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S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation
Optimization:
Expertise to augment the functionality of a system by
maximizing the efficiency of solutions and sincere efforts to
minimize the cost
Re-Engineering:
Existing Applications demanding improved performance in
terms of flexibility, cycle-time, precision, image-
enhancement, etc. through alternative-solutions or
upgradation of technology
1
Optimization & Re-Engineering > Two significant Pillars of Automation
Ashwin Vanikar
Cluster-Head South Asia: Application Engineering
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 2
Optimization & Re-Engineering through Application Engineering?1/2
Different Approaches towards working-out sol’ns for the Applications:
Based on the rule of Thumb:
Some people have certain ideas or concepts, which have been derived from some previous applied procedures
& are mostly approximated. This approach is not intended to be very accurate or reliable for every situation.
Result of such approach: a) If things work well, we don’t know, why & how
b) If things don’t work well, we still don’t know, why & how
Based on “Gut-feeling”:
Some people have an immediate or basic-feeling without a logical reasoning. There is no methodical-scientific
approach to reach a sol’n. They like to involve a lot of trial & error methods.
The approach is: just do it with your “gut feeling”
Result of such approach: a) same as for “rule of thumb” &
b) time wasted with huge cost involved
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 3
Optimization & Re-Engineering through Application Engineering?2/2
Different Approaches towards working-out sol’ns for the Applications:
Based on methodical & scientific approach (the Application-Engineering-approach):
Very few people may consider certain ideas or concepts, which have been derived from some previous
applied procedures or experiences, but always have a fresh approach, using scientific methods &
procedures to arrive at a technically reliable & competent sol’n.
Result of such approach: a) If things work well, we know, why & how
b) If things don’t work well, we still know, why & how > immediate corrective
measures
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation
Various opportunities for Automation?
4
.... there are many possibilities and many applications
1.
Conveying
2. Rotating 3. Gripping 4. Clamping 5. Stacking 6. Pick & Place
7.Transporting 8. Lifting 9. Inserting 10. Holding 11. Placing 12. Feeding
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 5
Convenience in Optimization & Re-Engineering using Engineering Tools
Secured selection & assured
performance
No room for any error:
• support tools guarantee the optimum
selection
• Saves lot of time
• Saves energy
• Saves cost
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 6
Optimization 1/3
Case-study-1:
Application: Hand-shake mechanism in CNC for machining of bearing cages
Operation requirement:
• The bearing cages (weight = 3.5 kg.) are to be machined from both the
sides
• Previously, the change of side was done either manually or with a pick &
place arrangement.
Technology challenge & need for optimization:
• In manual operation, monotonous work & fatigue to the operator
• The pick & place-sol’n occupied extra foot-print on the machine
• The cycle time was higher
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 7
Optimization 2/3
Case-study-1:
Application: Hand-shake mechanism in CNC for machining of bearing cages
Principles to be understood:
• Necessity of a mechanism, which has inherent features to do the hand-
shake with side change
• An axis, which can do pitching operation by moving apart & coming closer
with synchronization
• Requirement of Electrical actuator for flexibility in stroke-lengths for various
sizes
Suggested sol’n.:
A timer-belt-axis with two opposing slides, servo-motor, pneumatic-rotary
cylinders & 3-jaw-grippers
Advantage: 1) Operator relieved from monotony & fatigue
2) reduction of cycle-time
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 8
3/3
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 9
Optimization 1/2
Case-study-2:
Application: Pneumatic circuit optimization of a vertical-tooling-head system for
Engine block assembly
Operation requirement:
• The tooling-head, working in vertical orientation has to be lowered-down
by pneumatic cylinder & before it approaches the engine block, has to be
inched with position-control, so the tool engages with component without
impacting
Technology challenge & need for optimization:
• The existing circuit was able to lower the cylinder, but not able to inch with
proper position-control & used to dash against the engine-block &
damage the tool & block
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 10
Optimization 2/2
Case-study-2:
Application: Pneumatic circuit optimization of a vertical-tooling-head system for
Engine block assembly
Principles to be understood:
This problem needed a solution, which can counter the basic
dead-load of the tooling-head with reverse-pressure principle
Suggested sol’n.:
A counter-balance circuit with Precision-pressure regulator
with a 3/2-valve
Advantage: Operator has full control over the motion of the
tooling-head
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 11
Re-Engineering 1/2
Case-study-1:
Application: Seam welding of fuel-tanks for automobiles
Operation requirement:
Different components, especially sheet-metal or sometime even connecting-
rods to be seam-welded by vertical movement of the wheel-electrodes
Technology challenge & need for optimization:
• Existing application was done with pneumatic-cylinder
• The biggest challenges were position-control & force-control, due to which
components used to get damaged
• Time was wasted in trying to control three parameters > position, force &
speed
Welding schematic
principle
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 12
Re-Engineering 2/2
Case-study-1:
Application: Seam welding of fuel-tanks for automobiles
Principles to be understood:
• This needed a different approach from technology point-of-view
• A complete re-engineered sol’n >> from pneumatics to Electrical cylinder,
driven by a servo-motor
Suggested sol’n.:
Electrical-ball-screw-cylinder with servo-motor
Advantage:
Improved end-product quality via better control over all process
parameters >> position, speed & force with added advantage of
Electrode-wear compensation
Electrical-Cylinder
with Servo-motor
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 13
Re-Engineering1/2
Case-study-2:
Application: Re-engineered solution for twin-spindle CNC >> part-loading/unloading
Operation requirement:
• Bearing components to be loaded & unloaded in a twin-spindle CNC-
machine
• Previous solution with a horizontal-axis & a single axis-vertical-axis & that
too pneumatically-actuated. Thus, a single vertical axis had to cater for two
spindles with loading & unloading
Technology challenge & need for optimization:
• The vertical-axis, being single & pneumatic, could not fulfill the cycle-time
demand of the appl’n. The total cycle-time was around 52 sec for one
component, including machining.
• Thus, a re-engineered sol’n. was a dire need of this application
Previous-sol’n
Single-Z-axis-Pneumatic
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 14
Re-Engineering2/2
Case-study-2:
Application: Re-engineered solution for twin-spindle CNC >> part-loading/unloading
Principles to be understood:
• The first thing, which was needed was to have two vertical Z-axis
• Another necessity was to change the pneumatic-Z-axis to Electrical-Z-axis
Suggested sol’n.
Two Electrical-Boom-axis, individually servo-driven with grippers & to take the
increased load, the horizontal also was converted to twin axis
Advantage:
Drastic reduction of cycle-time from 52 sec to 34 sec with better control over
process parameters
Previous-sol’n
Re-engineered-sol’n
Single-Z-axis-Pneumatic
Twin-Z-axis >
Electrical-Boom axis
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 15
Emerging Technologies
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 16
• No wastage of compressed air during downtime• Automatic leak detection• Online process monitoring, remote maintenance and parameters regulation via PROFIBUS
Energy efficiency module
Goal: Reduction of Carbon-footprint
Reducing energy and regulating central operating parameters
Fieldbus nodes with
fieldbus interface for online
data transmission
2/2-way shut-off valve
permits auto-stop function
Flow sensor and pressure
sensor for process
monitoring
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 17
All set for automation with IO-Link >>> Point-to-Point
Benefits of IO-Link:
Parameterisation made simple
• Software-supported parameterisation of intelligent sensors
and actuators via the IO-Link master
• Automatic parameterisation in case of device replacement
Safe investment thanks to standardisation
• International, open and fieldbus-independent IO-Link standard
Less downtime, higher productivity
• Exchange of diagnostic and operational data between device
and master systems, accelerates troubleshooting
Simpler to install
• Uncomplicated wiring of the sensor-actuator combinations
with standardised, unscreened lines reduces material costs,
simplifies logistics, and saves time
S7-A\Ashwin Vanikar Optimization & Re-Engineering > Two significant Pillars of Automation 18