Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com TM Marcel Dekker, Inc. New York • Basel Handbook of Industrial Automation edited by Richard L. Shell Ernest L. Hall University of Cincinnati Cincinnati, Ohio Copyright © 2000 by Marcel Dekker, Inc. All Rights Reserved. Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com ISBN: 0-8247-0373-1 This book is printed on acid-free paper. Headquarters Marcel Dekker, Inc. 270 Madison Avenue, New York, NY 10016 tel: 212-696-9000; fax: 212-685-4540 Eastern Hemisphere Distribution Marcel Dekker AG Hutgasse 4, Postfach 812, CH-4001 Basel, Switzerland tel: 41-61-261-8482; fax: 41-61-261-8896 World Wide Web http://www.dekker.com The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/ Professional Marketing at the headquarters address above. Copyright # 2000 by Marcel Dekker, Inc. All Rights Reserved. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, micro®lming, and recording, or by any information storage and retrieval system, without permission in writing from the publisher. Current printing (last digit): 10987654321 PRINTED IN THE UNITED STATES OF AMERICA Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Preface This handbook is designed as a comprehensive reference for the industrial automation engineer. Whether in a small or large manufacturing plant, the industrial or manufacturing engineer is usually responsible for using the latest and best technology in the safest, most economic manner to build products. This responsibility requires an enormous knowledge base that, because of changing technology, can never be considered complete. The handbook will provide a handy starting reference covering technical, economic, certain legal standards, and guidelines that should be the ®rst source for solutions to many problems. The book will also be useful to students in the ®eld as it provides a single source for information on industrial automation. The handbook is also designed to present a related and connected survey of engineering methods useful in a variety of industrial and factory automation applications. Each chapter is arranged to permit review of an entire subject, with illustrations to provide guideposts for the more complex topics. Numerous references are provided to other material for more detailed study. The mathematical de®nitions, concepts, equations, principles, and application notes for the practicing industrial automation engineer have been carefully selected to provide broad coverage. Selected subjects from both under- graduate- and graduate-level topics from industrial, electrical, computer, and mechanical engineering as well as material science are included to provide continuity and depth on a variety of topics found useful in our work in teaching thousands of engineers who work in the factory environment. The topics are presented in a tutorial style, without detailed proofs, in order to incorporate a large number of topics in a single volume. The handbook is organized into ten parts. Each part contains several chapters on important selected topics. Part 1 is devoted to the foundations of mathematical and numerical analysis. The rational thought process developed in the study of mathematics is vital in developing the ability to satisfy every concern in a manufacturing process. Chapters include: an introduction to probability theory, sets and relations, linear algebra, calculus, differential equations, Boolean algebra and algebraic structures and applications. Part 2 provides background information on measurements and control engineering. Unless we measure we cannot control any process. The chapter topics include: an introduction to measurements and control instrumentation, digital motion control, and in-process measurement. Part 3 provides background on automatic control. Using feedback control in which a desired output is compared to a measured output is essential in automated manufacturing. Chapter topics include distributed control systems, stability, digital signal processing and sampled-data systems. Part 4 introduces modeling and operations research. Given a criterion or goal such as maximizing pro®t, using an overall model to determine the optimal solution subject to a variety of constraints is the essence of operations research. If an optimal goal cannot be obtained, then continually improving the process is necessary. Chapter topics include: regression, simulation and analysis of manufacturing systems, Petri nets, and decision analysis. iii Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Part 5 deals with sensor systems. Sensors are used to provide the basic measurements necessary to control a manufacturing operation. Human senses are often used but modern systems include important physical sensors. Chapter topics include: sensors for touch, force, and torque, fundamentals of machine vision, low-cost machine vision and three-dimensional vision. Part 6 introduces the topic of manufacturing. Advanced manufacturing pro- cesses are continually improved in a search for faster and cheaper ways to produce parts. Chapter topics include: the future of manufacturing, manufacturing systems, intelligent manufacturing systems in industrial automation, mea- surements, intelligent industrial robots, industrial materials science, forming and shaping processes, and molding processes. Part 7 deals with material handling and storage systems. Material handling is often considered a neces- sary evil in manufacturing but an ef®cient material handling system may also be the key to success. Topics include an introduction to material handling and storage systems, automated storage and retrieval systems, containeriza- tion, and robotic palletizing of ®xed- and variable-size parcels. Part 8 deals with safety and risk assessment. Safety is vitally important, and government programs monitor the manufacturing process to ensure the safety of the public. Chapter topics include: investigative programs, govern- ment regulation and OSHA, and standards. Part 9 introduces ergonomics. Even with advanced automation, humans are a vital part of the manufacturing process. Reducing risks to their safety and health is especially important. Topics include: human interface with automation, workstation design, and physical-strength assessment in ergonomics. Part 10 deals with economic analysis. Returns on investment are a driver to manufacturing systems. Chapter topics include: engineering economy and manufacturing cost recovery and estimating systems. We believe that this handbook will give the reader an opportunity to quickly and thoroughly scan the ®eld of industrial automation in suf®cient depth to provide both specialized knowledge and a broad background of speci®c information required for industrial automation. Great care was taken to ensure the completeness and topical importance of each chapter. We are grateful to the many authors, reviewers, readers, and support staff who helped to improve the manu- script. We earnestly solicit comments and suggestions for future improvements. Richard L. Shell Ernest L. Hall iv Preface Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Contents Preface iii Contributors ix Part 1 Mathematics and Numerical Analysis 1.1 Some Probability Concepts for Engineers 1 Enrique Castillo and Ali S. Hadi 1.2IntroductiontoSetsandRelations Diego A. Murio 1.3LinearAlgebra William C. Brown 1.4AReviewofCalculus Angelo B. Mingarelli 1.5OrdinaryDifferentialEquations Jane Cronin 1.6BooleanAlgebra Ki Hang Kim 1.7AlgebraicStructuresandApplications J. B. Srivastava Part 2 Measurements and Computer Control 2.1MeasurementandControlInstrumentationError-ModeledPerformance Patrick H. Garrett 2.2FundamentalsofDigitalMotionControl Ernest L. Hall, Krishnamohan Kola, and Ming Cao v Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 2.3In-ProcessMeasurement William E. Barkman Part 3 Automatic Control 3.1DistributedControlSystems Dobrivoje Popovic 3.2Stability Allen R. Stubberud and Stephen C. Stubberud 3.3DigitalSignalProcessing Fred J. Taylor 3.4Sampled-DataSystems Fred J. Taylor Part 4 Modeling and Operations Research 4.1Regression Richard Brook and Denny Meyer 4.2ABriefIntroductiontoLinearandDynamicProgramming Richard B. Darst 4.3SimulationandAnalysisofManufacturingSystems Benita M. Beamon 4.4PetriNets Frank S. Cheng 4.5DecisionAnalysis Hiroyuki Tamura Part 5 Sensor Systems 5.1Sensors:Touch,Force,andTorque Richard M. Crowder 5.2MachineVisionFundamentals Prasanthi Guda, Jin Cao, Jeannine Gailey, and Ernest L. Hall 5.3Three-DimensionalVision Joseph H. Nurre 5.4IndustrialMachineVision Steve Dickerson Part 6 Manufacturing 6.1TheFutureofManufacturing M. Eugene Merchant vi Contents Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 6.2ManufacturingSystems Jon Marvel and Ken Bloemer 6.3IntelligentManufacturinginIndustrialAutomation George N. Saridis 6.4Measurements John Mandel 6.5IntelligentIndustrialRobots Wanek Golnazarian and Ernest L. Hall 6.6IndustrialMaterialsScienceandEngineering Lawrence E. Murr 6.7FormingandShapingProcesses Shivakumar Raman 6.8MoldingProcesses Avraam I. Isayev Part 7 Material Handling and Storage 7.1MaterialHandlingandStorageSystems William Wrennall and Herbert R. Tuttle 7.2AutomatedStorageandRetrievalSystems Stephen L. Parsley 7.3Containerization A. Kader Mazouz and C. P. Han 7.4RoboticPalletizingofFixed-andVariable-Size/ContentParcels Hyder Nihal Agha, William H. DeCamp, Richard L. Shell, and Ernest L. Hall Part 8 Safety, Risk Assessment, and Standards 8.1InvestigationPrograms Ludwig Benner, Jr. 8.2GovernmentRegulationandtheOccupationalSafetyandHealthAdministration C. Ray Asfahl 8.3Standards Verna Fitzsimmons and Ron Collier Part 9 Ergonomics 9.1PerspectivesonDesigningHumanInterfacesforAutomatedSystems Anil Mital and Arunkumar Pennathur 9.2WorkstationDesign Christin Shoaf and Ashraf M. Genaidy Contents vii Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com 9.3PhysicalStrengthAssessmentinErgonomics Sean Gallagher, J. Steven Moore, Terrence J. Stobbe, James D. McGlothlin, and Amit Bhattacharya Part 10 Economic Analysis 10.1EngineeringEconomy Thomas R. Huston 10.2Manufacturing-CostRecoveryandEstimatingSystems Eric M. Malstrom and Terry R. Collins Index 863 viii Contents Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Contributors Hyder Nihal Agha Research and Development, Motoman, Inc., West Carrollton, Ohio C. Ray Asfahl University of Arkansas, Fayetteville, Arkansas William E. Barkman Fabrication Systems Development, Lockheed Martin Energy Systems, Inc., Oak Ridge, Tennessee Benita M. Beamon Department of Industrial Engineering, University of Washington, Seattle, Washington Ludwig Benner, Jr. Events Analysis, Inc., Alexandria, Virginia Amit Bhattacharya Environmental Health Department, University of Cincinnati, Cincinnati, Ohio Ken Bloemer Ethicon Endo-Surgery Inc., Cincinnati, Ohio Richard Brook Off Campus Ltd., Palmerston North, New Zealand William C. Brown Department of Mathematics, Michigan State University, East Lansing, Michigan Jin Cao Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Ming Cao Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Enrique Castillo Applied Mathematics and Computational Sciences, University of Cantabria, Santander, Spain Frank S. Cheng Industrial and Engineering Technology Department, Central Michigan University, Mount Pleasant, Michigan Ron Collier Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Terry R. Collins Department of Industrial Engineering, University of Arkansas, Fayetteville, Arkansas Jane Cronin Department of Mathematics, Rutgers University, New Brunswick, New Jersey Richard M. Crowder Department of Electronics and Computer Science, University of Southampton, Southampton, England Richard B. Darst Department of Mathematics, Colorado State University, Fort Collins, Colorado ix Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com [...]... above model of shock occurrence, but now suppose that the shocks are not fatal Once a shock of intensity 1 has occurred, there is a probability p1 of failure of component 1 Once a shock of intensity 2 has occurred, there is a probability p2 of failure of component 2 and, ®nally, once a shock of intensity 12 has occurred, there are probabilities p00 , p01 , p10 , and p11 of failure of neither of the components,... Paso, Texas Institute of Automation Technology, University of Bremen, Bremen, Germany Shivakumar Raman Department of Industrial Engineering, University of Oklahoma, Norman, Oklahoma George N Saridis Professor Emeritus, Electrical, Computer, and Systems Engineering Department, Rensselaer Polytechnic Institute, Troy, New York Richard L Shell Cincinnati, Ohio Department of Mechanical, Industrial, and Nuclear... the probability of a subset of values by an area under a curve (known as the probability density curve) instead of heights of vertical lines on top of each of the values in the subset For example, let X represent a number drawn randomly from the interval ‰0; 10Š The probability distribution of X can be displayed graphically as in Fig 4 The area under the curve on top of the support of X has to equal... Nuclear Engineering, University of Cincinnati, Department of Polymer Engineering, The University of Akron, Akron, Ohio Mathematics Research Group, Alabama State University, Montgomery, Alabama Krishnamohan Kola Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Eric M Malstromy Department of Industrial Engineering, University of Arkansas, Fayetteville,... University of Cincinnati, Christin Shoaf Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio J B Srivastava Department of Mathematics, Indian Institute of Technology, Delhi, New Delhi, India Terrence J Stobbe Industrial Engineering Department, West Virginia University, Morgantown, West Virginia Allen R Stubberud California Department of Electrical... F F F ; of disjoint subsets of , then p ‘  ˆ p…Ai † Ai ˆ Axiom 1 states that despite our degree of uncertainty, at least one element in the universal set  will occur (that is, the set  is exhaustive) Axiom 2 is an aggregation formula that can be used to compute the probability of a union of disjoint subsets It states that the uncertainty of a given subset is the sum of the uncertainties of its... independent of A This is because p…B j A† ˆ p…A ’ B† p…A† p…B† ˆ ˆ p…B† p…A† p…A† Because of the symmetry property, we say that A and B are independent or mutually independent The practical implication of symmetry is that if knowledge of B is relevant (irrelevant) to A, then knowledge of A is relevant (irrelevant) to B The concepts of dependence and independence of two events can be extended to the case of. .. the support of X on a horizontal line and erecting a vertical line or bar on top of each of these values The height of each line or bar represents the probability of the corresponding value of X For example, Fig 3 shows the probability distribution of the random variable X de®ned in Example 1 For continuous random variables, we have in®nitely many possible values in their support, each of which has... Dickerson Motoman, Inc., West Carrollton, Ohio Department of Mechanical Engineering, Georgia Institute of Technology, Atlanta, Georgia Verna Fitzsimmons Cincinnati, Ohio Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Jeannine Gailey Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Sean Gallagher Pittsburgh... can ®t well many sets of experimental data Figure 12 shows different examples of the pdf of the beta random variable Two The beta random variable is denoted as Beta…r; s†, where r > 0 and s > 0 Its name is due to the presence of the beta function Figure 10 An example of the pdf and cdf of the exponential random variable Copyright © 2000 Marcel Dekker, Inc Figure 12 Examples of pdfs of beta random variables . information on industrial automation. The handbook is also designed to present a related and connected survey of engineering methods useful in a variety of industrial and factory automation applications Institute of Automation Technology, University of Bremen, Bremen, Germany Shivakumar Raman Department of Industrial Engineering, University of Oklahoma, Norman, Oklahoma George N. Saridis Professor. Kola Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Eric M. Malstrom y Department of Industrial Engineering, University of Arkansas, Fayetteville,