.3 Image File Formats . . . . . . . . . . . . . . . . . 42
2.8 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.8.1 Hazard Analysis . . . . . . . . . . . . . . . . . . . 47
2.8.2 Emergency Stops . . . . . . . . . . . . . . . . . . 48
2.8.3 Physical Guarding . . . . . . . . . . . . . . . . . 51
2.8.4 Lockout/Tagout . . . . . . . . . . . . . . . . . . . 51
2.8.5 Design Mitigation . . . . . . . . . . . . . . . . . . 53
2.8.6 Guard Devices . . . . . . . . . . . . . . . . . . . . . 53
2.8.7 Software . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.8.8 Intrinsic Safety . . . . . . . . . . . . . . . . . . . . 56
2.9 Overall Equipment Effectiveness . . . . . . . . . . . 57
2.9.1 Availability . . . . . . . . . . . . . . . . . . . . . . . 58
2.9.2 Performance . . . . . . . . . . . . . . . . . . . . . . 58
2.9.3 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.9.4 Calculating OEE . . . . . . . . . . . . . . . . . . . 59
2.10 Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . 60
3 Components and Hardware . . . . . . . . . . . . . . . . . . . . . 61
3.1 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1.1 Computers . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1.2 Distributed Control Systems
(DCSs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1.3 Programmable Logic Controllers
(PLCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1.4 Embedded Controllers and
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Operator Interfaces . . . . . . . . . . . . . . . . . . . . . . . 65
3.2.1 Text-Based Interfaces . . . . . . . . . . . . . . . 66
3.2.2 Graphical Interfaces . . . . . . . . . . . . . . . . 66
3.2.3 Touch screens . . . . . . . . . . . . . . . . . . . . . 67
3.3 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.3.1 Discrete Devices . . . . . . . . . . . . . . . . . . . 70
3.3.2 Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3.3 Special Purpose Sensors . . . . . . . . . . . . 84
3.4 Power Control, Distribution, and Discrete
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Contents vii
3.4.1 Disconnects, Circuit Breakers, and
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.4.2 Distribution and Terminal Blocks . . . . 98
3.4.3 Transformers and Power Supplies . . . 100
3.4.4 Relays, Contactors, and Starters . . . . . 102
3.4.5 Timers and Counters . . . . . . . . . . . . . . 104
3.4.6 Push Buttons, Pilot Lights, and
Discrete Controls . . . . . . . . . . . . . . . . . 107
3.4.7 Cabling and Wiring . . . . . . . . . . . . . . . 110
3.5 Actuators and Movement . . . . . . . . . . . . . . . . 115
3.5.1 Pneumatic and Hydraulic Actuators
and Valves . . . . . . . . . . . . . . . . . . . . . . . 115
3.5.2 Electric Actuators . . . . . . . . . . . . . . . . . 119
3.5.3 Motion Control . . . . . . . . . . . . . . . . . . . 119
3.6 AC and DC Motors . . . . . . . . . . . . . . . . . . . . . . 121
3.6.1 AC Motors . . . . . . . . . . . . . . . . . . . . . . . 122
3.6.2 DC Motors . . . . . . . . . . . . . . . . . . . . . . . 126
3.6.3 Linear Motors . . . . . . . . . . . . . . . . . . . . 129
3.6.4 Servomotors and Stepper Motors . . . 129
3.6.5 Variable Frequency Drives . . . . . . . . . 132
3.7 Mechanisms and Machine Elements . . . . . . . 134
3.7.1 Cam-Driven Devices . . . . . . . . . . . . . . 135
3.7.2 Ratchet and Pawl Systems . . . . . . . . . 136
3.7.3 Gearing and Gear Reduction . . . . . . . 136
3.7.4 Bearings and Pulleys . . . . . . . . . . . . . . 141
3.7.5 Servomechanisms . . . . . . . . . . . . . . . . . 143
3.7.6 Ball Screws and Belt-Driven Linear
Actuators . . . . . . . . . . . . . . . . . . . . . . . . 144
3.7.7 Linkages and Couplings . . . . . . . . . . . 145
3.7.8 Clutches and Brakes . . . . . . . . . . . . . . . 147
3.8 Structure and Framing . . . . . . . . . . . . . . . . . . . 148
3.8.1 Steel Framing . . . . . . . . . . . . . . . . . . . . 148
3.8.2 Aluminum Extrusion . . . . . . . . . . . . . . 153
3.8.3 Piping and Other Structural
Systems . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.8.4 Electrical Enclosures and Ratings . . . 154
4 Machine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.1 Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.1.1 Belt Conveyors . . . . . . . . . . . . . . . . . . . 166
4.1.2 Roller Conveyors . . . . . . . . . . . . . . . . . 167
4.1.3 Chain and Mat Conveyors . . . . . . . . . 169
4.1.4 Vibrating Conveyors . . . . . . . . . . . . . . 170
4.1.5 Pneumatic Conveyors . . . . . . . . . . . . . 171
4.1.6 Accessories . . . . . . . . . . . . . . . . . . . . . . 171
viii Contents
4.2 Indexers and Synchronous Machines . . . . . . 172
4.2.1 Rotary Cam Indexers . . . . . . . . . . . . . . 172
4.2.2 Synchronous Chassis Pallet
Indexers . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.2.3 Walking Beams . . . . . . . . . . . . . . . . . . . 173
4.2.4 Pick-and-Place . . . . . . . . . . . . . . . . . . . . 174
4.3 Part Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.3.1 Vibratory Bowls and Feeders . . . . . . . 175
4.3.2 Step and Rotary Feeders . . . . . . . . . . . 176
4.3.3 Escapements and Parts Handling . . . 177
4.4 Robots and Robotics . . . . . . . . . . . . . . . . . . . . . 178
4.4.1 Articulated Robots . . . . . . . . . . . . . . . . 178
4.4.2 SCARA Robots . . . . . . . . . . . . . . . . . . . 179
4.4.3 Cartesian Robots . . . . . . . . . . . . . . . . . . 180
4.4.4 Parallel Robots . . . . . . . . . . . . . . . . . . . 180
4.4.5 Robot Basics and Terminology . . . . . . 181
4.4.6 Robot Coordinate Systems . . . . . . . . . 184
5 Process Systems and Automated Machinery . . . . . 185
5.1 Chemical Processing . . . . . . . . . . . . . . . . . . . . 186
5.2 Food and Beverage Processing . . . . . . . . . . . . 187
5.3 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
5.4 Web Handling and Converting . . . . . . . . . . . 190
5.5 Metal, Plastic, Ceramic, and Glass
Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.5.1 Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.5.2 Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.5.3 Ceramics and Glass . . . . . . . . . . . . . . . 206
5.6 Assembly Machines . . . . . . . . . . . . . . . . . . . . . 208
5.6.1 Part Handling . . . . . . . . . . . . . . . . . . . . 208
5.6.2 Fastening and Joining . . . . . . . . . . . . . 210
5.6.3 Other Assembly Operations . . . . . . . . 213
5.7 Inspection and Test Machines . . . . . . . . . . . . . 214
5.7.1 Gauging and Measurement . . . . . . . . 214
5.7.2 Leak and Flow Testing . . . . . . . . . . . . . 214
5.7.3 Other Testing Methods . . . . . . . . . . . . 217
6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.1 Programming Software . . . . . . . . . . . . . . . . . . 219
6.1.1 Programming Concepts . . . . . . . . . . . . 220
6.1.2 Programming Methodologies . . . . . . . 221
6.1.3 Languages . . . . . . . . . . . . . . . . . . . . . . . 225
6.2 Design Software . . . . . . . . . . . . . . . . . . . . . . . . 240
6.3 Analysis Software . . . . . . . . . . . . . . . . . . . . . . . 240
6.4 Offi ce Software . . . . . . . . . . . . . . . . . . . . . . . . . 241
6.5 SCADA and Data Acquisition . . . . . . . . . . . . 242
Contents ix
6.6 Databases and Database Programming . . . . 243
6.7 Enterprise Software . . . . . . . . . . . . . . . . . . . . . 245
7 Occupations and Trades . . . . . . . . . . . . . . . . . . . . . . . 251
7.1 Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
7.1.1 Mechanical . . . . . . . . . . . . . . . . . . . . . . . 252
7.1.2 Electrical and Controls . . . . . . . . . . . . . 252
7.1.3 Industrial and Manufacturing
Engineering . . . . . . . . . . . . . . . . . . . . 253
7.1.4 Chemical and Chemical Process
Engineers . . . . . . . . . . . . . . . . . . . . . . . . . . 254
7.1.5 Other Engineering Disciplines and
Job Titles . . . . . . . . . . . . . . . . . . . . . . . . . 255
7.2 Trades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7.2.1 Mechanical . . . . . . . . . . . . . . . . . . . . . . . 257
7.2.2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 260
8 Industrial and Factory Business Systems . . . . . . . . 263
8.1 Automation-Related Businesses . . . . . . . . . . . 263
8.1.1 Manufacturers . . . . . . . . . . . . . . . . . . . . 263
8.1.2 OEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
8.1.3 Manufacturers’ Representatives . . . . . 264
8.1.4 Distributors . . . . . . . . . . . . . . . . . . . . . . 264
8.1.5 Machine Builders . . . . . . . . . . . . . . . . . 264
8.1.6 Systems Integrators . . . . . . . . . . . . . . . 265
8.1.7 Consultants . . . . . . . . . . . . . . . . . . . . . . 265
8.2 Departments and Functions . . . . . . . . . . . . . . 265
8.2.1 Management . . . . . . . . . . . . . . . . . . . . . 266
8.2.2 Sales and Marketing . . . . . . . . . . . . . . . 267
8.2.3 Engineering and Design . . . . . . . . . . . 267
8.2.4 Maintenance . . . . . . . . . . . . . . . . . . . . . 268
8.2.5 Manufacturing and Production . . . . . 269
8.2.6 Finance and Human Resources . . . . . 270
8.2.7 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . 271
8.2.8 Information Technology . . . . . . . . . . . 273
8.3 Lean Manufacturing . . . . . . . . . . . . . . . . . . . . . 273
8.3.1 Kanban and “Pull” . . . . . . . . . . . . . . . . 275
8.3.2 Kaizen . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
8.3.3 Poka-Yoke . . . . . . . . . . . . . . . . . . . . . . . 277
8.3.4 Tools and Terms . . . . . . . . . . . . . . . . . . 278
8.4 Systemization . . . . . . . . . . . . . . . . . . . . . . . . . . 281
8.4.1 Job and Task Descriptions . . . . . . . . . . 282
8.4.2 Communications . . . . . . . . . . . . . . . . . . 283
8.4.3 Hiring and Training . . . . . . . . . . . . . . . 284
8.4.4 Engineering and Project
Notebooks . . . . . . . . . . . . . . . . . . . . . . . 285