Types of Automation

 

19 July, 2022.

In this post, we will see the various types of automation.

As the name suggests, automation is a means of automatically executing any process. In today’s industrial world, almost all the processes are becoming automatic. This is because it reduces time, increases efficiency and reliability, reduces human life endangering, increases overall environment safety, reduces errors and bugs in operating a system, and provides new means of increasing flexibility of industrial operations. Automation uses a wide range of machine-aided tasks and computers. It is used in almost every types of industries. In this post, we will see the different types of automation used in an industry.

Fixed Automation:

This is the most basic type of automation. As the name suggests, the machines and equipment which are designed to manufacture a product are fixed and cannot be changed. This type of automation is also called as hard automation. In systems where a large mass production is required continuously for a same type of product and without any change, this type is preferred. Because there will not be any change in operation and design, you can manufacture the products continuously without any stress to deliver new design products. So, you can also call fixed automation as repetitive automation. You get the highest profit margin in this type.

Everything in fixed automation; from cams to gears to wiring to hardware and program is fixed in this type. You do not have the option to change anything. It is therefore subjected to high initial investment; because once invested, you did not need to look at anything else. It is thus suitable for products which are required in large volumes daily.

There are some demerits too in this type. The first and foremost weak point is it’s inability to change anything. Also, this type is the costliest of all ones.

A classic example of fixed automation is a conveyor system or biscuit manufacturing system. The conveyor is designed to move at a fixed position with transferring materials. A biscuit manufacturing system will produce the same biscuit in bulk quantities repeatedly. You cannot change the biscuit, because a change in biscuit will require a corresponding change in machinery design.

Programmable Automation:

This is the second advanced layer of automation. As the name suggests, the machines and equipment which are designed to manufacture a product are variable and can be changed. This type of automation is also called as batch production automation. In systems where a large mass production is required continuously for different types of products, this type is preferred. But, remember that the production rate will be lower than fixed automation; because you will require time to change design and adjust accordingly. Once the system is adjusted for a particular batch, you can then run the system accordingly.

A company sometimes manufactures products in different batches. Suppose the same machine has to produce five types of foods; then the machine will be programmed and designed accordingly to manufacture that particular type. You need to write new programs for each new process. This type of automation is achieved by numerically controlled machine tools (NC and CNC machines), PLC’s and industrial robots. Here, you can write the program accordingly to vary the system design.

This type too has it’s own disadvantages. It has lower production levels as compared to fixed automation. Also, you require skilled manpower and good technical products to cater to changes in product design. Because, if there is inefficiency here, then the final result will deteriorate.

Flexible Automation:

This is the most advanced layer of automation. As the name suggests, the machines and equipment which are designed to manufacture a product are variable and can be changed; but without stopping the system. This type of automation is an advanced version of programmable automation. In systems where a large mass production is required continuously for different types of products and without hampering the production time, this type is preferred. But, remember that the production rate will be lower than fixed automation and higher than programmable automation. Because it’s true that you have changed the machine working instantly; but you will need to monitor how it is performing initially and if it is not performing, then you will need a downtime to do the changes. But, on the flip side, once the changeover of system has happened instantly without any hiccups, then you can then run the system accordingly.  

For example, consider that three different machines and systems have been designed and assembled to manufacture products. The PLC is controlling one type of product. When there is a need to manufacture second product, the PLC will automatically change the program to the second machine which is ready to run. This is flexibility. Means, you get to understand that you are able to manufacture different products without any downtime and hurdles.

I have covered the general types of automation. I have also not attempted to cover every theory of these types deeply; you can learn it easily once you get familiar with them. I have just given you an insight of these types of controls. Once you are done with these, I am hopeful you will be easily able to understand any system properly. Learn the basics and explore a new type of study in this type of automation. It will take some practice and as you go on selecting the automation type, you will become more familiar with it.

Thank you guys; I hope you enjoyed reading the practices normally used for this type of study in industrial automation.