Industrial Robots

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Invention of Robots has brought about revolutionary changes in the field of industrial manufacturing. In the earlier part of the century humans were engaged in jobs, which were very dangerous and involved serious health hazards, but in 1956, Unimation a company founded by George Devol and Joseph F. Engelberger invented the first robot. These were initially used in industries where it was required that dangers involved in working should be reduced like in spot welding, die casting and forging and then gradually they were employed in areas requiring greater strength and accuracy than human beings.

Industrial Robots are automatic devices, which to an extent simulate the human behavior or more specifically human activity. Robots are important part of the science of Automation. Automation involves machines and computers that are capable of learning and performing various types of operations. The word robot has been derived from the Czech word “robota” meaning compulsory labor. The robots are used in industries to perform various functions like material handling, spot welding, spray painting, die casting, ironing, forging, assembly operations, palletizing, dispensing, testing, water jet cutting, picking and placing heavy goods etc.

Robots are made in various shapes and sizes and generally their load carrying capacity depends up on their size and strength. An average human sized robot is capable of carrying a load of more than 100 pounds and can also move it very quickly at the rate of +/-0.006 inches. One of their major advantages is that they can work continuously for days and years at a stretch without developing any fault. Due to this persistent accuracy robots are fast becoming indispensable part of various industrial set-ups. Most often these robots are used for repetitive painting, welding and operations like picking up and placing products into the machines.

The industrial robots can be programmed for performing a single function at a time and can only perform that particular function till they are reprogrammed. The cost of a robot is not very huge, but generally the cost of programming the robot is so high that instead of reprogramming it the manufacturers find it more economical to buy a new one for a different task. In simpler terms we can say that usually the cost of the robot is just a fraction of the cost of programming it.

Robots are made up of easily available materials. Steel, cast iron and aluminum are commonly used for making the arms and bases of robots. In mobile robots, rubber tires are fixed for smooth and quiet operation. Robots may be electronically operated and also laser or radio controlled. The exposed parts of the robot are enveloped with flexible neoprene sheaths and bellows.

The importance of robots in industries is increasing day by day and they constitute a very important part of the modern industries. Robots have made so many things possible, which could not be even thought of around 6 decades ago. They have taken the place of manual labor, especially in places where people worked in very dangerous and hazardous conditions like welding, die casting and forging. They have brought about revolutionary changes in the field of industrial manufacturing. According to a research conducted by the United Nations Economic Commission for Europe the worldwide purchase for robots is increasing at the rate of approximately 19% every year.

In recent years Robots are also being used in industries like consumer electronics and food packaging where robots outweigh the precision and quality of assembling the products as compared to work done by human hands. Earlier on some people protested the inclusion of robots in industries on the account that this will render many people unemployed. But these fears have also been allayed and the best argument in this regard has been given by economist James Miller. He says “True, the existence of automation might depress workers’ wages but it shouldn’t ever leave them unemployable.”

Engineering Industry

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There are a number of branches of engineering and some like civil, mechanical, chemical, electrical and aerospace are highly popular. Regardless of the branch you may be interested in, becoming an engineer takes a lot of dedication and hard work. If you are interested in engineering as a career, you first need to research the different options at your disposal. Some diverse engineering specialties that you can work in are:

• Aerospace Engineering

Designing, production and testing of airborne vehicles and machines is the foundation of aerospace engineering. As an engineer in this specialty, you may have to design parts for satellites, missiles, rockets and airplanes and then test the air vehicles under several conditions.

• Architectural Engineering

The job of an architectural engineer is to assist architects in designing buildings. While the aesthetics and function of the building is the responsibility of the architect, the engineers are responsible for making the design efficient in its utility needs and physically sound. Green buildings that want to obtain LEED certification are heavily dependent on architectural engineers.

• Bio-engineering

The integration of medicine, biology and engineering for enhancing knowledge and improving human health is bioengineering. Healthcare devices and instruments that can be used for the treatment of diseases are designed by engineers. An excellent example of this engineering is prosthetics, which are customized for each patient.

• Chemical Engineering

The designing and creation of chemicals for serving customer and industrial purposes fall under chemical engineering. The properties of chemicals have to be studied by a chemical engineer to find out its uses. Different aspects of lives are touched by this form of engineering such as food, medicine, construction and industry.

• Civil Engineering

The design of large scale projects that meet the need of communities fall under the head of civil engineering. Some of these projects like bridges, dams, transit systems and roads need engineers to study the use and impact of public projects for providing the best design that is in accordance with the needs of the community.

• Computer and Software Engineer

Developing computer technology for meeting the needs of a user is the job of a computer and software engineer. Servers, computers and communication systems between users are designed by hardware engineer whereas software engineering involves the creation of programs and applications for coming up with new ways of using hardware in order to fulfill the practical needs of the users.

• Environmental Engineers

The combination of chemistry and biology for developing solutions to various environmental problems is defined as environmental engineering. Problems like water and air pollution are tackled by environmental engineers and they develop systems that can eradicate and prevent the sources of pollution. The environmental engineering field has grown rapidly because of environmental consciousness and the growth of green industries.

• Industrial and Manufacturing Engineering

Factories can be structured in a better way with the help of industrial and manufacturing engineers and they improve production. They design equipment and systems for building projects. It is their job to figure out how factories should be laid out and the machines that should be used for boosting efficiency.

• Electrical Engineering

As the name indicates, electrical engineers develop products that use electricity and other electrical systems. Electrical engineers work in developing a variety of high tech products. When you become an electrical engineer, you may have to work with engineers in other fields of design as well.

• Material Engineering

The development of new materials for meeting the needs of the industry and business is called material engineering. The materials can range from fabrics, plastics, ceramics and metal. Jobs of a material engineer can be found in high tech industries, manufacturing and construction. These engineers combine physics, material science and chemistry.

• Mechanical Engineering

Creating devices and machines is the job of mechanical engineers and it is the oldest and broadest field in the engineering industry. These engineers design manufactured goods by combining chemistry, physics, biology, mathematics and other science field for creating machines that work for mankind.

• Nuclear Engineering

Working and developing devices and systems that use nuclear radiation and energy for performing tasks is the responsibility of nuclear engineers. These engineers are needed in a horde of industries such as space travel, military, healthcare, energy and advanced research.

Before selecting one of the fields in engineering, you have to decide if you have what is needed for becoming an engineer. You have to have a college degree in engineering for becoming a professional. You should always apply to schools that have strong engineering programs in the area you are interested in. Bear in mind that the environment is highly competitive and seats are rather limited. You have to get good grades once you have enrolled in an engineering program. The first and second years are quite tough so outside employment is discouraged during this time because studies have to be the primary focus.

In the third, fourth or fifth year of engineering programs, you will be offered co-ops. Most of them are paid, but there may be unpaid ones. It is important to secure high grades in order to get a co-op. This can go a long way into getting you the related and valid work experience you need for entering the job market and it can help you in getting a job after graduation. When you are near the end of your program, you can seek the assistance of the career development center of your college. They will be able to help you in designing a good resume and direct you to internships and co-ops. This eventually aids you in applying for jobs in the engineering field after you have become qualified.

You can also join a professional engineering association or society, which caters to your particular interest. A large number of networking opportunities are offered by professional organizations, which are excellent for you, whether you are seeking employment or want to advance your career further in the field of engineering. You can be a good engineer as long as you utilize practical knowledge, science and mathematics for solving problems.

Using a Valve Actuator for Ball Valves

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A control valve actuator is used not only for controlling valves but also for precisely regulating their position. By providing compressed air to the piston actuator or diaphragm positioner, an adjustable valve is then adjusted in response to the control signal. In order to ensure the valve does adjust according to the requirements of the control system, the valve positioner is connected to the valve/actuator stem and monitors its position throughout the control process. It is possible to control the valve very precisely based on the feedback of the valve stem position.

Automatic control systems have the following components: a fluid to be controlled, a sensor to determine the process variable, an actuator to modulate the valve, a controller to modulate the actuator, and a control valve to regulate flow.

As the flow of fluids in pipes is controlled by the interplay of these elements, any control system can, in principle, regulate all fluids flowing through pipes using valve automation such as a valve actuator. According to the needs of the process, several different systems can be used depending on how the system is implemented.

Through the use of valve automation, a valve actuator regulates the rate of flow through valves. Consequently, it needs to be designed so that it can withstand all the challenges that may arise while working in the field, and even the most difficult or unusual ones. All valves may not be appropriate for every single conceivable fluid flow condition, and this cannot be stated explicitly. It is imperative that the valves are installed to handle the conditions of operation specified. Over the years, many types of control valves have been developed for use in various applications. There are a number of these types of systems which cover a range of processes in high numbers whilst others have been developed for special requirements.

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It is a general rule that ball valves are used for processes involving hydrocarbon oil and gas, as well as aggressive services where chemicals are present. Ball valves using actuators are usually used to control the flow of steam, rather than to throttle (control flow) using automation. As a result, use of the spherical ball can determine whether the flow is blocked by the inside diameter of the valve. When a hole is drilled into the ball by means of a lever, the hole in the ball will rotate 90°, and the flow will be allowed when the hole through the ball is drilled along the axis of the pipe.

With regard to high-pressure classes of reservoirs, injection lines leading to seawater injections are mixed in with the hydrocarbon services that provide enhanced oil recovery. A ball valve is by far the best valve to use in this type of application since it allows the valve to be switched on/off. In process pumping applications, there are other kinds of valves such as butterfly valves and wedge gate valves that are less robust than ball valves.

A big advantage of ball valves over through conduit gate (TCG) valves is that ball valves are more compact vertically than TCG valves. TCG valves fill up a lot of space vertically. However, their actuation occurs through a vertical mounted actuator that occupies a lot of space horizontally.

Fast opening applications are not suitable for ball valves since the valves open slowly. Generally, it is possible to reduce the opening time of a fail-open actuated valve through installation of a quick exhaust valve on the control panel to release the instrument air from the pneumatic actuator in the fail mode quickly. However, ball-valve seats and disks are in contact during the opening and closing, which can jeopardize the fast opening characteristic.

A smaller stem torque and a larger actuator are also necessary to move the relatively large and heavy ball. Moreover, moving the relatively large and heavy ball may take longer. Ball-valve manufacturers were consulted about the use of soft-seat balls for this application, but the manufacturers felt that the rapid opening of a soft seat ball valve in 2 seconds could lead to the soft seat being damaged due to the repeated contact with the ball.