Implementation of Affordable Automation Using Electro-Pneumatics: An Industrial Case Study of Multi-Process Machining

Abstract

This paper presents a case study on the implementation and productivity analysis of a real-time, multi-station automated rotary transfer line designed for drilling, tapping, and inspection operations. The system processes a standard block measuring 50 × 50 × 75 mm, performing drilling with a 5 mm diameter × 20 mm depth and tapping using an M6 machine tap. The clamping of the workpiece, part transfer between stations, and spindle feed during drilling are automated using electro-pneumatic systems. The system operates on a low-cost automation framework, controlled by microcontrollers. Key areas of investigation in this study include:

1. 1.                  Reduction in time for loading and unloading through pneumatic clamping,
2. 2.                  Enhanced productivity in both qualitative and quantitative terms,
3. 3.                  Improved accuracy and repeatability of operations,
4. 4.                  Minimal human intervention, reducing operator fatigue,
5. 5.                  Lower rejection rates due to reliable automatic control, and
6. 6.                  Overall reduction in production costs.

This study demonstrates the effectiveness of low-cost electro-pneumatic automation in increasing efficiency and reducing operational expenses in manufacturing.