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Automation engineering covers a wide range of components and technologies that work together to automate and optimize processes and machines. Mechanical components serve as one of the basic building blocks for the implementation of automated systems. These components include actuators, sensors, mechanical transmission systems and other mechanical elements required for the movement, control and monitoring of systems and machines. This article introduces the basics of automation and automation engineering and explains where mechanical components are used.
Automatization or automation refers to the general process of converting manual or repetitive tasks into automated processes, which can be carried out without human intervention, i.e. self-controlled. This can be achieved by using technologies such as machines, computer programs or robots.
In the past, automation efforts focused on having machine perform rigid and repetitive production processes. The main objective was to increase productivity by replacing human labor with machines. These rigid automation systems were designed to handle specific tasks with little requirement for flexibility and adaptability. Today, the focus shifted to process optimization of production. There is an increasing interest in developing flexible manufacturing systems that are able to master workflows with different tasks. These flexible systems are intended not only to enable productivity increases, but also offer flexibility and an overall increased efficiency. This development is driven, among other things, by the following aspects:
Automation Engineering is an engineering discipline that covers planning, development, implementation and operation of automation systems. These systems are used to automate processes or machines by combining sensors, actuators, controllers, and software to enable automatic control and monitoring. In the context of plant engineering, automation engineering deals with the integration of automation systems in large-scale industrial plants. Plant manufacturers use automation engineering to operate complex production facilities more efficiently and safely. In mechanical engineering, automation engineering is crucial in the development and integration of automated processes into individual machines and production lines to increase production capacity and improve quality.
Digitalization of production has a significant impact on automation in the industry. By integrating digital technologies such as Industry 4.0, Industrial Internet of Things (IoT), Artificial Intelligence (AI), big data, and cloud computing into industrial processes, automation systems are becoming increasingly more powerful and intelligent. This opens up new opportunities for automation as data can be collected, analyzed and used in real time to optimize processes and support decisions.
According to DIN IEC 60050-351, the international standard for definitions of terms in electrical engineering, electronics and related fields, the degree of automation refers to the degree of automation of a system or process. It is a measure of the extent to which human work is replaced or supported by automatic control and monitoring. A higher degree of automation means greater independence from human intervention and greater ability of the system to perform tasks autonomously. The degree of automation can be measured on a scale from manual control to complete automation:
The automation pyramid is a concept used in industrial automation to describe the hierarchical structure of automation systems. This pyramid serves as a model to represent the different levels of automation. The automation pyramid typically consists of the following levels:
In automation engineering, mechanical components are used for various purposes. They are used to realize automated systems in different application areas such as the manufacturing industry, logistics, transport and robotics. They allow movement control, force generation, material handling and they ensure the safety of people and equipment.
Sensors are devices that detect physical measured values such as temperature, pressure, fill level, position or speed and convert them into electrical signals. They are used to monitor the condition of machines or processes and to provide feedback to the controller. Examples for sensors in automation engineering are proximity sensors, pressure sensors, temperature sensors, positional detectors and motion sensors.
Actuators are devices that perform a mechanical motion based on a control signal. They are used to generate forces and perform movements, such as opening and closing valves, moving robot grippers, or positioning workpieces. Typical actuators are pneumatic and hydraulic cylinders, linear modules, electric motors, signal lights or indicator lights.
Mechanical transmission systems are used to transfer or modify movements or forces from one point to another. They can help vary the speed of movement, increase or decrease torque, and create complex patterns of movements. Examples for mechanical transmission systems are gear boxes, belt drives, belt conveyors and rollers, couplings and shafts.
Programmable Logic Controllers (PLCs) are real-time computerized control systems used in automation engineering to control machines, systems and processes. They are based on a special hardware device called PLC, as well as special programming and configuration software. The basic principle of a PLC is that it receives different input signals from sensors or other sources, processes them and sends output signals to actuators or other devices based on them. This process is controlled by a program programmed into memory that is stored in the PLC.
Automation engineering optimizes processes, increases efficiency, and relieves human labor from repetitive tasks. Below are some specific examples of automation:
Automation example - The automated door uses a cylinder mechanism for the automatic opening of the door. This mechanism can be controlled by a remote-controlled control center that allows users to open or close the door remotely. A confirmation sensor is mounted above the door to monitor the opening and closing process.
Automation example - This rotary and transfer mechanism allows a workpiece to be transferred from one conveyor belt to the next by rotating the workpiece by 180°. An arm first rotates the workpiece by 90°, while a rod moves the gripper by the remaining 90°. This is done by a motor and gear system that synchronously rotates the arm and the gripper.