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T h e R o l e o f S e n s o r s a n d C o n t r o l Te c h n o l o g y i n C I M
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In computer-aided manufacturing (CAM), computers are used to plan and conduct production. They can correct and process data, control the manufacturing process, and provide information that can be used in decision making. CAM can involve distributed quality control and product testing and inspection, which are built into the manufacturing process to support the larger functional relationships.
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The integration of different elements of CIM and sensor systems can be accomplished only with the aid of a computer. Because of the magnitude of the CIM and sensor database, a mainframe (or a minicomputer for a small enterprise) is necessary for storage and retrieval of information. The power of microcomputers has increased so dramatically, however, that they are suitable for most other applications, such as: Programmable logic controllers (PLCs). On the factory floor, microcomputers are subject to harsh conditions. Dust, high temperature, and high humidity can quickly destroy an ordinary personal computer. Traditionally, the shop floor belongs to the programmable logic controller. The components can operate in extreme conditions (e.g., 55 C and 90 percent humidity). In addition, PLCs are geared to real-time control of factory operations. Through advances in microprocessor technology, functions once controlled by relays and mechanical switching mechanisms can now be performed by PLCs. The ladder diagrams used to notate logic circuits can now be programmed directly into the memory of the programmable controller. Because of microelectronic circuitry, PLCs can process control information quickly and shut down automatically in case of emergencies. Whereas PLCs have become commonplace on the floor of discrete product operations, process control computers have become indispensable in the control of process plants where conditions must be monitored constantly. They are also used in the control of office and factory environments. For example, a PLC can turn furnaces and air-conditioning units ON and OFF to provide suitable working conditions while optimizing energy use. Industrial personal computers (PCs). Until recently, PCs were commonly found in the protected environments of offices. Now, manufacturers have introduced rugged versions of popular personal computers. For example, IBM has developed the 5531 and 7531/32, industrialized versions of PC/XT and PC/AT, respectively, to withstand the environment of the factory floor. They have the advantage of being able to run any PC-DOS-based software, but are unable to perform real-time control. This problem has been remedied with the
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advent of the industrial computer disk operating system (IC-DOS), a real-time operating system that is compatible with other IBM software. This allows a shop floor computer to provide real-time control while using software packages previously found only on office models. Microsupercomputers. The hardware of microsupercomputers has increased computing power significantly. Offering high performance, transportability, and low price, the new microsupercomputers compare favorably to mainframes for many applications.
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With an increase in production volume and efficiency comes a need to have a more effective method of scheduling and controlling resources. Herein lies a connection between CAE and computer-aided management. The long-range plans of a company must include forecasts of what the demand will be for various products in the future. Through these forecasts, the enterprise determines what strategy it will take to ensure survival and growth. For the enterprise to make intelligent decisions, reliable information must be available. In regard to the three levels of decision making, it is also important that the information be consistent throughout each level. The best way to assure this availability and consistency is to make the same database available to all individuals involved in the production process. Because of lack of good communication between levels, and sometimes the reluctance of upper-level managers to commit themselves to CIM, constructing a centralized database represents one of the most difficult problems in the implementation of CIM.
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The creation of a CIM DB is at the heart of the effective functioning of CIM. Most manufacturers have separate databases set up for nearly every application. Since data from one segment of an enterprise may not be structured for access by other segments software and hardware, a serious problem for meeting the CIM goal of having readily available data for all levels occurs. Another problem with multiple databases is in the redundancy of data. Both the strategic and tactical decision makers, for example, may need information concerning a bill of material file. Even with the assumption that the databases contain consistent data (i.e., the same information in each), maintaining them both represents inefficient use of computer time and storage
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