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From the international authority on advanced manufacturing technology and automation
The second edition of Sensors and Control Systems in Manufacturing fully explains the technical aspects of the latest senor technologies, showing how to select and install simple, affordable sensors to maximize productivity and minimize production errors. This "one-stop" guide offers you hands-on instruction on integrating various sensors with appropriate control means throughout manufacturing operations. The book presents state-of-the-art information on traditional sensors, laser sensors, LED sensing technology, and fiber optics in sensors and control systems.
A Comprehensive Guide to Sensors and Control Systems in Manufacturing
Thoroughly updated with cutting-edge technologies, this detailed resource offers proven methods for effectively evaluating, selecting and implementing sensors and controls to ensure error-free manufacturing environments. Sensors and Control Systems in Manufacturing 2nd Edition offers step-by-step guidance on applying sensors to measure product parameters, control manufacturing, develop precision manufacturing systems and generate and control motion. Real-world examples are included throughout to demonstrate successful industrial applications.
Coverage Includes:
- The latest sensor technologies, such as MEMS, photo-, bio-, nano-, and LED sensors.
- Sensor classification and types, including photoelectric, inductive and capacitive.
- Fiber optics in sensors and control systems.
- Networking of sensors and control systems.
- Sensors and control technology in computer-integrated manufacturing.
- Advanced sensor technology in precision manufacturing applications.
- Industrial sensors and control.
- Sensors in flexible manufacturing systems.
- Communications – indexing, data transmission, and signal processing.
- SpectRx sensing technology.
- Manufacturing operation control through financial planning.
From the Preface
Rising costs, shorter lead times, complex customer specifications, competition from across the street - and around the world.
Business today faces an ever-increasing number of challenges. The manufacturers that develop more effective and efficient forms of production, development, and marketing will be the ones who meet these challenges.
The use of advanced sensors and control technology makes a fundamental commitment to manufacturing solutions based on simple and affordable integration. With this technology, one can integrate manufacturing processes, react to rapidly changing production conditions, help personnel to react more effectively to complex qualitative decisions, and lower the cost of and improve product quality throughout the manufacturing enterprise.
The first step in achieving such flexibility is to establish an information system that can be reshaped whenever necessary, thus enabling it to respond to the changing requirements of the enterprise - and the environment. This reshaping must be accomplished with minimal cost and disruption to the ongoing operation.
Sensors and control technology will play a key role in achieving flexibility in the information system. However, this technology alone can not shorten lead time, reduce inventories, and minimize excess capacity to the extent required by today's manufacturing operation. This can be accomplished only by integrating various sensors with appropriate control means throughout the manufacturing operation within computer integrated manufacturing (CIM) strategy. The result is that individual manufacturing processes will be able to flow, communicate, and respond together as a unified cell, well structured for their functions.
In order to develop a sensory and control information system that will achieve these objectives, the enterprise must start with a specific long-range architectural strategy, one providing a foundation that accommodates today's needs as well as taking those of tomorrow's - including the support of new manufacturing processes, incorporating new data functions, and establishing new data bases and distributed channels - into account. The tools for this control and integration are available today.
The United States leads the world in inventing new products; however, many of these new products, ultimately, are manufactured by other countries. The inability of the United States manufacturers to compete globally cannot be blamed on low-cost labor in other countries; more than one-half the trade deficit comes from foreign industries that pay higher wages. The inability to apply affordable manufacturing systems for automation can be a contributing factor to this dilemma.
An affordable manufacturing system is, simply, a system that contains a variety of reliable parts, harmoniously joined together to generate a specific motion that will achieve a particular manufacturing operation, directed and controlled by simple and effective sensors and control systems. Modern manufacturing technology is prevalent in the design and control of engineering systems and also in applying the sensory and control technology in production systems to situations such as product fabrication and assembly.
When considering the design aspect of a system the following must be taken into account: dynamics, kinematics, statics, and even styling of parts. All of these play a vital role in forming optimum manufacturing parameters in system design. Motion generation and control through various sensors provide a review of manufacturing engineering concepts from a system's point of view, directed toward the manufacturing engineering problems.
Manufacturing engineering plays a key role in translating new product specifications from design engineering into process plans which are then used to manufacture the product. As the product is being designed, manufacturing technical evaluators work with design engineers to ascertain if sensors and control systems for process monitoring and control can be integrated into the design of a system, and at what cost. Tolerances, materials, clearances, appropriate handling of parts, acceptable types and positioning of sensors, and product assembly times are particularly important factors in this evaluation because they directly affect productivity, the guidelines of which are essential to this analysis.
Cost estimates are equally important. If a new process is needed because, for example, existing processes are deemed too expensive or incapable of producing the desired product, process engineers would be asked to either develop a new economical process or to change product design. Choosing the best alternative could be very difficult because such a decision is based on many conflicting objectives, for example, customer specifications, cost, feasibility, timeliness, market share, parts availability, standard parts, availability of part tooling, sensors locations, and the like. A well-designed system incorporating sensors and control technology for the generation of motion for a manufacturing system plays a fundamental role in the new manufacturing thinking.
Advanced sensory and control technology is more than an implementation of new technologies. It is a long-range strategy that allows components of the entire manufacturing operation to work together to achieve the qualitative and quantitative goals of business. It must have top management commitment and may entail changing the mind-set of people in the organization and managing that change. However, the rewards are great since successful implementation of this technology is, in large measure, responsible for the success of computer-integrated manufacturing strategy today.
About the Author
Sabrie Soloman PhD is Founder, Chairman and CEO of American SensoRx, Inc. He also teaches in the advanced manufacturing program at Columbia University.
Table of Contents
Foreword. Preface. Acknowledgments. Chapter 1: The Role of Sensors in the 21st Century. Chapter 2: Classification and Types of Sensors. Chapter 3: Fiber Optics in Sensors and Control Systems. Chapter 4: Networking of Sensors and Control Systems in Manufacturing. Chapter 5: The Role of Sensors and Control Technology in Computer Integrated Manufacturing. Chapter 6: Advanced Sensor Technology in Production Manufacturing Applications. Chapter 7: Industrial Sensors and Control. Chapter 8: Sensors in Flexible Manufacturing Systems. Chapter 9: Communications. Chapter 10: SpectRx NIR Technology. Chapter 11: Economic and Social Interests in the Workplace. Index. |
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