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Power Sources and Supplies (World Class Designs)

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Mechatronics: Principles and Applications

Mechatronics is a core subject for engineers, combining elements of mechanical and electronic engineering into the development of computer-controlled mechanical devices such as DVD players or anti-lock braking systems. This book is the most comprehensive text available for both mechanical and electrical engineering students and will enable them to engage fully with all stages of mechatronic system design. It offers broader and more integrated coverage than other books in the field with practical examples, case studies and exercises throughout and an Instructor’s Manual. A further key feature of the book is its integrated coverage of programming the PIC microcontroller, and the use of MATLAB and Simulink programming and modelling, along with code files for downloading from the accompanying website.
* Integrated coverage of PIC microcontroller programming, MATLAB and Simulink modelling
* Fully developed student exercises, detailed practical examples
* Accompanying website with Instructor’s Manual, downloadable code and image bank

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Automation is not just robotics

When a machine shop operator hears the word “automation,” he usually thinks of machines and devices such as bar feeders, pallet changes and robot arms that can reduce the human effort needed to move material and parts around the shop.

The motivation for using such machines and devices is simple – cutting the time a human spends doing those functions reduces the labor cost to make the parts and the time it takes to get those parts made. Both of those increase the shop’s profitability.

But the manual labor involved in making and moving parts and materials are not the only shop activities that can be automated profitably.

The first Computer Aided Design software (CAD) was created to “automate” some of the work done by designers and draftsmen. In fact, CAD originally stood for Computer Aided Drafting.

3D CAD took that idea a step further by automating more of the design functions. For example, change one feature on a 3D part model and all of the drawings associated with that part get changed automatically with no added human labor.

Computer Aided Manufacturing (CAM) software is used to reduce the amount of labor/time it takes for a CNC programmer to create a functioning CNC program that will make a desired part. And there are software packages that reduce the time it takes to program a Coordinate Measuring Machine (CMM) for part inspection.

But there are other software packages and related hardware tools that can be used to reduce the amount of labor it takes to run a machine shop, and usually those tools also increase the quality and accuracy of the work. In addition, they give the shop owner new capabilities that can help make a shop more productive and profitable.

However, fresh eyes and an open mind are needed to look at the activities that people do around the shop to consider if it is possible to “automate” those activities. If it is, you also have to consider if there are other benefits that might be gained from automating those activities besides a lower payroll cost. Of course, cost justifying any type of automation depends on a shop’s operations, size and needs.

One simple example is to use bar codes and hand-held bar code readers to record the things that a machinist does during the course of a day.

As work proceeds into and through a work station, capturing the completion of the steps in that process with bar codes and scanners offers a number of advantages over having a machinist write that information down on a piece of paper that is later collected and, perhaps, manually entered into a work tracking and reporting system. The time it takes to write down the information usually takes more time than it takes to scan a bar code on a work order. Most machine shop operators are always looking to reduce the time it takes to machine a part, but saving a machinist a few minutes here and there on non-machining activities can be just as profitable.

If step completion is recorded with a bar code scanner, it saves the machinist who is doing the work time, and also opens the possibility of better work order tracking and completion.

Accurate step completion recorded as it happens means that shop management can get a timely and accurate picture of what is happening on the shop floor.

By using some form of automated shop floor scheduling and control system, shop management can adjust work assignments more quickly to meet changing needs, priorities and unexpected situations such as machine breakdown or emergency orders from customers.

The same scanner/bar code equipment that is used to track process completion steps also can be used to track material flow, tool usage, inventory control, shipping and other activities around the shop. Every activity that every person does has the potential to be “automated” to some degree, and with automation can come time and cost savings and increased capabilities that might become more important than obvious cost savings.

By setting up an interactive Internet web site to allow customers and suppliers to see accurate order status or material or tool usage, the automation made possible by shop floor scanner/ bar code tracking extends automation beyond the shop to include those customers and suppliers.

Instead of a customer playing phone tag with a shop owner to find out the status of an order, customers could link to the shop’s website and see the status of their order for themselves. That saves the time of shop personnel in handling such customer calls and saves the customer’s time while reducing his stress about whether he will get his parts on time.

Some shops might be reluctant to be as open and honest about order status that such a system offers, but consider this – when you are trying to determine if you are going to get what you ordered on time, would you rather hear the bitter truth or a sweet lie? The truth, no matter how bitter, is something you can work with to minimize the problems that might arise from late deliveries or other problems.

Suppliers can use information on interactive websites to check on material and tool needs without having to call the shop. That also eliminates the need for someone to go to the floor or the tool crib to determine the status of an order. If the supplier sees a low inventory status, he can bring that to the attention of the shop operator, and determine if there is a need to order more materials or the tools needed to meet the shop’s production schedule and needs.

It used to be that setting up such an interactive website was a very costly proposition, but today there are packages available that don’t require a computer expert to create, setup and maintain.

Some of the more sophisticated Enterprise Resource Planning (ERP) software packages include such functions as a logical communication tool for internal and external use of the information that those packages are designed to gather.

While the implementation of any ERP system is not cheap and often is painful in the beginning, the potential benefits frequently justify both the cost and the pain. A seionr manager of one of American Machinist’s 2008 10 Best Shops said: “When we began to set up our ERP system, everyone hated it and demanded we stop trying to use it. We stuck with it, and now we can’t operate without it, we can’t grow without it.”

A shop with only a few employees probably doesn’t need a full-blown ERP system, but even small shops can benefit from automating as much of its employees’ activities as possible. Excel, which is free with the Windows operating system, can be used to set up spread sheets that can do more for shop floor scheduling than a white board can, and in less time. Using email to communicate with customers and suppliers can save time for everyone involved.

Using software to automate job functions is not about replacing employees with machines.

It is about enabling those employees to get the most productivity from the time they spend on the job. And as to cost, even if a software package costs several thousand dollars, all it has to do to be cost justified is to make the millions of dollars in machines sitting on the floor just a few percentage points more productive.

Most hardware and software used to automate functions costs money and time to implement, but such automation starts with something most shop operators already have – the desire to be more productive and profitable, and the intelligence to look at what everyone is doing and to figure out if there is a better way to do it.

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Food and beverages industries go wireless

An increasing population and growing consumer demand for packaged foods has forced food and beverages industry to look at new technologies that provide flexibility, easiness of operation and constant tracking of the production process. Complete transparency is required along the production process for assuring consumers health and hygiene. This demands continuous monitoring and efficient traceability of the entire production process in the food manufacturing plant. Wireless devices provide answers to the aforementioned requirements in the Food and Beverages industry.

Wireless technology helps in cost-cutting

Currently, robotics and packaging applications use relatively higher level of wireless devices in the Food and Beverages industry. It is estimated that almost 50 percent of a processed food product’s price is attached to its packaging. With the help of wireless technology, over 25 – 50 percent of damages due to inefficient packaging can be eliminated. Robotics employ wireless devices is application such as palletization, thickness measurement, sizing of the food item, and controlling the robotics arm movement in loading and packing food products. Use of wireless devices in some of these robotics applications reduces manual errors and provides flexibility in the operation.

Wireless devices are beneficial in monitoring applications such as temperature, pressure, yield, humidity, force, PH monitoring along with temperature maintenance during fermentation, sterilization and pasteurization process. Employing wireless sensors in the Clean-in-place monitoring has brought in a significant cost savings of up to 5000 USD per installation in large scale beverage manufacturers.

Instant decision making

Wireless sensors attached to a remote computer or a PDA is increasingly used to report any problem or defects in the production line. As a result, any data pertaining to handling, filling and packaging can be immediately relayed to the users’ remote computer or PDA, thereby enabling instant decision making. Wireless GPS connectivity is used to monitor the condition of fragile articles during transportation, and identify the exact location of the consignment. Some of the critical applications such as the acidity and the PH measurement in the line refractometer are additional wireless applications in the food and beverages industry.

The other advantages of the wireless devices such as work-force mobility, ease of installation and commissioning, as well as reduction in the cabling cost have created higher propensity in the food industry to invest in wireless technology.

Adoption to improve as end users gain confidence

However, food and beverages industries have critical applications that demand wireless devices; the conservative nature of the industry to invest in new technologies is a major restraint for adoption. The wireless market in food and beverage industry is expected to grow at low levels over the next two years. But as the suppliers are able to clearly justify the benefits, significant investments are expected to happen over a long term period. By the end of 2012, the European food and beverages industry is estimated close to 25 per cent for the wireless market among discrete industries.

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Automating with SIMATIC: Controllers, Software, Programming, Data Communication Operator Control and Process Monitoring

Hans Berger, “Automating with SIMATIC: Controllers, Software, Programming, Data Communication Operator Control and Process Monitoring”

Totally Integrated Automation is the concept by means of which SIMATIC controls machines, manufacturing systems and technical processes. Taking the example of the S7-300/400 programmable controller, this book provides a comprehensive introduction to the architecture and operation of a state-of-the-art automation system. It also gives an insight into configuration and parameter setting for the controller and the distributed I/O. Communication via network connections is explained, along with a description of the available scope for operator control and monitoring of a plant.
As the central automation tool, STEP 7 manages all relevant tasks and offers a choice of various text and graphics-oriented PLC programming languages. The available languages and their respective different features are explained to the reader.
For this third edition, the contents of all sections of the book have been revised, updated and the new data communications with PROFINET IO have been added. The STEP 7 basic software is explained in its latest version.
The book is ideal for those who have no extensive prior knowledge of programmable controllers and wish for an uncomplicated introduction to this subject.

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STEP 7 in 7 Steps – A Practical Guide to Implementing S7-300/S7-400 Programmable Logic Controllers

This unique new book has done it all! The book is uniquely organized to include seven practical steps associated with getting the job done efficiently and painlessly. A task-oriented guide to configuring, programming, deploying, troubleshooting, and maintaining S7-300/S7-400 PLCs and Simatic Networks. Each of the seven task areas are introduced with a brief tutorial that is followed up with a number of actual task examples. Each task is presented in an identical two-page spread layout. On the left-hand page, the task is described using a Basic Concept, Essential Elements, and Application Tips. On the right-hand page, the task is presented in a step-by-step table format. With over 175 example tasks, your tasks are surely already done! A great side-kick for every STEP 7 user! Book Highlights – 464 pages – Appendix, Glossary and Index – Brief Tutorial on each Key S7 Concept – Over 175 Examples of S7-300/S7-400 Tasks – Each Example Presented in a 2-Page Layout – Concise and Easily Read Language – STEP 7 Project/Library Tasks – Hardware Configuration Tasks – Program Design and Development Tasks – Online Operations Tasks – Monitoring and Diagnostics Tasks – Network Configuration Tasks Book Chapters (Steps) Step 1: Getting Started with STEP 7 Step 2: Working with Projects and Libraries Step 3: Working with Hardware Configurations Step 4: Working with Programs and Data Step 5: Managing Online Interactions with the CPU Step 6: Working with Monitoring and Diagnostic Tools Step 7: Working with Simatic Network Configurations… Buy this book in Amazon.com

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Bag 1. Kutipan – Latar belakang dan perkembangan PLC

Kini persaingan Industri semakin meningkat, efesiensi produksi umumnya dianggap sebagai kunci untuk sukses. Efesiensi produksi peliputi area yang luas seperti :

1. Kecepatan dimanan peralatan produksi dan line produksi dapat di set untuk membuat suatu produk.
2. Menurunkan biaya material dan upah kerja dari suatu produksi.
3. Meningkatkan kualitas dan menurunkan reject.
4. Meminimalkan downtime dari mesin produksi.

Biaya perawatan produksi murah.

Programable Controller memenuhi kebanyakan dari persyaratan diatas dan merupakan salah satu kunci dalam meningkatkan efesiensi produksi dalam industri.

Secara traditional, otomatisasi hanya diterapkan untuk suatu tipe produksi dengan volume yang tinggi. Tetapi kebutuhan ini menuntut otomatisasi dari bermacam-macam produk dalam jumlah sedang, sebagaimana untuk mencapai produktivitas keseluruhan yang lebih tinggi dan memerlukan investasi minimum dalam pabrik dan peralatan.

Sistem Manufaktur Luwes (Fleksible Manufacturing System = FMS) menjawab kebutuhan ini. Sistem ini mencakup peralatan otomatik seperti mesin NC, robot industri, transport otomatik dan produksi yang terkontrol komputer Programable Controller akan banyak dijumpai dalam perlatan industri semacam ini.