Computer Integrated Manufacturing

Unit 5 Process Control and Data

Analysis

Dr.S.Thirumalai Kumaran
Associate Professor / Mechanical
PSG iTech
 Continuous Vs Discrete Control

• Continuous control, in
which the variables
and parameters are
continuous and analog.
• Discrete control, in
which the variables
and parameters are
discrete, mostly binary
discrete.
 Continuous Control System

• Regulatory Control
• Feedforward Control
• Steady-State
Optimization
• Adaptive Control
 Continuous Control System

• Regulatory Control
• Feedforward Control
• Steady-State
Optimization
• Adaptive Control
 Continuous Control System

• Regulatory Control
• Feedforward Control
• Steady-State
Optimization
• Adaptive Control
 Continuous Control System

• Regulatory Control
• Feedforward Control
• Steady-State
Optimization
• Adaptive Control
 Discrete Control System

• Event Driven system

• Time Driven System
 Discrete Control System

• Event Driven system

• Time Driven System
 Examples

Event Driven: i) Robot loads a work part into fixture, and the
part is sensed by limit switch. Sensing the part’s presence and
then proceeding. ii) The hopper triggers a low-level switch, to
open a valve to start the flow of new plastic into hopper.
Time Driven: i) Heat-treating operations must be carried out
for a certain length of time. ii) Shop clock is set to sound a bell
at specific moments during the day to indicate these start and
stop times.
 Computer Process Control

a. Forms of computer process control

 Computer Process Control

b. Computer process monitoring

• Process data. These are measured values of input parameters and output
variables that indicate process performance. When the values are found
to indicate a problem, the human operator takes corrective action.
• Equipment data. These data indicate the status of the equipment in the
process. The data are used to monitor machine utilization, schedule tool
changes, avoid machine breakdowns, diagnose equipment malfunctions,
and plan preventive maintenance.
• Product data. Government regulations require certain manufacturing
industries to collect and preserve production data on their products. The
pharmaceutical and medical supply industries are prime examples.
Computer monitoring is the most convenient means of satisfying these
regulations. A firm may also want to collect product data for its own use.
 Computer Process Control

c. Direct Digital Control (DDC)

Analog control system vs DDC system
 Computer Process Control

d. Computer Numerical Control and Robotics

• It involves the use of the computer to direct a
machine tool through a sequence of processing steps
defined by a program of instructions specifying the
details of each step and their sequence.
• A robotic work cell usually includes other equipment
besides the robot, and the activities of the other
equipment in the work cell must be coordinated with
those of the robot.
 Computer Process Control

e. PLC
• It is a microprocessor-based controller that uses
stored instructions in programmable memory to
implement logic, sequencing, timing, counting, and
arithmetic control functions for controlling machines
and processes.
 Computer Process Control

f. Supervisory Control and Data Acquisition (SCADA)

 Computer Process Control

g. Distributed Control Systems (DCS)

 Computer Control Requirements

• Polling. In computer process control, polling refers to the

periodic sampling of data that indicates the status of the process.
• Interlocks. An interlock is a safeguard mechanism for
coordinating the activities of two or more devices and preventing
one device from interfering with the other(s).
• Interrupt system. It is a computer-control feature that permits
the execution of the current program to be temporarily
suspended to execute another program or subroutine in response
to an incoming signal indicating a higher priority event.
 Single-Level versus Multilevel
Interrupt Systems
Three interrupts representing tasks of three different priority
levels arrive for service in the reverse order of their
respective priorities. Task 1 with the lowest priority arrives
first. Soon after, higher priority Task 2 arrives. And soon after
that, highest priority Task 3 arrives. How would the
computer-control system respond under (a) a single-level
interrupt system and (b) a multilevel interrupt system?
Three interrupts representing tasks of three different priority levels arrive for service
in the reverse order of their respective priorities. Task 1 with the lowest priority arrives
first. Soon after, higher priority Task 2 arrives. And soon after that, highest priority
Task 3 arrives. How would the computer-control system respond under (a) a single-
level interrupt system and (b) a multilevel interrupt system?
 Automatic Identification and Data
Capture (AIDC)
• Data encoder. A code is a set of symbols or signals that usually
represent alphanumeric characters. When data are encoded, the
characters are translated into a machine-readable code. A label or
tag containing the encoded data is attached to the item that is to
be identified.
• Machine reader or scanner. This device reads the encoded
data, converting them to alternative form, usually an electrical
analog signal.
• Data decoder. This component transforms the electrical signal
into digital data and finally back into the original alphanumeric
characters.
 AIDC Technologies

• Optical
• Electromagnetic
• Magnetic
• Smart card
• Touch techniques
• Biometric
 Linear 1-D Bar Codes

Invented in 1840, Morse code is a series of long and short pulses

that convert the alphabet into electrical signals. The difference is that
Morse code uses dots/dashes and barcode uses vertical lines.

Height controlled Width controlled

Morse Code
 Types of Linear 1-D Bar Codes

UPC-Universal Product Code

 2-D Bar Codes

• A stacked bar code consists of multiple rows of conventional

linear bar codes stacked on top of each other.

• A matrix symbology consists of 2-D patterns of data cells that

are usually square and are colored dark (usually black) or white.
Their advantage over stacked bar codes is their capability to
contain more data.
 Radio Frequency Identification

In radio frequency identification, an identification tag or label

containing electronically encoded data is attached to the
subject item (part, product, or container). The identification
tag consists of an integrated circuit chip and a small antenna.
 Magnetic Strips

• A magnetic stripe is a thin plastic film containing

small magnetic particles whose pole orientations can
be used to encode bits of data into the film.
• The film can be encased in or attached to a plastic
card or paper ticket for automatic identification
• These are the same kinds of magnetic stripes used to
encode data onto plastic credit cards and bank access
cards.
 Optical Character Recognition
(OCR)

• OCR is the use of specially designed alphanumeric

characters that are machine readable by an optical
reading device.
• The substantial benefit of OCR technology is that
the characters and associated text can be read by
humans as well as by machines.
 Machine Vision

• Machine vision systems are used to read both data Matrix

and stacked bar codes.
• Machine vision systems are capable of distinguishing
among a variety of products moving down a conveyor so
that the products can be sorted.
• The recognition task is accomplished without using special
identification codes on the products and is instead based
on the inherent geometric features of the object.
 Statistical Process Control

• Control charts
• Histograms
• Pareto charts
• Check sheets
• Defect concentration diagram
• Scatter diagrams
• Cause-and-effect diagrams
 Control Charts

• 𝒙ഥ and R chart
Eight (m) samples of size 5 (n) have been collected from a
manufacturing process that is in statistical control, and the
dimension of interest has been measured for each part.
Determine the values of the center line, LCL, and UCL to
construct the x and R charts.
 P Chart
Ten samples m = 10 of 20 parts each n = 20 have been collected.
In one sample there were no defects; in three samples there was
one defect; in five samples there were two defects; and in one
sample there were three defects. Determine the center line, lower
control limit, and upper control limit for the p chart.
 C Chart

A continuous plastic extrusion process is operating

in statistical control. Eight meters of the extrudate
have been examined and a total of 14 surface
defects have been detected in that length. Develop a
c chart for the process, using defects per hundred
meters as the quality characteristic of interest.
 Histogarm

• The shape of the distribution

• Any central tendency
exhibited by the distribution
• Approximations of the mean
and mode of the distribution
• The amount of scatter or
spread in the data.
 Pareto Charts

• A Pareto chart is a special

form of histogram, in which
attribute data are arranged
according to some criteria
such as cost or value.
 Check Sheets

• A check sheet is a data gathering tool generally used

in the preliminary stages of the study of a quality
problem.
• The operator running the process (e.g., the machine
operator) is often given the responsibility for
recording the data on the check sheet, and the data is
often recorded in the form of simple checkmarks.
 Defect Concentration Diagrams

• It is a drawing of the product,

with all relevant views
displayed, onto which have
been sketched the various
defect types at the locations
where each occurred.
• An analysis of the defect types
and corresponding locations
can identify the underlying
causes of the defects.
 Scatter Diagram

• In many industrial
manufacturing
operations, it is
desired to identify a
possible relationship
between two process
variables.
• The scatter diagram
is useful in this
regard.
 Cause-and-Effect Diagrams

It is a graphical-tabular chart used to list and analyze the

potential causes of a given problem.
 Automated Inspection

• Automation of the inspection procedure will almost

always reduce inspection time per piece, and automated
machines do not experience the fatigue and mental errors
suffered by human inspectors.
• 100% automated inspection cannot guarantee 100% good
quality product.
• Some automated inspection systems can be adjusted to
increase their sensitivity to the defect they are designed to
detect.
 Contd.,

• A type I error (false-

positive) occurs if an
investigator rejects a null
hypothesis that is actually
true in the population;
a type II error (false-
negative) occurs if the
investigator fails to reject a
null hypothesis that is
actually false in the
population.
Contd.,
Thank You