Wednesday, March 31, 2010

Automating Manufacturing Systems with PLCs





Automating manufacturing is the use of control systems such as computers to control industrial machinery and processes, replacing human operators. In the scope of industrialization, it is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the physical requirements of work, automation greatly reduces the need for human sensory and mental requirements as well.

PLCs are well-adapted to a range of automation tasks. These are typically industrial processes in manufacturing where the cost of developing and maintaining the automation system is high relative to the total cost of the automation, and where changes to the system would be expected during its operational life. PLCs contain input and output devices compatible with industrial pilot devices and controls; little electrical design is required, and the design problem centers on expressing the desired sequence of operations.

PLC applications are typically highly customized systems so the cost of a packaged PLC is low compared to the cost of a specific custom-built controller design. On the other hand, in the case of mass-produced goods, customized control systems are economic due to the lower cost of the components, which can be optimally chosen instead of a "generic" solution, and where the non-recurring engineering charges are spread over thousands or millions of units.

The main advantage of the automated manufacturing are: higher consistency and quality, reduce the lead times, simplification of production, reduce handling, improve work flow and increase the morale of workers when a good implementation of the automation is made.



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