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Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage and retrieval system, without permission in writing from the publisher. This text addresses the need for todays industry to develop automation. For most industriesand, in many ways, for entire countriesto compete in the global economic environment, it is essential to become cost-competitive.

To do so requires that a person or team have the knowledge to either design a new auto- matic machine or write specifications for the purchase of a machine to perform an automated process.

The process of designing automation is not a new one, but there has been a void of current texts that are useful tools.

Although there is a good supply of books dedicated to machine design, including such topics as bearing supports, dynamic balancing, and modes of vibration, these books do not instruct the reader on options for the actual design of an automated process. Many people in the automation field have learned from experienced co-workers or through the school of hard knocks.

Some of todays implemented automation projects are regarded as miraculously brilliant, while others appear to be cursed. This range of unknown performance can be greatly reduced if the practice of designing auto- mation is approached by thinking both methodically and outside of the box.

This book covers the design process for automation, starting with the all- important understanding of the process to be performed by a machine. This step is often the most misunderstood and poorly addressed, and therefore leads to uncertain results. The steps in automation design parallel those of many college capstone design classes, but with a different view.

The process, not the product, is the focus. This book focuses on the many existing automation concepts used in recent history, and shows that there are often several machine configurations that will work satisfactorily. There is no one correct answer to automation problems, but my experiences and case studies, as well as those of my associates, will hope- fully allow readers to gain insight beyond their own years. I have included several major case studies of my startup automation companies that have lessons both for operational success and for disappointments when the market for sales goes sour.

At the end of most chapters the book presents problems that are very open- ended. Thus, there is no answer key to selected problems at the back of the book, nor a solutions manual. There are also project assignments for most chapters that allow the reader to systematically work through an automation project of his own, or to apply to the list present in Appendix B, Projects. The reader is assumed to have a technical background, either as a college senior or graduate student in mechanical or electrical engineering or as an engin- eering technology student.

Or the reader might be a practicing engineer who has worked his way up from the CAD terminal or drawing board. This book does not attempt to restate all the available theory and examples relation to dynamics, calculating rotational moments of inertia, machine elements, and bearings derived in earlier college courses. It assumes that the reader has encountered these topics in other courses or work-related experience and can use these topics when needed in the course of performing the projects in this text or in the creation of a real machine.

The reader is also required to have access to the Web, to investigate the current vendors and component options for the concepts presented.

Although the concepts will not change over time, the vendors can be bought or sold in a very short time, and are therefore not listed as an integral part of the discussions. Many people contributed to the material in this text. Some of the contributors who provided material for case studies or technical discussion are: Mr. Merritt Bell Mr. Bernhard Bringmann Mr. David Brown Mr. Peter Caratzas Mr.

Clay Cooper Mr. Paul Crilly Dr. Ryan Durante Mr. Van Judd Mr. Ned Kirchner. John McFadden Mr. Raymond Puffer Mr. Jesse Ruppel Mr. Donald Schneider, Sr. Matt Simon Ms. Jane Somers A special contribution was made by my daughter, Melanie Derby, who created the majority of the computer-generated concept drawings, and did so with great joy and earnest. Many people have influenced meand thus this textover the past almost half century.

This started with my parents, who let me build wooden robots in the garage, and who always knew that automation would be my calling. And over the last 25 years I have been influenced by my masters and Ph. I thank the late Dr. Joseph Duffy, who demonstrated during my Ph.

Clay Cooper, who showed me the real world of automation during a sabbatical in the late s. Thanks to Mr. Ned Kirchner, the first to step forward to assist me in bringing my inventions to market. Thanks also to Dr. John McFadden, Mr. David Brown, and the other participants of Distributed Robotics, LLC, who shared both the joy of creative genius and the frustrating times. I would like to thank Mr. John Corrigan of Marcel Dekker who inspired me to write this text. His vision on where the world needed to be in terms of auto- mation was my motivation to start this endeavor.

Finally, thanks must be given to my wife, Sharon, for all her encourage- ment, daughters Laura and Melanie, and all of my family and friends who assisted me in the writing of this book. Soli Deo Gloria Stephen J. Postal Worker 31 3. Automation: designing, building and implementing automatic machines. How can such an intriguing concept that has the potential to keep manufacturing located domestically also cause some to be so concerned?

The image of intelli- gent machines producing thousands of quality products for less cost is the dream of many an engineer. But to the current worker at the plant who might be replaced, automation is a potential nightmare. Depending on ones role in this world, the impact of automation can cause excitement or fear.

Let us look at some of these roles to gain an initial view before we start to think about designing and building an automatic machine:.

Manufacturing Director International competition continues to pressure almost all manufacturing operations to reduce production costs. Because labor costs rarely go down, and many workers are oper- ating at reasonably optimal rates, there are no significant gains to be made. Automation, if possible, is a goal of most Manufacturing Direc- tors to remove labor and increase output and quality.

Internal manufac- turing means greater control of production. Company CEO In addition to the concerns of the Manufacturing Director, the CEO is also concerned about employee injuries, Work- mans Compensation costs, and the flexibility to raise or lower pro- duction outputs if market conditions change.

Stockholders To be viable, an investment needs to be placed in a company that has room to grow when markets increase. Adding auto- mation is often easier than finding skilled employees willing to work third shift. So a company that is highly automated can be perceived to be a good long-term investment. Current Company Worker They have the most reason to be con- cerned with the implementing of automation.

Some may lose their jobs, while others may be retrained and relocated to maintain the auto- mated production. Fully automated, or lights out facilities, are not always cost-effective. However, the jobs that will be replaced are often ones that seem like drudgery and lead to repetitive motion injuries or other physical risks. In society as a whole, there are hopefully better jobs to be done that require the intelligence of a human being, but remaining competitive means staying in business.

Sales Representatives If a machine is to be sold to many customers, a set of independent representatives are often formed; or it could be your own companys sales force. Your new automation must generate enough cost savings to make the sale.

It needs to be a better mousetrap at a good price to be selected over the competition. Consumer The consumer wants high-quality goods at a low price. The social concerns of where and how it is made are often left behind when one gets to the checkout line. However, not all products made halfway around the world are of the quality one would expect.

Auto- mation, if done properly, can help to lower costs while keeping or improving quality. Environmentalist The product and its packaging will have an impact on the world, perhaps for many years after its useful life is over. How it can be recycled is a concern. Additionally, the automatic machine itself needs to be thought about.

A machine that will make only a single size and type of product might be obsolete before it has been assembled and debugged, with todays quickly changing markets. Can a machine be designed such that while still being cost-effective, it can live on to make future products not yet conceived?

Can it be designed and made in modules that can be reassembled as building blocks? Or will the one-product machine be limited to being a boat anchor in the not so distant future? Although the engineer responsible for automation may not hold many of these roles, the concerns of these groups do help to define the dynamics that will come into play either directly into the engineers world, or indirectly behind the scenes.

And if the engineer understands all of these issues, one can better anticipate them and be prepared. In this textbook, we will be primarily focused on the traditional engineering aspects of designing and building an automatic machine. The information in the book comes from many sources: companies that manufacture machines, trade show displays and product literature, professional articles and trade magazines, conferences, and the experiences of the author over the past 25 years.

These experiences include being a university professor, having a sabbatical at a local automation company, and being the president of two startup companies in automation. As the above role descriptions start to mention, there are many reasons to auto- mate a manufacturing process.

These include:. Reducing labor;. Avoiding labors sick days, lunch breaks, being late for work;. Improving quality;. Reducing waste;. Enabling production of multiple shifts and weekends;. Increasing repeatability and quality;. Increasing Workmans Compensation claims and expenses;.

Keeping production onshore. Some of these reasons have costs impact savings that are simple to com- pute. But it is more difficult for a company to put a price tag on improved quality, or to estimate the reduced Workmans Compensation claims. Different accounting practices and methods also create different answers. Since every manufacturer probably desires to address some, if not all, of these reasons, one could assume that automation is an obvious answer. However, there are not available today automation solutions for every production process.

Many production tasks have not yet had a machine designed and made for them. Or the existing machine is not cost-effective compared to the current labor expenses, both direct and indirect. So the task of automation is often thrust upon a single engineer or engin- eering team. In some cases there are ready solutions, where the engineers job is simply to find the best one at the right price.

This is similar to what a consumer usually does to buy his or her home washing machine. The consumer rarely designs and builds their own. But in automation, the engineers may need to design and build one from scratch. If the engineer or hopefully team has the skill set and experience, they can do just that, design and build a piece of custom automation.

In this case this text is designed to assist the team, either to bring along a novice, or to give more. It may be helpful as a reference to justify the methodology. Alternatively, the team may be charged to outsource the automation; to be responsible to define the system requirements, write a request for proposal, accept bids, select the right bid, and monitor the development and installation process.

In this case the text will assist the engineer to understand the basics, appreciate the range of solutions and the level of difficulty, and aid in the evaluation process so as to select a winning bid. Or it may help the engineer to come to the logical con- clusion that the process cannot be economically automated and must remain man- ual labor for the time being. As we will see, the field of designing automation is both logical and devel- oped, and as creative and individualistic as fine art.

There are often many sol- utions, no one right answer, and sometimes no answer at all. But there is often the better mousetrap waiting to be invented, sometimes by the untrained novice who does not know any better why it had not been done before.

The topics include the traditional areas, including:. Steps to Automation;. Justifying Automation;. The Automation Design Process;. Robotics as Automation Tools;. Feeders and Conveyors;. Of particular note is the Steps To Automation chapter, where the under- standing of the process to be automated is discussed in great detail. Many a machine was designed and built without a good fundamental investigation of how it was to perform the process, and thus never had a chance of succeeding.

Examples of both good designs and war stories of limited or complete failures will be addressed. Looking at alternative methods to perform the task may make or break the entire machine development program. For example, no one to date has developed a cost-effective alternative to the dexterity of the human hand.

These chapters of the book have been developed as a mix of examples, case studies, thought-provoking questions, and possible individual or student team projects. It has been found that university students learn these concepts best by. Most likely time and cost limitations limit a student to only building simple prototypes of key automation process areas, to further gain more understanding on if and how things might work. The degree to which a project is completed by the reader can be a function of time, education to date, and the ultimate goals of the engineer.

Many example projects are the results of previous engineering student teams. Some of these results are promising, while others might be limited. But the author makes note of any issues and limitations, since much can be learned from looking at not so great solutions as well as the great solutions.

This is based on the experiences of the author about his three new inven- tions, from concept, development, system debugging, and market conditions. A rapidly changing economy makes these efforts troubling at times. Patenting auto- mation is also discussed for its benefits and limitations in the chapter on Justi- fying Automation. The chapter on System Specifications will be useful for the engineers who must write a Request For Quote RFQ , understand the submitted proposals, com- pare alternate design, and look at project management issues.

This is useful to people from both sides of the fence, so as to better understand the partnership. The last chapter, on Packaging Machines, is an introduction to a large sub- set of automation machines. Packaging is the placing of the finished product into a bag or box, perhaps also into a larger carton, and maybe finally into a cardboard shipping container or box. Whereas many of the processes to be automated are very specific to a very few industries, the packaging market transcends many industries, and thus has a larger market, leading to a greater number of existing machines available off the shelf.

The methodology of how a machine is designed is more important than how many bolts are holding it together. The book will also lead the reader towards many existing bodies of knowledge found in more basic engineering textbooks. It will hopefully remind the reader or point to these principles such as calculating the rotational moment of inertia for motor sizing but will not develop these con- cepts within.

It is anticipated that the reader has access to these other textbooks as resources. The figures in this text have been created as a means to show a generalized concept, not a blueprint to be copied into your CAD design.

These figures are meant to show how something happens, since it is often difficult to gain such understanding from detailed photographs. Some figures are generalizations of. In these changing economic times, it seems more prudent to not focus on any particular brand of automation. So there are not a large number of photographs included.

The reader is referred to the Web to search on suggested topics for state-of-the-art components. The author has used this method quite successfully for more than a decade of teaching automation students.

So you want to design and build an automatic machine. Or at least your boss says that you will. Either way, good for you!

There is nothing as exciting, enlighten- ing, and sometimes frustrating as going from the overall customer need to seeing some equipment humming along, cranking out product after product. And since this often takes many months, it is not unlike the process of giving birth although male automation designers would have to take their wifes word on this!! So what exactly is an automatic machine?