UNIT 1

INTRODUCTION TO AUTOMATION
AUTOMATION: Automation is a technology by which a process or procedure is accomplished
without human assistance.
(or)
The techniques of making a process or a system operate automatically.
Robotics: It is the branch of technology that deals with the design, construction, operation
and application of Robots.
TYPES OF AUTOMATION:
There are three broad classes of Automation,
Automation

1.Fixed Automation

2. Programmable Automation

3. Flexible Automation

1. Fixed automation:
It is a system in which the sequence of processing (or assembly) operations is fixed
by the equipment configuration. The operations in the sequence are usually simple. It is the
integration and co-ordination of many such operations into one piece of equipment that
makes the systems complex. The typical features of fixed automation are:
High initial investment for custom-engineered equipment
High production rates
Relatively inflexible in accommodating product changes.
The economic justification for fixed automation is found in products with very high
demand rates and volumes. The high initial cost of the equipment can be spread over a very
large number of units, thus making the unit cost attractive compared to alternative methods of
production.

Examples of

fixed

automation

include mechanized

assembly lines (starting

around 1913-the product moved along mechanized conveyors, but the work stations along the
line were manually operated) and machining transfer lines (beginning around 1924).

2. Programmable automation:
In this the production equipment is designed with capability to change the sequence
of operations to accommodate different product configurations. The operations sequence is
controlled by a program, which is a set of instructions coded so that the system can read and
interpret them. New programs can be prepared and entered into the equipment to produce
new products. Some of the features that characterize programmable automation include:

High investment in general-purpose equipment

How production rates relative to fixed automation
Flexible to deal with changes in product configuration
Most suitable for batch production

Automated production systems that are programmable are used in low and mediumvolume production. The parts or products are typically made in batches. To produce each new
batch of different product, the system must be reprogrammed with the set of machine
instructions that correspond to the new product. The physical setup of the machine must also
be changed over: Tools must be loaded, fixtures must be attached to the machine table, and
the required machine settings must be entered. This changeover procedure takes time.
Consequently, the typical cycle for a given product includes a period during which the setup
and reprogramming takes place, followed by a period in which the batch is produced. Examples
of programmable automation include numerically controlled machine tools (first prototype
demonstrated in 1952) and industrial robots (initial applications around 1961), although the
technology has its roots in the Jacquard loom(1801).
3. Flexible automation:
It is an automation is an extension of programmable automation. The concept of
flexible automation has developed only over the last 15 to 20 years, and the principles are still
evolving. A flexible automated system is one that is capable of producing a variety of products
(or parts) with virtually no time lost for changeovers from one product to the next. There is no
production time lost while reprogramming the system and alternating the physical setup
(tooling,

fixtures,

machine

settings).

Consequently, the

system

can

produce

various

combinations and schedules of products, instead of requiring that they be made in separate
batches. The features of flexible automation can be summarized as follows:

High investment for a custom-engineered system

Continuous production of variable mixtures of products
Medium production rates
Flexibility to deal with product design variations
The essential features that distinguish flexible automation from programmable

automation are;

(i). The capacity to change part programs with no lost production time, and
(ii). The capacity to change over the physical setup, again with no lost production time.
These features allow the automated production system to continue production without
the downtime between batches that is characteristic of programmable automation. Changing
the part programs is generally accomplished by preparing the programs off-line on a computer
system and electronically transmitting the programs to the automated production system.
Therefore, the time required to do the programming for the next job does not interrupt
production on
responsible

the

for this

current

job. Advances

in computer

programming capability in

systems

technology are largely

flexible automation. Changing the physical

setup between parts is accomplished by making the changeover the off-line and then moving it
into place simultaneously as the next part comes into position for processing is one way of
implementing this approach. For these approaches to be successful, the variety of parts that
can be made on flexible automated production systems is usually more limited than a system
controlled by programmable automation. Examples of flexible automation are the flexible
manufacturing systems for performing machining operations that date back to the late 1960s.
Relationship of Fixed Automation, Programmable Automation & Flexible Automation,

Fixed

Programmable

Automation

Automation

Flexible
Automation

Sequence of operations are

Capability to change the

fixed

sequence of operations

Volume

of

production

is

very high
Product life cycle should be

Volume of production is

Mid-volume

production

relatively low

range (i.e.n Medium)

High unit cost

High unit cost relative to

long
4

Low unit cost

fixed or programmable
5

Mass production

Product variety is Low

automation
Mass / Batch

Batch production
Product variety is High

Medium product variety

NEED OF AUTOMATION:
Companies undertake projects in manufacturing automation and computer-integrated
manufacturing for a variety of good reasons. Some of the reasons used to justify automation
are the following,
(1). Increased productivity:
Automation

of

manufacturing

operations

holds

the

promise

of

increasing

productivity of labor. This means greater output per hour of labor input. Higher

the

production

rates (output per hour) are achieved with automation than with the corresponding manual
operations.
(2). High cost of labor:
The trend in the industrialized societies of the world has been toward ever-increasing
labor cost. As a result, higher investment in automated equipment has become economically
justifiable to replace manual operations. The high cost of labor is forcing business leaders to
substitute machines for human labor. Because machines can produce higher rates of output,
the use of automation results in a lower cost per unit of product.
(3). Labor shortages:
In many advanced nations there has been a general storage of labor. West Germany, for
example, has been

forced to

import labor

to

augment

its

own

labor

supply.

shortages also stimulate the development of automation as a substitute for labor.

Labor

(4). Trend of labor toward the service sector:

The trend has been especially prevalent in United States. At this writing(1986), the
proportion of the work force employed in manufacturing stands at about 20%. In 1947, this
percentage was 30%. By the year 2000, some

estimates

put

the

figure as low as 2%.

Certainly, automation of production jobs has caused some of this shift. However, there are also
social and institutional forces that are responsible for the trend. The growth of government
employment at the federal, state, and local levels has consumed a certain share of the labor
market which might otherwise have gone into manufacturing. Also, there has been a tendency
for people to view factory work as tedious, demeaning, and dirty. This view has caused them to
seek employment in the service sector of the economy (government, insurance, personal
services, legal, sales, etc.).
(5). Safety:
By automating the operation and transferring the operator from an active participa -tion
to a supervisory role, work is made safer. The safety and physical well-being of the worker
has become a national objective with the enactment of the Occupational Safety and Health
Act of 1970 (OSHA). It has also provided an impetus for automation.
(6). High cost of raw materials:
The high cost of raw materials in manufacturing results in the need for greater efficiency
in using these materials. The reduction of scrap is one of the benefits of automation.
(7). Improved productive quality:
Automated operations not only produce parts at faster rates than do their manual
counterparts, but

they produce

parts with

greater consistency and conformity to quality

specifications.
(8). Reduced manufacturing lead time:
For reasons that we shall examine in subsequent chapters, automation allows the
manufacturer to reduce the time between costumer order and product delivery. This gives the
manufacturer a competitive advantage in promotion good customer service.
(9). Reduced in-process inventory:
Holding large inventories of work-in-process represents a significant cost to the
manufacturer because it ties up capital. In-process inventory is of no value. It serves none of
the purposes of raw materials stock or finished product inventory. Accordingly, it is to the
manufacturers advantage to reduce work-in-progress to a minimum. Automation tends to
accomplish this goal by reducing the time a work part spends in the factory.
(10). High cost of not automating:

A significant competitive advantage is gained by automating a manufacturing plan.

The advantage cant easily be demonstrated on a companys project authorization form. The
benefits of automation often show up in intangible and unexpected ways, such as improved
quality, higher sales, better labor relations, and better company image. Companies that do
not automate are likely to find themselves at a competitive disadvantage with their customers,
their employees, and the general public.
AUTOMATION STRATEGIES:
There are certain fundamental strategies that can be employed to improve productivity in
manufacturing operations. Since these strategies are often implemented by means of
automation technology, we refer to them as automation strategies. Each strategy is discussed
in the following list
1. Specialization of operations:- The first strategy involves the use special purpose
equipment designed to perform one operation with the greatest possible efficiency. This is
analogous to the concept of labor specialization, which has been employed to improve labor
productivity
2. Combined operations:- Production occurs as a sequence of operations. Complex parts may
require dozens, or even hundreds, of processing steps. The strategy of combined operations
involves reducing the number of distinct production machines or workstations through which
the part must be routed. This is accomplished by performing more than one operation at a
given machine, thereby reducing the number of separate machines needed. Since each
machine typically involves a setup, setup time can usually be saved as a consequence of this
strategy. Material handling effort and nonoperation time are also reduced.
3. Simultaneous operations:- A logical extension of the combined operation strategy is to
perform at the same time the operations that are combined at one work station. In effect,
two or more processing (or assembly) operations are being performed simultaneously on the
same work part, thus reducing total processing time.
4. Integration of operations:- Another strategy is to link several workstations into a single
integrated mechanism using automated work handling devices to transfer parts between
stations. In effect, this reduces the number of separate machines through which the product
must be scheduled. With more than one workstation, several parts can be processed
simultaneously, thereby increasing the overall output of the system.
5. Increased flexibility:- This strategy attempts to achieve maximum utilization of equipment
for job shop and medium-volume situations by using the sa\me equipment for a variety of

products. It involves the use of flexible automation concepts explained in chapter1. Prime
objectives are to reduce setup time and programming timr for the production machine. This
normally translates into lower manufacturing lead time and lower work-in-process.
6. Improved

material

handling

and

storage:-

great

opportunity

for

reducing

nonproductive time exists in the use of automated material handling and storage systems.
Typical benefits included work-in-progress and shorter manufacturing lead times.
7. On-line inspection:- Inspection for quality of work is traditionally performed after the
process. This means that any poor-quality product has already been produced by the time it
is inspected. Incorporating inspection into the manufacturing process permits corrections to
the process as product is being made. This reduces scrap and brings the overall quality of
the product closer to the nominal specifications intended by the designer.
8. Process control and optimization:- This includes a wide range of control schemes
intended to operate the individual processes and associated equipment more efficiently. By
this strategy, the individual process times can be reduced and product quality improved.
9. Plant operations control:- whereas the previous strategy was concerned with the control
of the individual manufacturing process, this strategy is concerned with control at the plant
level. it attempts to manage and coordinate the aggregate operations in the plant more
efficiently. Its implementation usually involves a high level of computer networking within
the factory.
10.

Computer integrated manufacturing(CIM):- Taking the previous strategy one step

further, we have the integration of factory operations with engineering design and many of
the other business functions of the firm.CIM involves extensive use of computer applications,
computer data bases, and computer networking in the company.

BAISC ELEMENTS OF AN AUTOMATED SYSTEM:

1. Power source to accomplish the process and to operate the system.
2. Program of instructions to direct the process.
3. Control system to actuate the instructions.
(1)

POWER

(2)

(3)

PROGRAM
OF
INSTRUCTI

CONTRO
PROCESS
L
SYSTEM
Figure: Elements of an Automated System

1) Power, 2) Program of Instruction, and 3) Control System

1. Power Source: Power is required to drive the process as well as the controls. The term
process refers to the manufacturing operation that is performed on a work unit (casting,
forging, molding, machining, and welding). There are many sources of power available, but the
principal source of power used in automated system is electricity (electric power is widely
available at moderate cost).
Power is required for the following functions,
1.
2.
3.
4.
5.

To drive the process.

Loading and unloading the work unit.
Material transport between operations.
To actuate the control signals.
Data acquisition and information processing.

2. Program of Instructions: The actions performed by an automated process are defined by

a program of instructions. Whether the manufacturing operation involves low, medium or high
production, each part or product made in the operation requires one or more processing steps,
the particular processing steps for the work cycle are specified in a work cycle program. Work
cycle programs are called part program in numerical control.

Following points has to be considered while setting a work cycle program,

1.
2.
3.
4.
5.
6.

Number of steps in work cycle.

Manual participation in work cycle.
Process parameters.
Operator instructions.
Variations in part or product styles.
Variations in starting work units.

3. Control System: The control element of the automated system executes the program of
instructions. The controls in an automats system can be either closed loop or open loop.

Closed loop control system ( or feedback control system) is one in which the output
variable is compared with an input parameter.

Open loop control system operates without the feedback system. It is generally simpler
and less expensive than a closed loop system.

LEVELS OF AUTOMATION:
We can identify five possible levels of automation, in the production plant.

Level 5

Level 4

Level 3
Level 2
1

Enterprise Level

rate
Corporate
information system

Plant Level

Production
system

Cell or system Level

Machine
Device Level
Level

Manufacturing System
Individual
Sensors, actuators
machines
( group of machines)
Other hardware elements

1. Device level: This is the lowest level in automation hierarchy. It includes the actuators,
sensors and other hardware components that comprise the machine level. The device are
combined into the individual control loops of the machine, for example the feedback control
loop for one axis of a CNC machine or one joint of an industrial robot.
2. Machine level: Hardware at the device level is assembled into individual machines.
Examples include CNC machine tools and similar production equipment, industrial robots,
powered conveyors and automated guided vehicles. Control functions at this level include
performing the sequence of steps in the program of instructions in the correct order and
making sure that each step is properly executed.
3. Cell or system level: This is the manufacturing cell or system level, which operates under
instructions from the plant level. A manufacturing cell or system is a group of machines or
work-stations connected and supported by a materisl handling system, computer and other
equipment appropriate to the manufacturing process. Production lines are included in this level.
Functions include part dispatching and machine loading, coordination among machines and
material handling system and collecting & evaluating inspection data.
4. Plant level: This is the factory or production system level. It recieves instructions from the
corporate information system and translate them into operational plans for production. Likely
functions include order processing, process planning, inventory control, purchasing, material
requirements planning, shop floor control and quality control.
5. Enterprise level: This is the highest level of automation, consisting of the corporate
information system. It is concerned with all of the functions necessary to manage the company,

i.e., marketing & sales, accounting, design, research, aggregate planning and master
production schedule.
HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL
1. Sensors for measuring continuous and discrete process variables.
2. Actuators that drive continuous and discrete process variables.
3. Devices that convert continuous analog signals to digital data.
4. Devices that convert digital data into analog signal.
5. Input and output devices for discrete data.

Above figure shows the overall configuration of the process control system and how
these five components categories are used to interface the process with the computer. This
model represents the general arrangement of most of the material handling systems and
manufacturing systems.
Sensors: A sensor is device that converts a physical variable of one form into another form
that is more useful for the given application.
A continuous variable or parameter is generally considered to be analog, which means it
can take on any value within a certain range. Examples include force, temperature,
pressure, flow rate and velocity.
A discrete variable or parameter is one that can take on only certain values within a
given range, it can take on either of two possible values ON or OFF, open or closed.
Examples include limit switch open or closed, motor ON or OFF and workpart present or
not present in the fixture.
Common measuring devices used in automation,

Measuring device
Accelerometer

Description
Analog device used to measure vibrations

Ammeter

Analog device that measures the strength of an

Dynamometer

electrical current
Analog device used to measure force, power or
torque

Actuators: An actuator is a hardware device that converts a controller command signal into a
change i a physical parameter. The change in the physical parameter is usually mechanical,
such as a position or velocity change.
Most actuators can be classified into three categories,
1. Electrical actuators
2. Hydraulic actuators
3. Pneumatic actuators
1. Electrical actuators: These are most common, they include electric motors of various
kinds, stepper motors, and solenoids. Electrical actuators can be either linear (output is linear
displacement) or rotational (output is angular displacement).
The other type of Electrical actuators in addition to motors include, solenoids and relays, which
are electromagnetic devices like electric motors, but they operate differently.
2. Hydraulic actuators: These actuators use hydraulic fluid to amplify the controller
command signal. The available devices provide either linear or rotational motion. Hydraulic
actuators are often specified when large forces are required.
3. Pneumatic actuators: These actuators use compressed air (typically shop air in the
factory) as the driving power. Again both linear and rotatioanal pneumatic actuators are
available. Because of the relatively low air pressures involved, these actuators are usually
limited to relatively low force applications.
Analog to Digital Converters (ADC) / Digital to Analog Converters (DAC)
ADC converts the nalog signals from the process into the digital values to be used by the
computer. The process performed by a DAC is reverse to the ADC process. The DAC transfers
the digital output of the computer into a continuos signal to drive an analog actuator or other
analog device.
The procedure for converting an analog signal from the process into digital form typically
consists of the following steps,

1. Sensor and Transducer: This is the measuring device that generates the analog signal.
2. Signal Conditioning: The contiuos analog signal from the transducer may require
conditioning to render it into more suitable form.
3. Multiplexer: The multiplexer is a switching device connected in series with each input
channel from the process.
4. Amplifier: these are used to scale the incoming signal up or down to be compatible with
the range of the analog-to-digital converter.
5. Analog-to-digical converter: As its name indicates, the function of the ADC is to convert
the incoming analog signal into its digital counterpart.
Input and Output Devices:
1. Contact Input/output Interface: A contact i/p interface is a device by which binary data
are read into the computer from some external source. The contact o/p interface is the
device that communicates on/off signals from the computer to the process.
2. Pulse Counters & Generators: A pulse counter is a device used to convert a series of
pulses into a digital value. The value is then entered in to the computer through its i/p
channel. A pulge generator is a device that produces a siries of electrical pulses whose
total number & frequency are specified by the control computer. The total number of
pulses might be used to drive the axes of a positioning system.
FEEDERS, HOPPERS, ORIENTERS:
SELECTOR AND ORIENTOR: The purpose of the selector and/or is to establish the proper
orientation of the components for the assembly work head. A selector is a device that acts as a
filter, which allows only those parts to pass through which are in correct orientation.

Improperly oriented components are rejected back into the hopper. An orientor is a device that
allows properly oriented parts to pass through but provides a re-orientation of components that
are not properly oriented initially.
Feeders are commonly vibratory bowl feeders, where parts in a bowl are vibrated using a
rotary motion, so that they climb a helical track. As they climb, a sequence of baffles and
cutouts in the track create a mechanical filter that causes parts in all but one orientation to
fall back into the bowl for another attempt at running the gauntlet. Other common devices use
centrifugal forces, reciprocating forks, or belts to push parts through filters. These devices all
have the disadvantage that design and setup for new parts requires manual trial and error,
which is slow and error-prone. Vibration frequencies have been studied to optimize throughput
and sensors have been proposed to make feeders more efficient and effective. Parts feeders
provide a cast-effective alternative to manual labor, saving manufacturers valuable time and
labor costs. One operator can oversee a number of automated machines, as opposed to one
worker hand loading one machine.

Types of Feeders

Apron Feeders
Belt Feeders
Vibratory Feeders
Rotary Feeders
Reciprocating Feeders
Disc Feeders
Screw Feeders
Centrifugal Feeders
Flexible Feeders

Some of the commonly used feeders are described below:

Apron Feeders: Apron feeders are useful for feeding large tonnages of bulk solids being
particularly relevant to heavy abrasive ore type bulk solids and materials requiring feeding at
elevated temperatures. They are also able to sustain extreme impact loading. Apron feeders
use overlapping. Reinforced pans attached to chains or joined by links. An endless conveyor

travelling over rollers is created. The products are made by a number of manufacturers and
come in multiple shapes and widths.

Some feeders are made of extra heavy structural steel and are particularly suited to
handling coarse, abrasive material. For service applications such as feeding the primary
crusher, producers should make sure the feeder is up to the job. As with any product, it is best
to shop around not just for price, but to make certain the feeder matches the application.
Reciprocating feeders (Plate feeders): Plate Feeders also known as reciprocating feeders
as shown in below figure, are in widespread use, usually at the tail end of a conveyor or
elevator to relieve pressure and drag. Designed for feeding at a fixed rate, a plate is driven
reciprocally under a head of bulk material. Size varies and the feed rate can be controlled
easily. These feeders use rollers to support the product ranging from sand and gravel to
crushed stone that pass over belt feeders.

Advantages

Low cost
Ability to handle a wide range of miscellaneous materials.

Disadvantages

Not self - cleaning

Not recommended for highly abrasive materials.

Reciprocating-Tube Hopper Feeder: Reciprocating tube hopper feeder consists of a

conical hopper with a hole in the center through which the delivery tube passes. Relative
vertical motion between the hopper and the tube is achieved by reciprocating either the tube or
the hopper. During the period when the top of the tube is below the level of parts, some parts
will fall into the delivery tube.

Vibratory Bowl Feeder: Vibratory parts feeding is a technology used to orient (proper
position), singulate (proper quality) and differentiate (separate/sort) and move parts to a
desired location. Vibratory bowl feeders are used for feeding in oriented form a wide range of
components such as steel balls, nuts, belts, washers, rivets, nails, caps, plugs, spoons,
droppers, rings and various other components having very odd shapes. The vibratory bowl
feeder is the oldest and still most common approach to the automated feeding (orienting) of
industrial parts. These feeders are very useful for automatic feeding of such components to
various machines, etc., and on automatic assembly lines. The size of the feeders varies from
200mm 1000 mm diameters depending upon size, shape and weight of components. There
are no moving parts in the equipment and thus no wear and tear and need no maintenance.
The reason for the success of vibratory bowl feeders is the underlying principle of sensor less
manipulation that allows parts positioning and orienting without sensor feedback. This principle
is even more important at small scales, because sensor data will be accurate and more difficult
to obtain.
Vibratory feeder terminology
Hopper (or storage hopper). The storage hopper is the storage area provided to backlog
bulk parts prior to entering the feeder bowl. This hopper eliminates overloading or in sufficient

loads of parts, causing the bowl not to function as required. Feed rate from the hopper to a
bowl is mattered by a level control switch.
Basic bowl. The band, bottom and track assembly prior to any tooling for a specific part. Basic
bowls are not off the shelf standard items. They are individually designed and can be
supplied for any profile of part up to approximately 5 long.
Screw Feeder:

Centrifugal Hopper Feeder:

A centrifugal feed device is a hopper feeder system as shown

in figure with a central flat or conical turntable, which drives the working materials on this via a
rotary action. The resulting centrifugal force causes work pieces to separate out of the heap
and move towards the edge of the drum. Here they meet the delivery ring and slide onto ramp.
The speeds of the turntable and the delivery ring can be adjusted separately. Separated out
work pieces can be aligned by orienting devices and thus proceed to the hopper. Complex work
pieces can be fed by means of a conveyor belt. Any excess conveyed work pieces fall back into
the heap in the hopper.

Belt Feeders: Belt feeders are used to provide a controlled volumetric flow of bulk solids from
storage bins and bunkers. Like screw feeders, belt feeders can be an excellent choice when
there is a need to feed material from an elongated hopper outlet. Belt feeders generally can
handle a higher flow rate than screw feeders. These types of feeders have more moving parts
and therefore generally require more attention and maintenance than a well-designed screw or
vibrating pan feeder. They generally consist of a flat belt supported by closely spaced idlers and
driven by end pulleys.

Some particular Features of belt feeders include:

Suitable for withdrawal of material along slotted hopper outlet when correctly designed.
Can sustain high impact loads from large particles.

Centreboard Hopper Feeder: In this feeder, a blade made of hardened steel, with a shaped
top is oscillated up and down (by a crank mechanism) through a mass of parts. Properly
oriented parts are picked by the blade and discharged by gravity into the track. This type of
feeder is suitable for parts having simple shape like balls, cylinders, nuts and bolts, rivets, etc.
These are very robust and have long working life. The capacity of centerboard hopper is large.
The disadvantage of these is that they cannot be used for fragile components and the degree
to which they can orient is rather limited.

Flexible Feeders: A Crucial component of any assembly system is parts feeder. Unfortunately,
parts feeders are also one of the most specialized components of such systems. While a
modular approach could be employed which would allow specialized feeders to be quickly
brought into the work cell, there are several difficulties, which present themselves using this
approach. First, a feeding system tends to be large and bulky in comparison to other
specialized components, such as a robots gripper. Size alone could make storingall the
specialized feeders difficult. Second, a feeding system is generally more expensive than other
specialized components. It might be difficult to economically justify building several new
feeders for each new product being assembled. Third, the lead time to build and adjust most
current feeding systems is rather along. This diminishes the ability of the work cell to be
rapidly adapted to new products. Therefore. Simple placing current feeding technology behind
a generic, modular interface is not a feasible solution.
A typical robotic mechanical assembly work cell may have several feeders that are tooled
specifically for particular parts. Any change to the design of a part requires that the feeder be
either re tooled or completely replaced. With todays product life cycle as short as a few
months for many consumer products, this is no longer acceptable. The need for a greater
flexibility, lower cost of automation and faster product change over time has brought about a
new approach to pars feeding, termed flexible feeding. Flexible feeding is a emerging
alternative to traditional part feeding methods. This alternative greatly enhances the versatility
of a manufacturing work cell by using a robot manipulator and sophisticated sensing devices
such as machine vision; thereby significantly reducing both cost and set up time.
Just as robots are considered flexible devices with certain designs better suited to
certain tasks, the same is true for flexible feeders. A single flexible is not capable of feeding all
parts types. Part size, part geometry, mass and material will all affect the choice of the feeder
used. Similarly, the choice of vision system will depend on requirements for image resolution,
the vision algorithms and tool sets needed, and the vision processing performance required.
Advantages of flexible feeding:
Some of the advantages of the flexible concept of automation are:

Tooling is soft. The tooling is the vision and robot software. No long lead times to

fabricate tooling.
Tooling is flexible. Simultaneous product and tooling development can occur with flexible
feeding. Flexible feeding easily accommodates design changes that occur in product

development.
The ability to quickly produce new products at production volumes is a competitive
advantage.

Avoids the expense of building prototype and manual assembly tooling.

Can automate with lower production volumes through combining of product on same flex

feeding cell.
Simultaneous quality vision inspection using the vision system that guides robot.
Majority of tooling capital expense is reusable if new product is not successful in the
marketplace.