What does production automation include? Industrial automation in Russia: problems, experience, solutions

1. Levels of automation and their distinctive features

Automation of production processes can be carried out at different levels.

Automation has a so-called zero level - if human participation in production is excluded only when performing working moves (spindle rotation, tool feed movement, etc.). This automation was called mechanization. We can say that mechanization is the automation of working moves. It follows that automation involves mechanization.

First-level automation is limited to the creation of devices whose purpose is to eliminate human participation when performing idle movements on individual equipment. This automation is called work cycle automation in serial and flow production.

Idlings in the standard piece time, which determines the complexity of the operation, are taken into account in the form of auxiliary time t in and maintenance time t so:

where t o is the main time, which takes into account the time of working strokes, t o =t p.x ; t during auxiliary time, includes removal and supply of tools, loading of equipment and control; t means maintenance time spent on tool changes, equipment adjustments, waste disposal and management; t org equipment maintenance time; t department – ​​worker’s rest time.

At the first level of automation, working machines are not yet connected to each other by automatic communication. Therefore, transportation and control of the production facility are carried out with human participation. At this level, automatic and semi-automatic machines are created and used. On automatic machines, the work cycle is performed and repeated without human intervention. On semi-automatic machines, human participation is required to perform and repeat the work cycle.

For example, a modern multi-spindle lathe performs turning, drilling, and countersinking. unrolling and cutting threads on a rod workpiece. Such an automatic machine can replace up to 10 universal machines due to automation and combination of idle and working strokes, high concentration of operations.

Second-level automation is the automation of technological processes. At this level, the problems of automation of transportation, control of the production facility, waste disposal and control of machine systems are solved. Automatic lines and flexible production systems (GPS) are created and used as technological equipment.

An automatic line is an automatically operating system of machines installed in a technological sequence and combined by means of transportation, loading, control, management and disposal of waste. For example, a line for processing the drive bevel gear of a car gearbox frees up to 20 workers and pays for itself in three years with an appropriate production program.

An automatic line consists of technological equipment that is configured for a specific type of transport and is connected to it by loading devices (manipulators, trays, lifts). In addition to working positions, the line also includes idle positions, which are necessary for inspection and maintenance of the line.

If the line includes positions with human participation, then the line is called automated.

The third level of automation is comprehensive automation, which covers all stages and links of the production process, from procurement processes to testing and shipping of finished products.

Complex automation requires mastering all previous levels of automation. It is associated with high technical equipment of production and high capital costs. Such automation is effective for fairly large production programs for products of a stable design and a narrow range (production of bearings, individual machine units, electrical equipment elements, etc.).

At the same time, it is complex automation that allows for the development of production as a whole, since it has the greatest efficiency of capital costs. To show the possibilities of such automation, consider 1ZT as an example: a magical plant for the production of automobile frames in the USA. With a production capacity of up to 10,000 frames per day, the plant has a staff of 160 people, which mainly consists of engineers and adjusters. When working without the use of comprehensive automation, at least 12,000 people would be needed to complete the same production program.

At the third level of automation, the tasks of automating the storage and inter-shop transportation of products with automatic addressing, waste processing and production management are solved on the basis of the widespread use of computers. At this level, human participation is reduced to servicing the equipment and keeping it in working order.

2. Development of automation in the direction of technological flexibility and widespread use of computers

Flexible production systems are a set of technological equipment and systems for ensuring its operation in automatic mode during the manufacture of products of varying nomenclature. The development of GPS is moving towards unmanned technology, ensuring the operation of equipment for a given time without the participation of an operator.

For each product, with given requirements for the quantity and quality of products, various versions of GPS can be developed, differing in methods and routes of processing, control and assembly, the degree of differentiation and concentration of technological process operations, types of transport and loading systems, the number of service vehicles (STV), the nature of inter-unit and inter-section connections, design solutions of main and auxiliary mechanisms and devices, principles of building a control system.

The technical level and efficiency of the GPS is determined by such indicators as the quality of products, the performance of the GPS and its reliability, and the structure of the flow of components entering its input. It is with these criteria in mind that tasks such as the choice of the type and quantity of technological equipment, interoperational storage facilities, their capacity and their locations, the number of service operators, the structure and parameters of the transport and warehouse system, etc. must be solved.

Flexible manufacturing systems can be built from interchangeable cells, from complementary cells, or in a mixed way.

The figure shows a diagram of a flexible system of two identical interchangeable machining centers (MCs). Machining centers are served by two transport carts (robocars) that support the movement of material flows (parts, workpieces, tools). Automated control is common. If manual operations are allowed, the operator must be given some freedom of action. The joint work of the OC and the transport system is controlled from the central computer.

In general, robocars are controlled from a central computer through an intermediate device or from a local control system (LCS). Commands can be transmitted to robotic vehicles only at stops that divide traffic routes into zones. The computer allows only one robotic vehicle to remain in a specific area. The maximum movement speed can reach 1 m/s.

The upper part of the robotic vehicle can be raised and lowered using a hydraulic drive to perform reloading, unloading and loading operations. If control from the computer fails or is disconnected, the robocar can be controlled by the LCS.

There are various options for robocars used as vehicles in GPS. The most common option is when the robotic car moves along a track (route, route) or other structure laid in the floor or on its surface. One of the tracing options is that a track in the form of a strip (fluorescent, reflective, white with black edging) is applied to the floor surface, and route tracking is carried out using optoelectronic methods. The disadvantage is the need to monitor the cleanliness of the strip. Therefore, it is more common to trace robocars with an inductive conductor laid in a groove at a shallow depth (about 20 mm). Other interesting solutions are also known - using, for example, television navigation equipment for free movement in space under computer control.

The source of supplying the robotic vehicles with material flows is an automated warehouse with stackers that provide targeted access to any warehouse cell. The warehouse itself is a rather complex management object.

Programmable controllers, computers, or specialized devices are used as its control system.

The most common robocars with inductive route tracking have the following characteristics: load capacity - 500 kg; moving speed - 70 m/min; acceleration during acceleration and braking, respectively - 0.5 and 0.7 m/s 2 ; acceleration during emergency braking 2.5 m/s 2 ; pallet lifting value - 130 mm; robotic car stopping accuracy - 30 mm; overload cycle time - 3 s; turning radius at maximum speed - 0.9 m; operating time without recharging batteries - 6 hours; battery voltage - 24V; the power of each of the two drive motors is 600 W; The robocar's own weight is 425 kg.

An important advantage of robocars as vehicles is the absence of any serious restrictions on the arrangement of equipment, which can be carried out for reasons of greatest efficiency according to any criteria. The robocar route often turns out to be quite complex, with parallel branches and loops.

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 design 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 a process of complete mechanization - a production process in which a person does not expend physical strength to perform operations.

As technology developed, the functions of controlling processes and machines expanded and became more complex. In many cases, humans were no longer able to manage mechanized production without special additional devices. This led to the emergence of automated production, in which workers are freed not only from physical labor, but also from the functions of monitoring and managing machines, equipment, production processes and operations.

Automation of production processes is understood as 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 basic operations without direct human participation.

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

In the 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, saving labor and money.

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

To improve efficiency, they must cover a larger number of heterogeneous operations;

A thorough study of the technology is required, analysis of production facilities, traffic routes and operations, ensuring 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 clear and 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 one 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. its production should require a minimum amount of materials, time and money;

Unification of product processing and control methods;

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-operation technology. The number of intermediate processing operations of raw materials and semi-finished products should be minimized, and their supply routes should be optimized.

3. The principle of low-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, increase the reliability of equipment and information support for the process.

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

5. The principle of optimality. All management objects and production services are subject to a single optimality criterion, 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 modular equipment with interoperational tanks. Depending on the product being processed, this equipment can be adjusted.

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 filling liquids into bottles or bags.

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

Depending on the intermediate transport, automated production can be:

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

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

With intermediate capacity.

Automated production is distinguished by types of equipment layout (aggregation):

Single-threaded;

Parallel aggregation;

Multi-threaded.

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

In 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 the slaughter of livestock or the removal of fruits from trees. This requires equipment that has high mobility (the ability to produce a wide range of products from the same type of raw materials and process different types of raw materials using the same type of equipment).

For this purpose, 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 process automation tools, operating autonomously and having the ability to be integrated into a higher-level system (Fig. 1.1).

Figure 1.1 – 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, an instrumentation system, a locally controlled handling and transport system, or a mixing plant with similar additional equipment.

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

Figure 1.2 – Structure of a production cell: 1- equipment to perform one or more operations; 2- receiving hopper; 3-loading and unloading device; 4- conveyor; 5 - intermediate container; 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 warehouse 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 Fig. 1.3.

In contrast to an automated line, a reconfigurable automated section allows for the possibility of changing the sequence of use of technological equipment. A line and a section may have separately functioning units of technological equipment. The structure of the automated section is shown in Fig. 1.4.

Figure 1.3 – 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.

1. Features of designing technological processes in automated production conditions

The basis of production automation is technological processes (TP), which should ensure high productivity, reliability, quality and efficiency of product manufacturing.

A characteristic feature of technological processing and assembly is the strict orientation of parts and tools relative to each other in the work process (the first class of processes). Heat treatment, drying, painting, etc., unlike processing and assembly, do not require strict orientation of the part (the second class of processes).

TPs are classified according to continuity into discrete and continuous.

The development of TP AP in comparison with manual production technology has its own specifics:

1. Automated technological processes include not only various operations of machining by cutting, but also pressure processing, heat treatment, assembly, control, packaging, as well as transport, storage and other operations.

2. Requirements for flexibility and automation of production processes dictate the need for a comprehensive and detailed study of technology, a thorough analysis of production facilities, development of route and operational technology, ensuring reliability and flexibility of the process of manufacturing products with a given quality.

3.With a wide range of products, technological solutions are multivariate.

4.The degree of integration of work performed by various technological departments is increasing.

Basic principles for constructing machining technology in APS

1.The principle of completeness . You should strive to perform all operations within one APS without intermediate transfer of semi-finished products to other divisions or auxiliary departments.

2.The principle of low-operation technology. Formation of technological processes with the maximum possible consolidation of operations, with a minimum number of operations and installations in operations.

3.The principle of “low-crowd” technology. Ensuring automatic operation of the APS throughout the entire production cycle.

4.The principle of “non-debugging” technology . Development of technological processes that do not require debugging at work positions.

5.The principle of active-controlled technology. Organization of process management and correction of design decisions based on working information about the progress of the process. Both technological parameters formed at the management stage and the initial parameters of technological preparation of production (TPP) can be adjusted.

6.Optimality principle . Decision-making at each stage of TPP and TPP management based on a single optimality criterion.

In addition to those discussed, other principles are also characteristic of APS technology: computer technology, information security, integration, paperless documentation, group technology.

2. Standard and group TP

Typification of technological processes for groups of parts that are similar in configuration and technological features provides for their manufacture using the same technological process, based on the use of the most advanced processing methods and ensuring the achievement of the highest productivity, efficiency and quality. The basis of typification is the rules for processing individual elementary surfaces and the rules for assigning the order of processing of these surfaces. Typical TPs are used mainly in large-scale and mass production.

The principle of group technology underlies the technology of reconfigurable production - small- and medium-scale production. In contrast to the typification of TP, with group technology, a common feature is the commonality of the processed surfaces and their combinations. Therefore, group processing methods are typical for processing parts with a wide range.

Both the typification of technological processes and the group technology method are the main directions for the unification of technological solutions, increasing production efficiency.

Classification of parts

Classification is carried out in order to determine groups of technologically homogeneous parts for their joint processing in group production conditions. It is carried out in two stages: primary classification, i.e. coding of parts of the production being examined according to design and technological characteristics; secondary classification, i.e. grouping of parts with the same or slightly different classification characteristics.

When classifying parts, the following characteristics must be taken into account: structural - overall dimensions, weight, material, type of processing and workpiece; number of processing operations; accuracy and other indicators.

Grouping of parts is carried out in the following sequence: selection of a set of parts at the class level, for example, a body of revolution for machining production; selecting a set of parts at the subclass level, for example, a shaft type part; classification of parts by combination of surfaces, for example shafts with a combination of smooth cylindrical surfaces; grouping by overall dimensions with highlighting areas with maximum density of size distribution; Determination from the diagram of areas with the largest number of part names.

Manufacturability of product designs for accident conditions

The design of a product is considered technologically advanced if its manufacture and operation require minimal costs of materials, time and money. Assessment of manufacturability is carried out according to qualitative and quantitative criteria separately for workpieces, machined parts, and assembly units.

Parts to be processed in AM must be technologically advanced, that is, simple in shape, dimensions, consist of standard surfaces and have a maximum material utilization rate.

Parts to be assembled must have as many standard joint surfaces as possible, the simplest elements of orientation of assembly units and parts.

3. Features of designing technological processes for manufacturing parts on automatic lines and CNC machines

An automatic line is a continuously operating complex of interconnected equipment and a control system, where complete time synchronization of operations and transitions is necessary. The most effective methods of synchronization are concentration and differentiation of TP.

Differentiation of the technological process, simplification and synchronization of transitions are necessary conditions for reliability and productivity. Excessive differentiation leads to more complex service equipment, an increase in area and volume of service. An appropriate concentration of operations and transitions, without practically reducing productivity, can be achieved through aggregation and the use of multi-tool setups.

To synchronize work in an automatic line (AL), a limiting tool, a limiting machine and a limiting section are determined, according to which the real AL release cycle (min) is established according to the formula

Where F - actual equipment operating fund, h; N- release program, pcs.

To ensure high reliability, the AL is divided into sections that are connected to each other through drives that provide so-called flexible communication between sections, ensuring independent operation of adjacent sections in the event of a failure in one of them. A rigid connection is maintained within the area. For rigidly coupled equipment, it is important to plan the timing and duration of planned shutdowns.

CNC machines provide high precision and quality products and can be used when processing complex parts with precise stepped or curved contours. This reduces the cost of processing, qualifications and the number of service personnel. Features of processing parts on CNC machines are determined by the features of the machines themselves and, first of all, their CNC systems, which provide:

1) reduction of setup and changeover time of equipment; 2)increasing complexity of processing cycles; 3) the possibility of implementing cycle moves with a complex curvilinear trajectory; 4) the possibility of unifying the control systems (CS) of machine tools with the control systems of other equipment; 5) the possibility of using a computer to control CNC machines included in the APS.

Basic requirements for the technology and organization of machining in reconfigurable APS using the example of manufacturing basic standard parts

The development of technology in APS is characterized by an integrated approach - a detailed study of not only the main, but also auxiliary operations and transitions, including transportation of products, their control, warehousing, testing, and packaging.

To stabilize and increase the reliability of processing, two main methods for constructing TP are used:

1) the use of equipment that provides reliable processing with almost no operator intervention;

2) regulation of technological process parameters based on control of products during the process itself.

To increase flexibility and efficiency, APS uses the principle of group technology.

4. Features of the development of TP for automated and robotic assembly

Automated assembly of products is carried out on assembly machines and AL. An important condition for the development of a rational TP for automated assembly is the unification and normalization of connections, i.e., bringing them to a certain nomenclature of types and accuracies.

The main difference between robotic production is the replacement of assemblers with assembly robots and control by control robots or automatic control devices.

Robotic assembly should be carried out according to the principle of complete interchangeability or (less often) according to the principle of group interchangeability. The possibility of adjustment and adjustment is excluded.

Assembly operations should progress from simple to complex. Depending on the complexity and dimensions of the products, the form of assembly organization is chosen: stationary or conveyor. The composition of the RTK is assembly equipment and devices, a transport system, operational assembly robots, control robots, and a control system.

Automation of production processes is the main direction along which production is currently moving throughout the world. Everything that was previously performed by man himself, his functions, not only physical, but also intellectual, are gradually transferred to technology, which itself carries out technological cycles and controls them. This is now the general direction of modern technology. The role of a person in many industries is already reduced to only a controller behind an automatic controller.

In general, the concept of “technological process control” is understood as a set of operations necessary to start, stop the process, as well as maintain or change in the required direction physical quantities (process indicators). Individual machines, units, devices, devices, complexes of machines and devices that carry out technological processes that need to be controlled are called control objects or controlled objects in automation. Managed objects are very diverse in their purpose.

Automation of technological processes– replacement of human physical labor spent on controlling mechanisms and machines with the work of special devices that ensure this control (regulation of various parameters, obtaining a given productivity and product quality without human intervention).

Automation of production processes makes it possible to increase labor productivity many times over, increase its safety, environmental friendliness, improve product quality and make more efficient use of production resources, including human potential.

Any technological process is created and carried out to achieve a specific goal. Manufacturing the final product, or to obtain an intermediate result. Thus, the purpose of automated production can be sorting, transportation, and packaging of a product. Automation of production can be complete, complex or partial.

Partial automation occurs when one operation or a separate production cycle is carried out automatically. At the same time, limited human participation in it is allowed. Most often, partial automation occurs when the process proceeds too quickly for the person himself to fully participate in it, while fairly primitive mechanical devices driven by electrical equipment cope well with it.

Partial automation, as a rule, is used on existing equipment and is an addition to it. However, it shows the greatest efficiency when it is included in the overall automation system from the very beginning - it is immediately developed, manufactured and installed as its component part.

Comprehensive automation should cover a separate large production area, this could be a separate workshop or power plant. In this case, the entire production operates in the mode of a single interconnected automated complex. Complex automation of production processes is not always advisable. Its field of application is modern highly developed production, which uses extremelyreliable equipment.

The breakdown of one of the machines or units immediately stops the entire production cycle. Such production must have self-regulation and self-organization, which is carried out according to a previously created program. In this case, a person takes part in the production process only as a permanent controller, monitoring the state of the entire system and its individual parts, and intervenes in production for start-up and when emergency situations arise, or when there is a threat of such an occurrence.

The highest level of automation of production processes – full automation. With it, the system itself carries out not only the production process, but also complete control over it, which is carried out by automatic control systems. Full automation is advisable in cost-effective, sustainable production with established technological processes with a constant operating mode.

All possible deviations from the norm must be previously foreseen, and systems for protecting against them must be developed. Full automation is also necessary for work that may threaten human life, his health, or is carried out in places inaccessible to him - under water, in an aggressive environment, in space.

Each system consists of components that perform specific functions. In an automated system, sensors take readings and transmit them to make a decision on system control; the command is carried out by the drive. Most often this is electrical equipment, since it is more expedient to carry out commands with the help of electric current.

It is necessary to distinguish between automated control systems and automatic ones. At automated control system the sensors transmit readings to the operator’s console, and he, having made a decision, transmits the command to the executive equipment. At automatic system– the signal is analyzed by electronic devices, and after making a decision, they give a command to the executing devices.

Human participation in automatic systems is still necessary, albeit as a controller. He has the ability to intervene in the technological process at any time, correct it or stop it.

So, the temperature sensor may fail and give incorrect readings. In this case, electronics will perceive its data as reliable without questioning it.

The human mind is many times superior to the capabilities of electronic devices, although it is inferior to them in terms of response speed. The operator can understand that the sensor is faulty, assess the risks, and simply turn it off without interrupting the process. At the same time, he must be completely confident that this will not lead to an accident. Experience and intuition, which are inaccessible to machines, help him make a decision.

Such targeted intervention in automatic systems does not carry any serious risks if the decision is made by a professional. However, turning off all automation and switching the system to manual control mode is fraught with serious consequences due to the fact that a person cannot quickly respond to changing conditions.

A classic example is the accident at the Chernobyl nuclear power plant, which became the largest man-made disaster of the last century. It occurred precisely because the automatic mode was turned off, when the already developed programs to prevent emergency situations could not influence the development of the situation in the plant’s reactor.

Automation of individual processes began in industry back in the nineteenth century. Suffice it to recall the automatic centrifugal regulator for steam engines designed by Watt. But only with the beginning of the industrial use of electricity did wider automation, not of individual processes, but of entire technological cycles, become possible. This is due to the fact that previously mechanical force was transmitted to machines using transmissions and drives.

Centralized production of electricity and its use in industry, by and large, began only in the twentieth century - before the First World War, when each machine was equipped with its own electric motor. It was this circumstance that made it possible to mechanize not only the production process on the machine, but also to mechanize its control. This was the first step towards creating automatic machines. The first samples of which appeared in the early 1930s. Then the term “automated production” itself arose.

In Russia - then still in the USSR - the first steps in this direction were taken in the 30-40s of the last century. For the first time, automatic machines were used in the production of bearing parts. Then came the world's first fully automated production of pistons for tractor engines.

Technological cycles were combined into a single automated process, starting with the loading of raw materials and ending with the packaging of finished parts. This became possible thanks to the widespread use of modern electrical equipment at that time, various relays, remote switches, and of course, drives.

And only the advent of the first electronic computers made it possible to reach a new level of automation. Now the technological process has ceased to be considered as simply a collection of individual operations that must be performed in a certain sequence to obtain a result. Now the whole process has become one.

Currently, automatic control systems not only conduct the production process, but also control it and monitor the occurrence of abnormal and emergency situations. They start and stop technological equipment, monitor overloads, and work out actions in case of accidents.

Recently, automatic control systems have made it quite easy to rebuild equipment to produce new products. This is already a whole system, consisting of separate automatic multi-mode systems connected to a central computer, which links them into a single network and issues tasks for execution.

Each subsystem is a separate computer with its own software designed to perform its own tasks. It's already flexible production modules. They are called flexible because they can be reconfigured for other technological processes and thereby expand production and diversify it.

The pinnacle of automated production is. Automation has permeated production from top to bottom. The transport line for the delivery of raw materials for production operates automatically. Automated management and design. Human experience and intelligence are used only where electronics cannot replace it.

Automation of production processes lies in the fact that part of the functions of management, regulation and control of technological complexes is carried out not by people, but by robotic mechanisms and information systems. In fact, it can be called the main production idea of ​​the 21st century.

Principles

At all levels of the enterprise, the principles of automation of production processes are the same and uniform, although they differ in the scale of the approach to solving technological and management problems. These principles ensure that the required work is carried out efficiently and automatically.

The principle of consistency and flexibility

All activities within a single computerized system must be coordinated with each other and with similar positions in related areas. Full automation of operational, production and technological processes is achieved due to the commonality of the operations performed, recipes, schedules and the optimal combination of techniques. Failure to comply with this principle will compromise the flexibility of production and the integrated execution of the entire process.

Features of flexible automated technologies

The use of flexible production systems is a key trend in modern automation. As part of their action, technological optimization is carried out due to the coordinated operation of all system elements and the ability to quickly replace tools. The methods used make it possible to effectively rebuild existing complexes to new principles without significant costs.

Creation and structure

Depending on the level of production development, automation flexibility is achieved through the coordinated and integrated interaction of all system elements: manipulators, microprocessors, robots, etc. Moreover, in addition to mechanized production of products, transport, warehouse and other divisions of the enterprise are involved in these processes.

The principle of completeness

An ideal automated production system should be a complete cyclic process without intermediate transfer of products to other departments. High-quality implementation of this principle is ensured by:

• multifunctionality of the equipment, which allows processing several types of raw materials at once in one unit of time;
• the manufacturability of the manufactured product by reducing the required resources;
• unification of production methods;
• a minimum of additional adjustment work after the equipment is put into operation.

The principle of comprehensive integration

The degree of automation depends on the interaction of production processes with each other and with the outside world, as well as on the speed of integration of a particular technology into the overall organizational environment.

Independent Execution Principle

Modern automated systems operate on the principle: “Don’t interfere with the machine’s work.” In fact, all processes during the production cycle must be carried out without human intervention, with only minimal human control allowed.

Objects

You can automate production in any field of activity, but computerization works most effectively in complex monotonous processes. Such operations occur in:

• light and heavy industry;
• fuel and energy complex;
• agriculture;
• trade;
• medicine, etc.

Mechanization helps in technical diagnostics, scientific and research activities within a separate enterprise.

Goals

The introduction of automated tools in production that can improve technological processes is a key guarantee of progressive and efficient work. The key goals of automation of production processes include:

• staff reduction;
• increasing labor productivity due to maximum automation;
• expansion of the product line;
• growth in production volumes;
• improving the quality of goods;
• reduction of the consumption component;
• creation of environmentally friendly production by reducing harmful emissions into the atmosphere;
• introduction of high technologies into the regular production cycle with minimal costs;
• increasing the safety of technological processes.

When these goals are achieved, the enterprise receives a lot of benefits from the implementation of mechanized systems and recoups the costs of automation (subject to stable demand for products).

High-quality implementation of the assigned mechanization tasks is determined by the implementation of:

• modern automated tools;
• individually developed computerization methods.

The degree of automation depends on the integration of innovative equipment into the existing technological chain. The level of implementation is assessed individually depending on the characteristics of a particular production.

Components

The following elements are considered as part of a unified automated production environment at the enterprise:

• design systems used to develop new products and technical documentation;
• machines with program control based on microprocessors;
• industrial robotic complexes and technological robots;
• computerized quality control system at the enterprise;
• technologically advanced warehouses with special lifting and transport equipment;
• general automated production control system (APCS).

Strategy

Compliance with an automation strategy helps to improve the entire range of necessary processes and obtain maximum benefits from the implementation of computer systems in the enterprise. Only those processes that have been fully studied and analyzed can be automated, since the program developed for the system must include different variations of one action depending on environmental factors, the amount of resources and the quality of execution of all stages of production.

After defining the concept, studying and analyzing technological processes, the turn of optimization comes. It is necessary to qualitatively simplify the structure by removing from the system processes that do not bring any value. If possible, you need to reduce the number of actions performed by combining some operations into one. The simpler the structural order, the easier it is to computerize it. After simplifying the systems, you can begin to automate production processes.

Design

Design is a key stage in the automation of production processes, without which it is impossible to introduce comprehensive mechanization and computerization in production. Within its framework, a special diagram is created that displays the structure, parameters and key characteristics of the devices used. The scheme typically consists of the following points:

1. scale of automation (described separately for the entire enterprise and for individual production departments);
2. determination of control parameters for the operation of devices, which will subsequently act as verification markers;
3. description of control systems;
4. configuration of the location of automated means;
5. information about equipment blocking (in what cases it is applicable, how and by whom it will be launched in the event of an emergency).

Classification

There are several classifications of enterprise computerization processes, but it is most effective to separate these systems depending on their degree of implementation in the overall production cycle. On this basis, automation can be:

• partial;
• complex;
• complete.

These varieties are just levels of production automation, which depend on the size of the enterprise and the volume of technological work.

Partial automation is a set of operations to improve production, within which one action is mechanized. It does not require the formation of a complex management complex and complete integration of related systems. At this level of computerization, human participation is allowed (not always to a limited extent).

Comprehensive automation allows you to optimize the work of a large production unit in a single complex mode. Its use is justified only within a large innovative enterprise, where the most reliable equipment is used, since the breakdown of even one machine risks stopping the entire working line.

Full automation is a set of processes that ensure independent operation of the entire system, incl. Production Management. Its implementation is the most expensive, so this system is used in large enterprises in conditions of profitable and stable production. At this stage, human participation is minimized. Most often it consists of monitoring the system (for example, checking sensor readings, troubleshooting minor problems, etc.).

Advantages

Automated processes increase the speed of cyclic operations, ensure their accuracy and safety, regardless of environmental factors. By eliminating the human factor, the number of possible errors is reduced and the quality of work is improved. In case of typical situations, the program remembers the algorithm of actions and applies it with maximum efficiency.

Automation allows you to increase the accuracy of managing business processes in production by covering a large amount of information, which is simply impossible in the absence of mechanization. Computerized equipment can perform several technological operations simultaneously without compromising the quality of the process and the accuracy of calculations.

The concept of process automation is inextricably linked with the global technological process. Without the introduction of computerization systems, the modern development of individual departments and the entire enterprise as a whole is impossible. Mechanization of production makes it possible to most effectively improve the quality of finished products, expand the range of types of goods offered and increase production volume.