生产自动化专业英文译文

Production Automation

Introduction to production Automation

Automation is a widely used term in manufacturing. In this context ,automation can be defined as technology concerned with the application of mechanical, electronic, and computer-based systems to operate and control production. Examples of this technology include:

·Automatic machine tools to process parts.

·Automated transfer lines and similar sequential production systems

·Automatic assembly machines

·Industrial robots

·Automatic material handing and storage systems

·Automated inspection systems for quality control.

·Feedback control and computer process control.

·Computer systems that automate procedures for planning, data collection, and decision making to support manufacturing activities.

Automated production systems can be classified into two basic categories: fixed automation and programmable automation.

Fixed Automation

Fixed automation is what Harder was referring to when he coined the word automation. Fixed automation refers to production systems in which the sequence of processing or assembly operations is fixed by the equipment configuration and cannot be readily changed without altering the equipment. Although each operation in the sequence is usually simple, the integration and complex. Typical features of fixed automation include 1.high initial investment for custom-engineered equipment, 2.high production rates,3.application to products in which high quantities are to be produced ,and 4.relative inflexibility in accommodating product changes.

Fixed automation is economically justifiable for products with high demand rates. The high initial investment in the equipment can be divided over a large number of units, perhaps millions, thus making the unit cost low compared with alternative methods of production. Examples of fixed automation include transfer lines for machining, dial indexing machines, and automated assembly machines. Much of the

technology in fixed automation was developed in the automobile industry; the transfer line (dating to about 1920 ) is an example.

Programmable Automation

For programmable automation, the equipment is designed in such a way that the sequence of production operations is controlled by a program, i.e., a set of coded instructions that can be read and interpreted by the system. Thus the operation sequence can be readily changed to permit different product configurations to be produced on the same equipment. Some of the features that characterize programmable automation include 1. high investment in general-purpose programmable equipment, 2. lower production rates than fixed automation, 3. flexibility to deal with changes in product configuration, and 4. suited to low and / or medium production of similar products or parts (e.g. part families). Examples of programmable automation include numerically controlled machine tools, industrial robots, and programmable logic controllers.

Programmable production systems are often used to produce parts or products in batches. They are especially appropriate when repeat orders for batches of the same product are expected. To produce each batch of a new product, the system must be programmed with the set of machine instructions that correspond to that product. The physical setup of the equipment must also be changed; special fixtures must be attached to the machine, and the appropriate tools must be loaded. This changeover procedure can be time-consuming. As a result, the usual production cycle for a given batch includes 1. a period during which the setup and reprogramming is accomplished and 2. a period in which the batch is processed. The setup-reprogramming period constitutes nonproductive time of the automated system.

The economics of programmable automation require that as the setup-reprogramming time increase, the production batch size must be made larger so as to spread the cost of lost production time over a larger number of units. Conversely , if setup and reprogramming time can be reduced to zero, the batch size can be reduced to one. This is the theoretical basis for flexible automation, an extension of programmable automation. A flexible automated system is one that is capable of producing a variety of products ( or parts) with minimal lost time for changeovers from one product to the next. The time to reprogram the system and alter the physical setup is minimal and results in virtually no lost production time . Consequently, the system is capable of producing various combinations and schedules

of products in a continuous flow, rather than batch production with interruptions between batches. The features of flexible automation are 1. high investment for a custom-engineered system, 2. continuous production of mixtures of products , 3. ability to change product mix to accommodate changes in demand rates for the different products made, 4. medium production rates, and 5. flexibility to deal with product design variations.

Flexible automated production systems operate in practice by one or more of the following approaches: 1. using part family concepts, by which the parts made on the system are limited in variety; 2. reprogramming the system in advance and / or off-line, so that reprogramming does not interrupt production; 3. downloading existing programs to the system to produce previously made parts for which program are already prepared; 4. using quick-change fixtures so that physical setup time is minimized; 5. using a family of fixtures that have been designed for a limited number of part styles; and 6. equipping the system with a large number of quick-change tools that include the variety of processing operations needed to produce the part family. For these approaches to be successful , the variation in the part styles produced on a flexible automated production system is usually more limited that a batch-type programmable automation system. Examples of flexible automation are the flexible manufacturing systems for performing machining operations that date back to late 1960s.

Numerical Control

Numerical control ( often abbreviated NC) can be defined as a form of programmable automation in which the process is controlled by numbers, letters , and symbols. In NC, the numbers form a program of instructions designed for a particular workpart or job. When the job changes, the program of instructions is changed. This capability to change the program for each new job is what gives NC its flexibility . It is much easier to write new programs than to make major changes in the production equipment.

NC equipment is used in all areas of metal parts fabrication and comprises roughly 15% of the modern machine tools in industry today. Since numerically controlled machines are considerably more expensive than their conventional counterparts , the asset value of industrial NC machine tools is proportionally much larger than their numbers. Equipment utilizing numerical control has been designed

to perform such diverse operations as drilling, milling, turning, grinding, sheetmetal pressworking spot welding, are welding , riveting, assembly , drafting ,inspection, and parts handling. And this is by no means a complete list. Numerical control should be considered as a possible mode of controlling the operation for any production situation possessing the following characteristics:

1.Similar workparts in terms of raw material (e.g. , metal stock for machining).

2.The workparts are produced in various sizes and geometries.

3.The workparts are produced in batches of small to medium-sized quantities.

4.A sequence of similar processing steps is required to complete the operation on each workpiece.

Many machining jobs meet these conditions. The machined workparts are metal, they are specified in many different sizes and shapes, and most machined parts produced in industry today are made in small to medium-size lot sizes. To produce each part, a sequence of drilling operations may be required, or a series of turning or milling operations. The suitability of NC for these kinds of jobs is the reason for the tremendous growth of numerical control in the metalworking industry over the last 25 years.

Basic Components of an NC System

An operational numerical control system consists of the following three basic components :

1. Program of instructions.

2. Controller unit, also called machine control unit(MCU).

3. Machine tool or other controlled process.

Transfer Machines

The highest degree of automation obtainable with special-purpose , multifunction machines is achieved by using transfer machines. Transfer machines are essentially a combination of individual workstations arranged in the required sequence, connected by work transfer devices, and integrated with interlocked controls. Workpieces are automatically transferred between the stations, which are equipped with horizontal, vertical, or angular units to perform machining, gagging, workpiece repositioning, assembling, washing, or other operations . The two major classes of transfer machines are rotary and in-line types.

An important advantage of transfer machines is that they permit the maximum number of operations to be performed simultaneously. There is relatively no limitation on the number of workpiece surfaces of planes that can be machined, since devices can be interposed in transfer machines at practically any point for inverting, rotating, or orienting the workpiece, so as to complete the machining operations. Work repositioning also minimizes the need for angular machining heads and allows operations to be performed in optimum time. Complete processing from rough castings or forgings to finished parts is often possible.

One or more finished parts are produced on a transfer machine with each index of the transfer system that moves the parts from station to station. Production efficiencies of such machines generally range from 50% for a machine producing a variety of different parts to 85% for a machine producing one part, in high production, depending upon the workpiece and how the machine is operated ( materials handling method , maintenance procedures, etc.)

All types of machining operations, such as drilling , tapping, reaming, boring, and milling, are economically combined on transfer machines . Lathe-type operations such as turning and facing are also being performed on in-line transfer machine, with the workpieces being rotated in selected machining stations. Turning operations are performed in lathe-type bridge units. Workpieces are located on centers and rotated by chucks at each turning station. Turning stations with CNC are available for use on in-line transfer machines. The CNC units allow the machine cycles to be easily altered to accommodate changes in workpiece design and can also be used for automatic tool adjustments.

Maximum production economy on transfer lines is often achieved by assembling parts to the workpieces during their movement through the machine . Such item as bushings, seals , welch plugs, and heat tubes can be assembled and then machined or tested during the transfer machining sequence. Automatic nut torquing following the application of apart subassemblies can also be carried out.

Gundrilling or reaming on transfer machines is an ideal application provided that proper machining units are employed and good bushing practices are followed . contour boring and turning of spherical seats and other surfaces can be done with tracer-controlled single-point inserts, thus eliminating the need for costly special form tools. In-process gagging of reamed or bored holes and automatic tool setting are done on transfer machines to maintain close tolerances.

Less conventional operations sometimes performed on transfer machines include grinding , induction heating of ring gears for shrink-fit pressing on flywheels, induction hardening of valve seats, deep rolling to apply compressive preloads, and burnishing.

Transfer machines have long been used in the automotive industry for producing identical components at high production rates with a minimum of manual part handling . In addition to decreasing labor requirements , such machines ensure consistently uniform, high-quality parts at lower cost. They are no longer confined just to rough machining and now often eliminate the need for subsequent operations such as grinding and honing.

More recently, there has been an increasing demand for transfer machines to handle lower volumes of similar or even different parts in smaller sizes, with means for quick changeover between production runs. Built-in flexibility, the ability to rearrange and interchange machining units , and the provision of idle stations increases the cost of any transfer machine, but such features are economically feasible when product redesigns are common. Many such machines are now being used in nonautomotive applications for lower production requirements.

Special features now available to reduce the time required for part changeover include standardized dimensions, modular construction, interchangeable fixtures mounted on master pallets that remain on the machine, interchangeable fixture components , the ability to lock out certain stations for different parts by means of selector switches, and programmable controllers. Product design is also important, and common transfer and clamping surfaces should be provided on different parts whenever possible.

Programmable Logic Controllers

A programmable logic controller (PLC) is a solid-state device used to control machine motion or process operation by means of a stored program. The PLC sends output control signals and receives input signals through input / output (I/O) devices.

A PLC controls outputs in response to stimuli at the inputs according to the logic prescribed by the stored program. The inputs are made up of limit switches , pushbuttons, thumbwheels, switches, pulses, analog signals , ASCII serial data, and binary or BCD data from absolute position encoders . The outputs are voltage or current levels to drive end devices such as solenoids, motor starters , relays, lights,

and so on . Other output devices include analog devices, digital BCD displays , ASCII compatible devices, servo variable-speed drives , and even computers.

Programmable controllers were developed (circa in 1968) when General Motors Corp, and other automobile manufactures were experimenting to see if there might be an alternative to scrapping all their hardwired control panels of machine tools and other production equipment during a model changeover .This annual tradition was necessary because rewiring of the panels was more expensive than buying new ones.

The automotive companies approached a number of control equipment manufactures and asked them to develop a control system that would have a longer productive life without major rewiring , but would still be understandable to and repairable by plant personnel. The new product was named a “programmable controller”.

The processor part of the PLC contains a central processing unit and memory .The central processing unit (CPU) is the “traffic director” of the processor, the memory stores information. Coming into the processor are the electrical signals from the input devices, as conditioned by the input module to voltage levels acceptable to processor logic . The processor scans the state of I/O and updates outputs based on instructions stored in the memory of the PLC .For example, the processor may be programmed so that if an input connected to a limit switch is true (limit switch closed),then a corresponding output wired to an output module is to be energized.This output might be a solenoid, for example . The processor remembers this command through its memory and compares on each scan to see if that limit switch is , in fact, closed . If it is closed, the processor energizes the solenoid by turning on the output module.

The output device ,such as a solenoid or motor starter, is wired to an output module’s terminal, and it receives its shift signal from the process or, in effect, the processor is performing a long and complicated series of logic decisions. The PLC performs such decisions sequentially and in accordance with the stored program. Similarly, analog I/O allows the processor to make decisions based on the magnitude of a signal, rather than just if it is on or off. For example ,the processor may be programmed to increase or decrease the steam flow to a boiler (analog output) based on a comparison of the actual temperature in the boiler (analog input) to the desired temperature. This is often performed by utilizing the built-in PID (proportional, integral, derivative) capabilities of the processor.

Because a PLC is “software based”, ifs control logic functions can be changed by reprogramming its memory. Keyboard programming devices facilitate entry of the revised program, which can be designed to cause an existing machine or process to operate in a different sequence or to respond to different levels of, or combinations of stimuli. Hardware modifications are needed only if additional, changed, or relocated input/output devices are involved.

生产自动化

生产自动化介绍

自动化是一个在制造成业中广泛使用的术语。文中，自动化可被定义为有关应用机械、电子和计算机的系统去管理和控制生产的技术。这种技术的例子包括：

·加工零件的自动化机床。

·自动连续生产线和类似的顺序生产系统。

·自动化装配机器。

·工业机器人。

·自动材料处理和储存系统。

·用于质量控制的自动检验系统。

·反馈控制和计算机程序控制。

·使支持制造业活动的计划、数据收集和决策的过程自动化的计算机系统。 自动化生产系统可被化分为两个基本类别：硬性自动化和可编程序自动化。 硬性自动化

硬性自动化是哈德尔（Harder ）杜撰“自动化”这个单词时所提出的。硬性自动化是指生产系统中开关顺序或装配工作由设备配置确定，并且在没更换设备的情况下不能轻易改变。虽然顺序中的每一个操作通常是简单的，但是，将许多简单的操作集成和协调成一个单一系统使硬性自动化变得复杂化。硬性自动化的典型特点包括：1 定做设计设备的先期投资高，2 高生产效率，3 应用于大批量产品生产，和4 适应产品变更的相对固定性。

硬性自动化对高需求率产品是经济合适的。先期设备的高投入可以被大量部件分摊，也许是数百万件，这样与其他生产方法相比部件花费低。硬件自动化的例子包括加工连续生产线、转盘换位机械和自动装配机器。硬性自动化的大部分

技术是在汽车工业中发展起来的；连续生产线（追溯到大约1920年）就是一个例子。

可编程自动化

对于可编程自动化，以由程序，即一套可以被系统识别和解释的编码指令来控制生产操作工序的方式来设计设备。这样就可毫无困难地改变操作顺序以允许在同一设备上生产不同的产品结构。表现可编程自动化的一些特性包括：1 通用可编程设备的高投入，2比硬性自动化更低的生产率，3应付产品结构变化的柔性，和4，适合于类似产品或零件的小和/或中等产量的生产（例如，零件族）。可编程自动化的例子包括数控机床、工业机器人和可编程逻辑控制器。

可编程生产系统经常用于成批的生产零件或产品。它们尤其适合于相同产品成批的重复订单。为了生产一批新产品，必须为系统编制与新产品相适应的一套机器指令。设备的实际装备也必须改变，必须给机器附加特殊的夹具，必须装上适当的刀具。这种转换过程式可能是耗时的。结果，一批特定产品的一般生产周期包括1完成准备和重编程的阶段和2 该批产品的加工阶段。设置-重编程阶段构成了自动化系统的非生产时间。

可编程自动化的经济要求：随着设置-重编程时间增长，生产批量的大小必须被编得较大以便在众多设备中分散损失的生产时间的消耗。相反，如果设置和重编程时间能降低到零，则批量的大小可降至一个。这是柔性自动化的理论基础，即可编程自动化的延伸。柔性自动化系统是从一个产品转产到另一个产品时，时间损失最少的能生产许多种类产品（或零件）的系统。系统重编程和改变实际装备的时间是最少的，并且事实上导致无生产时间损失。因此，系统能在连续流程中生产不同的产品组合和进程，而不是批处理间有中断的批处理生产。柔性自动化的特点包括：1用于工程定制系统的高投资2连续的产品混合生产。3改变产品混合以适应对所生产的不同产品的需求率能力，4中等生产率，和5处理产品设计变更具有柔性。

柔性自动化生产系统通过下面一个或更多的途径应用于实践中：1使用零件族概念，根据此概念系统中制造的零件在种类上有限制；2预先，并且/或离线对系统再编程以便再编程不会中断生产；3下载已有程序到系统中来生产以前制造过的零件，为这些零件已编写过程序；4使用快速装卸的夹具以便最大限度地缩短实际装备时间；5使用为有限零件类型所设计的夹具族；和6给系统装配大量的快速装卸刀具，它们包括用来生产零件族的各式各样的加工操作工具。为了实现这些应用，在柔性自动化生产系统上生产的零件类型的变化通常比批处理类型的可编程自动化系统要局限的多。柔性自动化生产系统的例子可追溯到20世纪60年代晚期的进行机加工操作的柔性制造系统。

数字控制

数字控制（常缩写为数控）可定义为一种可编程自动化的形式，其中工艺是由数字、字母和符号来控制的。在数控中，数字构成了为某特定工件或任务设计的指令程序。当任务变更时，指令程序也相应改变，改变每种新任务程序的能力使数控具有柔性。编写新程序比改变主要生产设备要容易得多。

数控设备用于所有的金属零件制造领域，在当今工业的现代机床中大约占15%。因为数控机床比传统机床昂贵得多，工业数控机床资产价值比起他们的所

占比值来要大得多。应用数控的设备已被用来定然成各式各样的操作，如钻削、铣削、车削、磨削、钣金压制、点焊、弧焊、铆接、装配、制图、检验及零件处理等。这绝不是一个完全的列举。应把数字控制看成一种加工控制的可行方法，用于具有下列特点的任何生产情况：

1． 用原材料加工类似工件（如用于机加工的金属材料）。

2． 工件被生产成各种尺寸和形状。

3． 以小到中等规模批量生产工件。

4． 完成每个工件的加工要求一系列的相似加工步骤。

许多机加工零件满足这些条件。这些机加工零件是金属的，给它们规定了不同的尺寸和形状，而且当今工业生产的大部分机加零件被制成小到中等规模的多种尺寸。为了生产第一个零件，需要一系列的钻削操作或一系列的车削或铣削操作。数字控制对这引起零件的适应性是数字控制在过去25年中在金属制造业中巨大增大的原因。

数字控制系统的基本部件

一个可操作的数字控制系统由下列三个基本部件组成：

1. 指令程序。

2. 控制器单元，也称为机床控制单元。

3. 机床或其他被控工艺。

指令程序

指令程序是告诉机床如何去工作的一套详尽的一步步的指令集。它被以数字或符号的形式编码在一些可以被控制器单元翻译的输入介质上。最常用的输入介质是1英寸宽的穿孔带。在这些年中，也使用了其他形式的输入介质，包括穿孔片、磁带、甚至35mm 电影胶片。

还有其他两种向数字控制系统进行输入的方法必须提及。第一种是用手工将指令数据输入到控制器单元。这是费时的，除非作为辅助控制手段或只制造