In the modern world, the importance of industrial automation can’t be overstated. Responsible for the rapid development of technology and consumerism across the globe, industrial automation created a massive boom by improving accuracy and precision.
By automating the process, its accuracy and repeatability are increased exponentially, leading to effortless mass production of parts.
Furthermore, industrial automation and precision also lead to improving the entire manufacturing process itself. With reduced margins of error, it helped manufacturers to improve the pace of production and make it more efficient.
Therefore, accuracy and precision in industrial automation are responsible for not only the part quality but also the effectiveness of the entire process itself. This role of accuracy and precision in industrial automation will be addressed in detail below.
The Role of Accuracy in Automation
Accuracy serves a dual role in industrial automation, namely enhancing product quality and minimizing waste generation and errors.
Enhancing Product Quality
In many industrial sectors, especially automotive manufacturing, aerospace, medical equipment manufacturing and more, there is a major emphasis on the quality of the products. These parts have to be produced with very tight tolerances, meaning there is little to no margin for error.
Even the smallest of deviations in quality and measurement can have disastrous consequences. Industrial automation handles this demand with a focus on accuracy.
Since the production, machining and finishing are done by automated equipment, one can ensure a very high degree of accuracy, thereby improving product quality and making sure it can handle the stringent demands of the sectors mentioned above.
Minimizing Waste and Errors
On the flip side, a significant improvement in accuracy directly leads to a reduction in waste generation. When errors are present, a part has to be reworked or finished extensively, leading to the creation of more waste. Fortunately, with industrial automation, this is not the case.
The accuracy of the part produced not only eliminates any errors but also makes sure that there is minimal waste generation. This makes the process reliable as well as profitable for manufacturers in the long term.
Precision as a Key Driver in Industrial Processes
Precision is another key factor of industrial automation. Here’s how it contributes to the entire process:
Consistency in Repetitive Tasks
While accuracy helps determine how close a part is produced with respect to the actual value, precision focuses more on repeating this accuracy from one part to another. For a profitable venture, it is absolutely vital to achieve this accuracy consistently. Without this repeatability, the accuracy is of no tangible value.
Therefore, precision in automation ensures that parts created en masse are as identical to each other as possible. This will not only ensure the quality of the end product but will also determine the reputation of a company among its consumers.
Importance of Measurement Tools
Automation plays a major role in achieving the appropriate accuracy and precision for a given part. However, another failsafe needs to be in place to ensure there are no errors. This is done primarily with the help of measurement tools.
A classic example is linear scales, a precision measurement tool used in milling machines and lathes to ensure each part produced matches the other exactly. This combination of high-quality automation tools along with measurement equipment ensures an exceptional level of accuracy and precision in all industrial manufacturing.
Tools and Technologies Supporting Precision
Advanced Measurement Systems
To ensure precision, industrial automation also employs a variety of advanced measurement systems apart from linear scales. Some of the most prominent technologies include coordinate measuring machines, robotic inspection systems and laser scanners.
Coordinate Measuring Machines: This is a precision measuring device used to test parts or assemblies to see if their dimensions match the initial design. The measuring is done primarily using a probe, which can be mechanical or optical.
Laser Scanners: These hi-tech devices use laser capture 3D images or data of parts or objects, providing a comprehensive look at their dimensions.
Robotic Inspection Systems: This technology employs advanced robotics to check for dimension accuracy, surface finish and overall production quality.
Integration of Smart Sensors in Automation
Apart from directly measuring the precision of parts produced by automation, smart sensors also aid in improving the part quality. A great example is hybrid harmonic filters. Since all automated machines run on electricity, they require stable power to ensure optimal functioning.
These filters ensure this by counteracting any distortions present in the input current, ensuring clean, stable power. Therefore, sensors and filters are the underlying support structure for precision in industrial automation.
Benefits of Accuracy and Precision in Industrial Automation
Improved Operational Efficiency
The importance of accuracy and precision in industrial automation far extends part quality and repeatability. By making sure that the part is highly accurate and precise, it also helps solidify the entire manufacturing process, right from procuring the source material to its machining and subsequent finishing.
Thus, a high degree of accuracy helps to streamline and hone the entire manufacturing process. The end result is a process that is highly efficient and effective.
Increased Cost Savings and ROI
Although industrial automation is quite expensive on paper, it is actually more cost-effective in the long run. Apart from the initial cost of investment, the high degree of accuracy and precision of the parts and assemblies leads to minimal waste generation, improvement in reputation for the manufacturer and elimination of extra processes, namely finishing.
Moreover, by making the process more efficient, automation reduces any possible downtime, increases production speed and further contributes towards cost savings for a company. Keeping these factors in mind, accuracy and precision in industrial automation is an excellent return on investment for most manufacturers.
Conclusion
In the end, accuracy and precision in industrial automation are ensured by measurement tools such as linear scales, coordinate measuring machines and other advanced technology. This is further supported by the right sensors and filters, such as hybrid harmonic filters.
The end result is a part that is of high quality and accuracy and one that can be repeated quickly and efficiently with little to no human intervention.
Article and permission to publish here provided by Dhruv Mehta. Originally written for Supply Chain Game Changer and published on November 29, 2024.
Cover image by Michal Jarmoluk from Pixabay.