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What is Automation?

Automation or industrial automation is the use of control systems such as computers to control industrial machinery and processes therefore reducing the need for human intervention. In the scope of industrialization, automation is a step beyond mechanization. Mechanization provided human operators with machinery to assist them with the physical requirements of work; automation greatly reduces the need for human sensory and mental requirements as well.

Specialized hardened computers, referred to as programmable logic controllers (PLCs), are frequently used to synchronize the flow of inputs from (physical) sensors and events with the flow of outputs to actuators and events. This leads to precisely controlled actions that permit a tight control of almost any industrial process.

Human-machine interfaces (HMI) formerly known as man-machine interfaces, are usually employed to communicate with PLCs and other computers, such as entering and monitoring temperatures or pressures for further automated control or emergency response.

For manufacturing companies, the purpose of automation is shifting from increasing productivity and reducing costs, to broader issues, such as increasing quality and flexibility in the manufacturing process. Don't get me wrong, increasing productivity and reducing costs is not a bad thing, in fact it is a must to stay competitive with the company down the street that offers the same products and services that you do.

Today, manufacturers are putting increased emphasis on the need for flexibility and convertibility in their processes. Our customers are increasingly demanding the ability to easily switch from manufacturing Product A to manufacturing Product B without having to completely rebuild their production lines. 

As a systems integrator, the technology we use at Quigg International is "current" and we stay up to date with leading edge technologies so that we can offer our customers the best possible solutions for their automation requirements. We have been told by our customers that our innovative ideas and the unique way we look at things has provided them with solutions and results, above and beyond their expectations.

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What is a PLC?

A programmable logic controller (PLC) is a digital computer used for automation of electromechanical processes such as the control of machinery or processes. Unlike general-purpose computers, PLCs are armored for severe conditions (dust, moisture, heat, cold, etc) and have extensive input/output (I/O) arrangements which connect the PLC to sensors and actuators.

These PLCs read limit switches, analog process variables (such as temperature and pressure), and the positions of complex positioning systems. On the actuator side, PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic relays or solenoids, or analog outputs. Programmable controllers are widely used in motion and positioning control.

The input/output arrangements may be built into a simple PLC, or the PLC may have external I/O modules attached to a computer network that plugs into the PLC. PLCs have built in communications ports and can communicate over a wide range of media including RS-485, Coaxial, and even Ethernet for I/O control at network speeds up to 100 Mbit/s. A PLC is an example of a real time system since output results must be produced in response to input conditions within a certain period of time.

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Origin of the PLC

The PLC was invented in response to the needs of the American automotive manufacturing industry. PLCs were initially adopted by the automotive industry where software revision replaced the re-wiring of hard-wired control panels when production models changed.

Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was accomplished using hundreds or thousands of relays, cam timers, and drum sequencers and dedicated closed-loop controllers. The process for updating such facilities for the yearly model change-over was very time consuming and expensive, as the relay systems needed to be rewired by skilled electricians.

Early PLCs were designed to replace these relay logic systems. These PLCs were programmed in "ladder logic", which strongly resembles a schematic diagram of relay logic. Modern PLCs can be programmed in a variety of ways, from ladder logic to more traditional programming languages such as BASIC and C.

Ladder logic can be thought of as a rule-based language, a "rung" in the ladder represents a rule. When implemented with relays and other electromechanical devices, the various rules "execute" simultaneously and immediately. When implemented in a programmable logic controller, the rules are typically executed sequentially by software, in a continuous loop.

Ladder logic is widely used to program PLCs, where sequential control of a process or manufacturing operation is required. Ladder logic is useful for critical control systems, or for reworking old hardwired relay circuits.

The functionality of the PLC has evolved over the years to include sequential relay control, motion control, process control, distributed control systems and networking. The data handling, storage, processing power and communication capabilities of some modern PLCs are equivalent to desktop computers.

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What is HMI?

PLCs may need to interact with people for the purpose of configuration, alarm reporting or everyday control. A Human-Machine Interface (HMI) is employed for this purpose. HMIs are also referred to as MMIs (Man Machine Interface) and GUI (Graphical User Interface).

A simple system may use only  buttons and lights to interact with the user. Text displays are available as well as graphical touch screens or panelviews. More complex systems use programming and monitoring software installed on a computer, with the PLC connected via a communication interface.

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What is a Robot? 

A robot is a programmable machine for performing tasks: a mechanical device that can be programmed to carry out instructions and perform complicated repetitive tasks more quickly, cheaply, and accurately than humans. Another definition of a robot is: a computer-controlled machine that is programmed to move, manipulate objects, and accomplish work while interacting with its environment.

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Are robots hard to work with?

No, there is no need to fear the “know-how” required to use robots. With today’s technology if you can operate the remote control on your TV, you can learn how to teach a robot. Quigg International has a simple yet comprehensive training program that we guarantee will give you a comfort level operating robots that you probability didn’t think you could have.

Today, commercial and industrial robots are in widespread use performing jobs more cheaply and with greater accuracy (quality) and reliability than humans. They are also employed for jobs which are too dirty, dangerous or dull to be suitable for humans. Robots are widely used in manufacturing, assembly and packing and the mass production of consumer and industrial goods.

Over the last 30 years automobile factories have become dominated by robots. A typical factory contains hundreds of industrial robots working on fully automated production lines. On these automated production lines, a vehicle chassis can be welded, glued, painted and finally assembled by a sequence of robot stations.

Most of todays manufacturers in the supply chain use some form of automation in their facilities as well. In a metal stamping operation for example, robots can be used to "destack" a pile of metal blanks and load them automatically into the stamping presses. Once the metal has been stamped the robot will transfer the part to another operation or restack the part for the next operation. Assembly work is also performed by robots, the repeatability aspect of operations being done the same way every time increases productivity and product quality over human labour. Industrial robots are also used extensively for palletizing and the packaging of manufactured goods.