Mechanical Components for Automation Engineering

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.

What is Automation?

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.

Objectives of Automation

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:

• Variability of products: In an increasingly globalized economy and in markets with rapidly changing customer preferences, it is important that manufacturing systems are able to produce a wide variety of products without the need for expensive changeovers or adaptations.
• Small series production: The demand for customized products and individual solutions is leading to an increased production of small series. Flexible manufacturing systems enable companies to produce also smaller batch sizes efficiently and cost-effectively.
• Fast time-to-market: The ability to respond quickly to market changes and to introduce new products is crucial to the success of a company. Flexible manufacturing systems make it possible to develop new products quickly and bring them into production.
• Efficiency and cost-effectiveness: By making production more flexible, companies can use their resources more efficiently and reduce costs. The adaptability of the systems makes it possible to adapt production optimally to the current demand and avoid overproduction.

What is automation engineering?

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.

Degrees of Automation

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:

• Manual control: A system or process is controlled and monitored completely through human interaction without automation. All decisions and actions are made and executed by people.
• Partial automation: In partial automation, some sub-processes or sub-functions are automated, while others are controlled manually. Human interaction is still required to perform certain tasks or make decisions.
• Semi-automation: Semi-automation refers to systems in which most tasks are automated but human intervention is still required to solve certain complex tasks or deal with unforeseen events.
• Full automation: Here, the system or process is fully automated and does not require any human interaction during normal operation. The system is able to make all necessary decisions and perform all actions to carry out operations efficiently and safely.

Automation Pyramid

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:

• (1) Field level: The physical devices that interact directly with the process variables in the real world are at the field level. This level forms the basis for data collection and control of the production process. Sensors are responsible for collecting data and actuators perform the actions.
• (2) Control level: The control level includes the hardware and software used to control and monitor the field equipment. Stored Program Controllers (SPCs) and Programmable Logic Controllers (PLCs) are typical representatives of this level. They collect the data from the field level sensors, process them, and send control signals to the actuators.
• (3) Process control level: At this level, the entire production is monitored and controlled. Supervisory Control and Data Acquisition (SCADA) systems are typical for this level. They enable visualization of process data, the monitoring of system status and the possibility of manual intervention in the process. SCADA systems often offer data collection and reporting capabilities.
• (4) Operational management level: At this level, different process areas are coordinated and information is exchanged between the departments. Manufacturing Execution Systems (MES) support operational decisions and the control of production performance.
• (5) Company management level: The company management level includes the higher-level management and administration of the company. Enterprise Resource Planning systems (ERP systems) are typical for this level. They support the planning and control of all company resources, including production, procurement, sales, finance and human resources.

Mechanical Components in Automation Engineering

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.

Automation Examples

Automation engineering optimizes processes, increases efficiency, and relieves human labor from repetitive tasks. Below are some specific examples of automation: