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Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Handbook of Industrial Automation edited by Richard L. Shell Ernest L. Hall University of Cincinnati Cincinnati, Ohio Marcel Dekker, Inc. TM Copyright © 2000 by Marcel Dekker, Inc. All Rights Reserved. Copyright © 2000 Marcel Dekker, Inc. New York • Basel 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): 10 9 8 7 6 5 4 3 2 1 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 undergraduate- 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 iv Preface 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 processes 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, measurements, 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 necessary 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, containerization, 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, government 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 manuscript. We earnestly solicit comments and suggestions for future improvements. Richard L. Shell Ernest L. Hall Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Contents Preface iii Contributors Part 1 ix Mathematics and Numerical Analysis 1.1 Some Probability Concepts for Engineers Enrique Castillo and Ali S. Hadi 1.2 Introduction to Sets and Relations Diego A. Murio 1.3 Linear Algebra William C. Brown 1.4 A Review of Calculus Angelo B. Mingarelli 1.5 Ordinary Differential Equations Jane Cronin 1.6 Boolean Algebra Ki Hang Kim 1.7 Algebraic Structures and Applications J. B. Srivastava Part 2 1 Measurements and Computer Control 2.1 Measurement and Control Instrumentation Error-Modeled Performance Patrick H. Garrett 2.2 Fundamentals of Digital Motion Control 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 vi 2.3 Contents In-Process Measurement William E. Barkman Part 3 Automatic Control 3.1 Distributed Control Systems Dobrivoje Popovic 3.2 Stability Allen R. Stubberud and Stephen C. Stubberud 3.3 Digital Signal Processing Fred J. Taylor 3.4 Sampled-Data Systems Fred J. Taylor Part 4 Modeling and Operations Research 4.1 Regression Richard Brook and Denny Meyer 4.2 A Brief Introduction to Linear and Dynamic Programming Richard B. Darst 4.3 Simulation and Analysis of Manufacturing Systems Benita M. Beamon 4.4 Petri Nets Frank S. Cheng 4.5 Decision Analysis Hiroyuki Tamura Part 5 Sensor Systems 5.1 Sensors: Touch, Force, and Torque Richard M. Crowder 5.2 Machine Vision Fundamentals Prasanthi Guda, Jin Cao, Jeannine Gailey, and Ernest L. Hall 5.3 Three-Dimensional Vision Joseph H. Nurre 5.4 Industrial Machine Vision Steve Dickerson Part 6 6.1 Manufacturing The Future of Manufacturing M. Eugene Merchant Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Contents vii 6.2 Manufacturing Systems Jon Marvel and Ken Bloemer 6.3 Intelligent Manufacturing in Industrial Automation George N. Saridis 6.4 Measurements John Mandel 6.5 Intelligent Industrial Robots Wanek Golnazarian and Ernest L. Hall 6.6 Industrial Materials Science and Engineering Lawrence E. Murr 6.7 Forming and Shaping Processes Shivakumar Raman 6.8 Molding Processes Avraam I. Isayev Part 7 Material Handling and Storage 7.1 Material Handling and Storage Systems William Wrennall and Herbert R. Tuttle 7.2 Automated Storage and Retrieval Systems Stephen L. Parsley 7.3 Containerization A. Kader Mazouz and C. P. Han 7.4 Robotic Palletizing of Fixed- and Variable-Size/Content Parcels Hyder Nihal Agha, William H. DeCamp, Richard L. Shell, and Ernest L. Hall Part 8 Safety, Risk Assessment, and Standards 8.1 Investigation Programs Ludwig Benner, Jr. 8.2 Government Regulation and the Occupational Safety and Health Administration C. Ray Asfahl 8.3 Standards Verna Fitzsimmons and Ron Collier Part 9 Ergonomics 9.1 Perspectives on Designing Human Interfaces for Automated Systems Anil Mital and Arunkumar Pennathur 9.2 Workstation Design Christin Shoaf and Ashraf M. Genaidy Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com viii 9.3 Contents Physical Strength Assessment in Ergonomics Sean Gallagher, J. Steven Moore, Terrence J. Stobbe, James D. McGlothlin, and Amit Bhattacharya Part 10 Economic Analysis 10.1 Engineering Economy Thomas R. Huston 10.2 Manufacturing-Cost Recovery and Estimating Systems Eric M. Malstrom and Terry R. Collins Index 863 Copyright © 2000 Marcel Dekker, Inc. Simpo PDF Merge and Split Unregistered Version - http://www.simpopdf.com Contributors Hyder Nihal Agha C. Ray Asfahl Research and Development, Motoman, Inc., West Carrollton, Ohio University of Arkansas, Fayetteville, Arkansas William E. Barkman Tennessee Fabrication Systems Development, Lockheed Martin Energy Systems, Inc., Oak Ridge, 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 Jin Cao Ohio Department of Mathematics, Michigan State University, East Lansing, Michigan Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ming Cao Ohio Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, 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 Ohio Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Terry R. Collins Jane Cronin Department of Industrial Engineering, University of Arkansas, Fayetteville, Arkansas 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.