Industrial revolution during the 18th century was characterized by wide use of human labor to operate machines. While this was not necessarily a problem, the cost of production was very high due to labor charges. Consequently, profit margins were also very low. On realizing the need to have a better solution, manufacturers had to look for alternative solutions, and automation won their hearts. Plant automation meant that fewer workers were needed to operate machines because things happened automatically.
Automated processes do not rely on human input. Sensors detect the state of the manufacturing process and respond accordingly. The number of supervisors or machine operators needed in these systems is quite low. Factories can also run non-stop 365 days a year, except when routine maintenance is needed.
The main goal and advantage of automating a plant, is reducing labor costs. Another important goal is to increase production. This can translate to both increased profits and reduced production costs. The few employees who oversee the process can also get higher wages.
In the city of Hudson WI, plants can be automated through the use of controllers such as programmable logic controllers (PLCs). These are basically industrial-grade computers that execute programmed instructions to accomplish a specific task. This may include turning motors on or off, controlling their speed as well as powering other actuators in the process. PLCs were designed for use in small plants. They usually come with a limited number of ports, so they can only control a small process.
Plants can be controlled using SCADA. This is similar to a PLC, but there is a central computer and field modules that take-in the inputs and give out the output signals. The acronym SCADA stands for Supervisory Control and Data Acquisition. This system is very powerful and can be used to run huge plants like vehicle assembly from a control room.
The capital investment that goes towards automating an industry can be huge, but it can be rewarding in the long run. This process normally entails acquiring equipment to use, installation of the controllers and computers, programming of PLCs and finally commissioning of the automated process. A few technicians and at least one engineer are needed to supervise the whole process. Once operational, the system becomes less prone to breakdowns.
Automating a process in a factory for its long term benefits is highly recommended. The old way of doing things should be avoided. Key industry players in manufacturing and processing, should adopt new technologies which are known to be very efficient and cost effective. These changes will make it possible for old factories to be transformed into modern assembly, processing or manufacturing plants. Examples of the available technologies include DCS, PLC and SCADA.
However much a manufacturer may want to transition into a new-age type of process, there are some cases where automating a system does not make sense financially. For instance, small plants only have a couple of essential personnel. If a PLC or SCADA is installed, the same number of workers may still be needed. Therefore, it will not make any sense to automate the process.
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Why Opt For Industrial Plant Automation
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