Best part being an automation engineer in
small-scale firm which manufacturing special machine is you could have
opportunity to involve in all steps of manufacturing.
- Design and drafting
- Production
- Factory testing
- Commissioning
Let me explain all steps based on my previous
company experience.
Design and drafting
This part is the most important area. Here we
discuss the with client and note all the requirements from the client side.
Mechanical design engineers check the space constraints and prepare the spacing
layouts and complete the dimensions.
In the Electrical design section includes the
following steps:
Design of sequence of operation.
Sequence of operation design is based on the
clients required. From the client side, they give the process details or
machine operation details and final product. According to that one, we design
the sequence of operation.
Design of Cause-and-effect matrix.
Cause and effect matrix designs includes
operation of machine in the different mode like auto, semi-auto, manual. In
this section, we design the response of the machine when the inputs are
energized. Emergency response of the machine is designed in this section. From
these we will get the exact idea of machine response. According to these causes
and effect diagram, we prepare the operating manual and parameter list.
Design of schematic diagram.
Once panel SOP and Cause and effect design
completed according to that we prepare the schematic diagram for the machine in
this section we select the controller and input and output allocation.
Panel sizing, IO listing and material
selection.
After schematic preparation we prepare the
general layout of the control panel and according to that we decide the panel
size also need to consider the temp effect in panel. VFD panels required
additional cooling systems.
Cable routing design
From the 3D models of the machine, we prepare
the cable routing and cable tray locations. As per the electrical load, we
select the cable size. For instruments required specials cables for the
communication systems requires shielded cables. As per the cable's selection,
we prepare the cable Termini nation Lay-out. According to the glands and gland
plate size is done.
BOM preparation
From the above sections we prepare the bill
of materials and in this section, we consider the costing side. We take
Quotations from different suppliers and finalize the materials.
Production.
In this section, design is handed over to
production department. As per the schematic and BOM, they prepare the control
panel wiring and fix it in the machine. Cable routing and terminations are done
as per the design.
PLC programming, HMI Design and testing.
As per the sequence of operation and IO
listing, we prepare a logic program. Initial stage program output is simulated
using software and verify the cause-and-effect diagram. Once simulation is ok
then we download the Program to the actual controller.
To be continued......
Best part being an automation engineer in
small-scale firm which manufacturing special machine is you could have
opportunity to involve in all steps of manufacturing.
- Design and drafting
- Production
- Factory testing
- Commissioning
Let me explain all steps based on my previous
company experience.
Design and drafting
This part is the most important area. Here we
discuss the with client and note all the requirements from the client side.
Mechanical design engineers check the space constraints and prepare the spacing
layouts and complete the dimensions.
In the Electrical design section includes the
following steps:
Design of sequence of operation.
Sequence of operation design is based on the
clients required. From the client side, they give the process details or
machine operation details and final product. According to that one, we design
the sequence of operation.
Design of Cause-and-effect matrix.
Cause and effect matrix designs includes
operation of machine in the different mode like auto, semi-auto, manual. In
this section, we design the response of the machine when the inputs are
energized. Emergency response of the machine is designed in this section. From
these we will get the exact idea of machine response. According to these causes
and effect diagram, we prepare the operating manual and parameter list.
Design of schematic diagram.
Once panel SOP and Cause and effect design completed according to that we prepare the schematic diagram for the machine in this section we select the controller and input and output allocation.
Panel sizing, IO listing and material
selection.
After schematic preparation we prepare the
general layout of the control panel and according to that we decide the panel
size also need to consider the temp effect in panel. VFD panels required
additional cooling systems.
Cable routing design
From the 3D models of the machine, we prepare
the cable routing and cable tray locations. As per the electrical load, we
select the cable size. For instruments required specials cables for the
communication systems requires shielded cables. As per the cable's selection,
we prepare the cable Termini nation Lay-out. According to the glands and gland
plate size is done.
BOM preparation
From the above sections we prepare the bill
of materials and in this section, we consider the costing side. We take
Quotations from different suppliers and finalize the materials.
Production.
In this section, design is handed over to
production department. As per the schematic and BOM, they prepare the control
panel wiring and fix it in the machine. Cable routing and terminations are done
as per the design.
PLC programming, HMI Design and testing.
As per the sequence of operation and IO
listing, we prepare a logic program. Initial stage program output is simulated
using software and verify the cause-and-effect diagram. Once simulation is ok
then we download the Program to the actual controller.
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