5 Industrial Automation Technologies

Industrial Automation Technologies Full Automation Magazine Co-MERCX broadcast 1. Industrial Automation Technologies It covers technologies for the maintenance, repair, programming and production of machines that make automatic production in the industry, to gain the competencies of performing hardware and software operations for measuring, monitoring and controlling production using the network structures of automation systems. The process that enables industrial systems to be controlled in the planned order and monitored in real time can be called industrial automation. Industrial automation can be examined under 2 headings. a. Classical control method involving mechanical elements such as relays, contactors and counters, b. It is a PLC-based automation that is widely used in all areas of the industry due to its reduction in production cost, easy installation, and increasing quality and reliability. The relentless competition in the production and manufacturing sector forces companies to work with low profit margins. Today, the way to produce low-cost production without sacrificing quality is through automation. The initial investment for the robot pays for itself in a short time and enables the business to gain much more profit. Therefore, not being afraid of this investment should be the first step. While these winds of change are blowing in Turkey, businesses should aim to grow with restraint. Priority should be to get to know the innovations in this area and allow modernization before buying more process centers-lathes. The most basic way for companies to reduce costs is through minimizing labor and faulty production costs. PLC control is applied as the easiest way of minimizing user errors that may occur on the machine and providing safe use, as well as making the productions in the same standard. While the automation of the work done in many companies' facilities will be carried out with much less cost, new automation installation projects are signed as a result of wrong decisions. First of all, the machine automation and process automation projects that can be applied should be checked by the experts of the facility. A significant portion of businesses experience an annual yield loss of 20% due to their manual operations. Their robotic industrial facilities operated for years after the first day's installation, almost unchecked. Changes in business processes were not reflected in the facility, perhaps it was tried to be done manually. The automation project team analyzes the facility and offers you the necessary improvements. 1

Industrial Automation Technologies Full Automation Magazine Co-MERCX broadcast For industrial facilities with owned robots; It is possible to produce better products in a shorter time by accelerating, improvement studies, quality and efficiency improvement studies and equipment integration studies. Generally, there are 2 jobs to be done in the facilities; Machine and process automation or a wider automation configuration for the project. a. Machine & Process Automation: After the examinations to be made by the Automation Project officials, the machine automation and process automation projects that can be applied in your facility are determined. Professional solutions are produced for the automation of the entire facility as well as improvements in your existing automation system. b. Project-Specific Automation Configuration: Thanks to innovative software services in software and automation fields, automation configuration processes are carried out quickly and easily by producing professional solutions. Providing users to work effectively with intuitive operation, easy and user-friendly interactive solutions are offered thanks to highly usable automation software. 1. Industrial Software for Automation a. PLC Software: Programmable Logic Controller (PLC), or Programmable Controller; It is a microprocessor-based device that processes the information received from the sensors according to the program provided and transfers it to the work staff. PLCs contribute greatly to production in terms of p roviding production speed and automation. From its inception, PLCs have been the keystone of industrial automation, functioning as a critical link between humans and machines. As the control architecture continues to change and network technology continues to evolve, these changes have supported integrated HMI-PLCs that leverage an installed and portable programming environment. Many brands have produced PLCs around the world. Some of these are Siemens, Eaton, ABB, Delta, Mitsubishi, Omron, Hitachi, Schneijder, Bosch, Fatec, GE, Yaskawa, Allen Bradley. 2

Industrial Automation Technologies Full Automation Magazine Co-MERCX broadcast A PLC interacts with I/O with the environment it controls. PLC inputs accept signals from different types of sensors, switches, and other control devices. The PLC makes decisions based on the values of these input signals in conjunction with the program written to take advantage of its own power to operate in its environment. Historically PLC programs are created in ladder logic, a language that closely resembles a relay-based wiring diagram. But modern PLC programming is not limited to ladder logic. PLCs provide numerous performance benefits such as less hardware required, greater efficiency and less waste. Modern PLCs are highly specialized solutions that consume less assets at the factory level and can be customized as stand-alone control applications. As an internal controller, PLCs simplify installation as they use less cabinet space. In addition, the visual terminals of many PLCs increase machine / operator interaction and production efficiency. For example, local screens with PLCs' easy-to-use interfaces provide simple instructions for machine operators as well as data entry paths to support alarm monitoring and / or formula management. The programmable logic controller (PLC) market was wo rth US $ 11.21 billion in 2020 and is expected to reach US $ 15.58 billion by 2026, with a CAGR of 5.3% over the forecast period (2021 - 2026). 3

Industrial Automation Technologies Full Automation Magazine Co-MERCX broadcast The deployment of PLC systems enables errors to be identified and corrected and can initiate rapid responses even without human intervention. Therefore, it is estimated that these automated PLC systems will help reduce machine downtime from 20% to almost 4%. b. HMI Software: With Human-Machine Interface (HMI) software, your new productions offer solution-oriented benefits specific to your system in all the machinery, machine park, building automation and facility work you need in the field of automation in the working process. c. SCADA Software: Supervisory Control And Data Acquisition (SCADA) provides systematic services in software and hardware items by providing professional solutions for industrial organizations in the field of SCADA, called \"Central Supervision Control and Data Acquisition\". These; It allows you to control industrial processes locally or remotely, perform real-time data monitoring, collection and processing, interact directly with devices such as sensors, valves, pumps, motors and more, allows you to record events in a log file. For SCADA system needs and requests required in factory automation; SCHNEIDER SCADA and SIEMENS SCADA, ABB SCADA, ROCKWELL SCADA and so on. products of many brands are used in the market. The basic logic of SCADA is to monitor and control all production stages from a single center, to collect and report data and to control units. It has a large usage area due to these features it provides. Interest in factory automation has increased even more with Industry 4.0. Thanks to the developing technologies, factories have been completely digitalized and the use of products such as smart sensors, smart motors etc. has increased. Factory automations (process automations) provide a lot of benefits in terms of both cost and quality with their innovative structures. 4

Industrial Automation Technologies Full Automation Magazine Co-MERCX broadcast SCADA, which we frequently encounter in automation systems, is a system that can visually monitor and control consulting, control and data collection systems. A SCADA system is a collection of software and hardware components that allow facilities to be supervised and controlled both locally and remotely. As it is known, it is possible to summarize it as the general name of a system that can be controlled and controlled from computers and communication devices in general. Generally, it is divided into two as Energy SCADA and Process SCADA. It is processed in general terms in this way. While water, natural gas and electricity are included in the energy scada, automation systems such as facilities and factories are included in the process scada. Scada Components  Alarm system,  Data analysis and reporting system,  Communication system,  Control center (Central servers),  User interface (Graphical interface),  Monitoring system. SCADA Functions: a. Automation: Most SCADA products allow actions to be triggered automatically by events. A scripting language provided by SCADA products allows these operations to be defined. In general, at SCADA, one can load a specific screen, send an email, run and write an application or a user-defined script. b. Access Control: Users are assigned to groups that have read / write access rights defined for process parameters in the system and often for product specific functions. c. Human-Machine Interface (HMI): Computer based HMI products provide the means by which process personnel interact with the PLC control system. There are 3 basic types of HMIs: the pushbutton replacer, the data handler, and the overseer. Supports multiple displays, which can contain Human-Machine Interface (HMI), synoptic diagrams and text combinations. Online configuration and customization of the HMI is possible for users with appropriate privileges. Links can be created between the screen pages to navigate from one view to another. 5

Industrial Automation Technologies Full Automation Magazine Co-MERCX broadcast 2. Robot Assisted Automation Applications in Industry: Professional software support is provided in the field of robotic systems by moving robots consisting of developing technologies, sensors, electronic decision mechanisms and mechanical applicators between workstations. Systems Developed with Industrial Robots; Robotic handling, palletizing and packaging, robotic assembly, robotic bench feeding, robotic surface processing, painting, robotic cutting process, robotic heat treatment, robotic welding, etc. a. Robotic Transport, Palletizing and Packaging: It is more advantageous to do it with robots in terms of occupational safety and negative effects on human health. Standard and customized palletizing systems are designed to increase productivity and save money. The modular design of Robotic Palletizing offers flexibility, high efficiency and ease of use. To hold the product, the grippers can be of vacuum and gripper type. These systems are reinforced with conveyor and feeding systems. b. Robotic Assembly: Although Robotic Assembly is common in the Automotive industry, it is also used for lean industrial processes and expands manufacturing capabilities in the manufacturing world. An assembly line robot can significantly increase production speed and consistency, as well as save workers from tedious and repetitive assembly line work. c. Robotic Machine Feeding: Robotic Machine Feeding is planned for demanding and dangerous repetitive jobs that require a high level of consistency. It protects workers from tedious, injury-causing jobs and increases safety levels in facilities. CNC offers automatic product loading and unloading in the Press Lines, high speed and flexible product change. Nowadays, casting feeding, forging feeding, honing feeding, injection feeding, milling-press-CNC feeding have become widespread. 6

Industrial Automation Technologies Full Automation Magazine Co-MERCX broadcast d. Robotic Surface Processing, Painting: Robotic surface processing; covers grinding, sanding, deburring, drilling, threading applications. It has a variety of applications ranging from the aerospace industry to the ship industry. It can be used to process objects before they are painted. Also useful for sanding molded parts or composite materials. In addition, the operations to be performed with spraying or bonding equipment such as guns and pumps can be increased. It is used in surface treatment applications such as 3D Machining, Styrofoam, wood and marble. e. Robotic Cutting Process: Robotic cutting is the process of removing material from a workpiece or dividing the workpiece into smaller, distinct pieces. Cutting robots are extremely precise and accurate while increasing speed. Reduced cutting errors reduce product waste. Laser cutting (CO2 laser cutting, Fiber laser cutting), plasma cutting, water jet cutting, spindle cutting and ultrasonic cutting can be applied according to your product features. 7

Industrial Automation Technologies Full Automation Magazine Co-MERCX broadcast f. Robotic Heat Processing: Robotic Heat Processing is a controlled process used to alter the microstructure of metals and alloys such as steel and aluminum to impart properties that benefit a component's working life, such as increased surface hardness, temperature resistance, and strength. In the production of plastic parts in the automotive industry with the Flame Unit, robotic flaming application is used to make the surface of the part before painting suitable for the paint process.. g. Robotic Welding: Robotic Welding is an automatic welding process that involves the operation of special robotic arms and automatic welding equipment. Meeting the requirements for robotic welding, consistent weld quality and increased production capacity. Robot systems can be used to work 24/7. It is widely used for resistance spot welding and arc welding in high production applications such as the automotive industry. It is inevitable to see a welding robot in every sector that currently manufactures welded products.. Mech. Engr. Erdinc Cihan Autoweld Advisor Co-MERCX Machinery Ltd Weldermaster Robotic www.commercx.com 8