The automation equipment

Customer value creation process

The customer value creation process is based on the main flow (C Fig. 1), i.e. core business, such as product manufacturing, transport of persons or conveyance of a load. This process requires equipment in the form of machines and automated devices. This equipment can be confined to a single place, such as a factory, or else spread over extensive areas, as is the case for a water treatment and distribution plant. To work smoothly, the process requires additional flows such as electricity, air, water, gas and packaging. The process engenders waste which must be collected, transported, treated and discarded.

Five basic functions

Electrical power supply

Ensures the distribution of power to the power devices capacity and control parts. It must be uninterrupted and protected in compliance with electrical installation and machines standards. This function is usually ensured by a circuit-breaker or fuse holder switch.

Power control

Controls loads driven by the automatic device, either a contractor is used as a direct on-line starter or an electronic controller is used to graduate the power supply of a motor or heater.

Dialogue

Commonly named man-machine interface, it is the link between the operator and the machine. It is function is to give orders and monitor the status of the process Control is made by push buttons, keyboards and touch screens and viewed through indicator lights, illuminated indicator banks and screens.

Data processing

the software, part of the automation equipment, fusing the orders given by the operator and the process status measurements is the brain of the equipment. It controls the pre-actuators and sends information when and where required. The automation engineer has a wide range of options, from the simplest (as a set of push buttons directly controlling a contactor), through programmable logic systems to a collaborative link between the automated devices and computers. Today as simple low-cost automated devices are available, relay diagrams have practically disappeared.

Data acquisition

Data acquisition is mandatory to send feedback is to the controller or the PLC. Due to technological progress most of all physical value can now be detected or measured.

The equipment must satisfy the external constraints

- to ensure the safety of the people and the production tools, - to respect the requirements of the environment such as the temperature, the shock protection, dust or environments aggressive.

Power Links

These are the connections between parts and include cables, busbars, connectors and mechanical protection such as ducts and shields. Current values range from a few to several thousand amperes. They must be tailored to cover electrodynamic and mechanical stress as well as heat stress.

Control Links

These are used to drive and control the automated devices. Conventional cabling systems with separate wires are gradually being replaced by ready-made connections with connectors and communication buses.

Lifecycle of an automated equipment

An equipment is designed, then used and maintained throughout its lifecycle. This lifecycle depends on the users and their needs, the customer’s requirements and external obligations (laws, standards, etc.). The steps are as follows:

-          definition of the machine or process by the customer,

-          choice of automation equipment, - component supply,

-          commissioning, tests,

-          operation,

-          maintenance,

-          dismantling, recycling, destruction.

Cost of an equipment

Cost reduction is an issue at every level during the choice and decision-making process. It’s tightly bound with the customer needs. Though this guide only describes the technical aspects, it has been written with cost-effectiveness in mind.

Evolution of user needs and market pressure

Over the last few years, the automated device market has been subject to great economic and technological pressure. The main customer priorities are now:

-          shorten time to market,

-          expand the offer through flexible design so that new products can be marketed without having to overhaul the entire offer,

-          expand the offer through customisation,

-          cost reduction.

This situation has created new needs:

-          reduction of development time,

-          reduction of complexity,

-          greater flexibility in particular when manufacturers have to change series,

gathering information for production management and maintenance (cost reduction, down times, etc.).