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Modular Automation INTRODUCTION

“The key to a much shorter time-to-market and thus to higher productivity of a machine or plant is modularization. The concept of success is called

modular automation”

The Modular Production Systems concept represents a radically new product-oriented manufacturing paradigm which is based on building production system from standardized machine elements. The overallobjective is to provide a production methodology which will enable entire

production system to be rapidly designed and configured for a wide range of consumer products with minimal delay, costs and need for specializedmachinery. The potential benefits include, shortening machine design time,improved machine reliability reduced construction costs and simplifying

service/repair. More significantly, the modular approach, combined with powerful computer tools, offers the potential to provide an important meansof meeting the large and growing need for low cost 'flexible' automation.

Newly developed machines and plants must bring the machinemanufacturer a quick return on the development costs, and the owner a quick return on the investment costs. This is especially true of packing machines,

because the product life cycle for consumer products continues to get shorter and shorter. The possibility of building machines in such a way that they can

be reconfigured quickly and extensively, and thus adapted to new tasks, iscritical for the competitiveness of these manufacturers today. Numerousmachine manufacturers have therefore started to give their machines’mechanics a modular structure, and to use developed and tested modulesover and over again with minimal adaptation. A module or modular systemdeveloped in this way has enormous advantages, and saves a great deal of money. The preconditions for efficient module building were created yearsago in mechanical design by CAD systems. In the electrical departments, bycontrast, traditional principles are frequently still being applied: the controlsoftware is produced by adapting and altering existing software. Every

software project then becomes unique, and with every machine, the varietyof software that a service technician must deal with on visits to customersincreases. This dilemma has become worse as the proportion of software hasgrown continuously since the division of drives a few years ago, and costsfor the integration of automation systems have reached considerable

proportions with many manufacturers. The machines’ development costs andtime can be reduced significantly only if the modules of the drive, control,

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Modular Automation and visualization software are standardized as well as the mechanicalmodules. The greatest benefit for the machine manufacturer emerges whencurrent automation trends such as the use of Ethernet at the field level, or Component Based Automation with distributed intelligence, are integratedinto the modular machine concept.

Its the function that counts

The definition of a modular system demands extensive conceptual work. Themachine modules are self-contained function blocks with defined interfaces.They can be exchanged without influencing the other modules of themachine. Modules for example can contain mechanical, pneumatic, andelectrical elements, and of course also control functions. The controlfunctions typically include motion control, logic control, technology

functions (for example, temperature control), and HMI. When it comes tocontrol design, every machine module has elements assigned to these four areas from a control-technical point of view. At the moment, there are two

basic topology structures for modular automation. The first is more suitablefor compact machines with central control. With this structure, theautomation functionality of the machine is already determined in theengineering. The control programs for motion control, logic control,technology, the user interface, and the appropriate hardware configurationare selected from modules of a library. This process can be implementedwithin the engineering system, or with the help of a master configurationdatabase – even manually in simple systems. The basic program in thecontrol is the same in every machine variant. Depending on the machineoptions used, extra program modules are loaded, and the appropriatefaceplates are added to the user interface.The second topology variant refers to a distributed automation structure withmechatronic function blocks. Here the Modularization continues to befurther developed using the new possibilities offered by modern industrialcommunication and Component Based Automation. The modules have their own intelligence and are connected with each other by clearly defined

interfaces. The functionality of the modules is encapsulated inside of themodule software.

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Modular Automation

The advantages are obvious: individual modules can be developed, produced, and commissioned independently; extensions to a module can bemade largely without influencing the machine as a whole; modules can beexchanged without affecting adjacent sections of the machine; andmultifunctional communication interfaces reduce wiring expenses.

EXAMPLE:

Mechatronic function blocks with distributed synchronization

( SEIMENS)

In packing machines, the drives are often coordinated by a synchronizationsystem – that is, by electronic gears or electronic cams. In this situation, thecontrollers of a distributed automation system must be synchronized witheach other, and the synchronization relations maintained between individualmachines and systems. Distributed Simotion controllers synchronize their task systems with each other via the isochronous Profibus. The “distributedsynchronization” function makes it easy to install mechatronic function

blocks with their own control and to synchronize master-slave relationships

over several Simotion devices. A virtual master in the basic machine, for example, sets the production speed for the entire automation system. Amodular bagging machine with two mechatronic function blocks, the basicmachine and the product feed is used as an example. Both function blockshave one self-contained function each, and are connected to each other bydistributed synchronization. They can be programmed, tested, andcommissioned separately – a time advantage that pays dividends. Inaddition, the customer can order the machine with or without productionfeed, without the need for modifications to the software.

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Modular Automation

Why Modular automation?

The speed of design, construction and commissioning of the control systemis the immediate benefit. Depending if you are an OEM or End-User thespecific benefits may vary from project to project however always includethe items below.

OEM benefits are:

• Improved consistency of proposals• Reduced engineering time• Increased speed of machine integration• Increased speed of system commissioning

End user benefits:

• Increased plant floor space available for manufacturing• Reduced Mean time To Repair (MTTR)• Faster time to Market

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Modular Automation

General Concept of Modular systems

A growing number of system integrators, OEMs and users are evaluating theuse of modular manufacturing techniques to lower costs while providingincreasingly customized solutions in less time. With traditional approaches(see Figure 1), the mechanical engineering and control systems are

performed independently. While parts of designs and drawings may be usedfrom past projects, most of the engineering is custom in nature. After themechanical and control systems are designed, they are then integrated,started up, debugged, and commissioned. Modular manufacturing systemsstart with the combination of mechanical assemblies with the requiredsensors/actuators, automation devices and control software blocks intosubsystems. These pre-engineered and pre- documented subsystems are

combined to create a customized machine or manufacturing process.Subsystems based on this approach can be combined and recombined,without costly re-engineering.

A material handling warehouse distribution center can be used as oneexample. When an end user purchases a new distribution center theengineering or material-handlingfirm begins withmechanicalengineering laying outa system. This wouldtypically includestorage areas,conveying equipment,sortation equipmentand so on. When thisdesign is complete the

project is sent to

electrical engineering.They in turndetermine the requirements for motors, sensors, actuators and pilot devices.Control cabinets are designed, built and tested. Depending on the systemsand the specification they may be stage completely, in part or integrated withthe mechanical equipment at the job site.

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Modular Automation Contrast this to the use of modular automation concepts where the scenariowould be as follows: Mechanical and electrical engineering would developstandard electrical designs for each controlled or driver subassembly.Examples would include that each motorized section of conveyor wouldhave a standard electrical drawing and control software that would be self contained for the section, the same could be done for each divert unit on asortation "subassembly". Now when mechanical engineering lays out thesystem no control panel construction is required. Electrical engineering stillsmust do the power distribution and will have the additional task of devicelevel network layout however all the time previously spent building control

panels and developing custom application programming is eliminated.

Components of Modular Automation Systems

There are 3 key components that are required to implement a modular manufacturing system.

Pre- Engineered Subsystems:

The subsystems include the mechanical assemblies with the requiredautomation devices, sensors and actuators already engineered, documentedand installed into them (see Figure below-2a). Each subsystem is terminatedwith the standardized connection means that allow the quick installation andre-configuration of subsystems with minimal installation time/errors.

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Modular Automation

Modular Subsystem Software

Instead of using the traditional approach of custom programming, or themajor re-addressing or re-entry of control programs, modular subsystems arecontrolled by interchangeable pre-engineered control software modules (seeFigure Below-2b). Standardized object oriented software control languages,

provide reusable subsystem libraries. These libraries of subsystem functionsare built on a common database and can be quickly combined without re-

programming or re-addressing.

Open Networks

The modular-manufacturing trend requires the distribution of intelligenceand system functions with a common database. The Modular manufacturing

system must also integrate to the rest of the companies' networks andsystems. Ethernet and /or device level networks integrate the varioussubassemblies into the finished solution (see Figure below-3). The networksare also used as the sub-networks to connecting various vendors' deviceswithin the subassemblies.

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Modular Automation

Hardware requirements

Control

The concepts can be implemented on the following platforms PLC, IPC or Embedded platforms. The selection of the platform depends on the needs of the application. Each of the available platforms offers advantages andcompromises, which are summarized on the pages below.

•

IPC• Embedded

HMI

• IPC• Embedded• Text / Graphic displays

Software

• Control• HMI• Diagnostic & set up

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Modular Automation Networks

• Device level• CanOpen• DeviceNet• Ethernet• INTERBUS• Profibus• Ethernet

I/O

• Machine mount• IP20

Drives

System Application Examples

The Lanco's HFL 2002-S Transfer System gives you the flexibility to startwith a simple system and to expand or increase automation as your

production requirements change. The modularity of the system allows you tomodify layouts or reuse modules for new programs.

Here are just a few of the types of configurations possible using Lanco'sHFL 2002-S Transfer System components

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Modular Automation

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Modular Automation

Traditional Approaches to Automation

1. The Legacy PLC System

Beginning some 30 years ago, automation equipment suppliers createdcustom computers, running proprietary software to replace hard-wiredcontrol panels. Over the years, these systems have evolved into complex

systems capable of controlling a wide variety of processes. The coretechnology, however, remains proprietary in both hardware and software.

Legacy automation infrastructure for logic control is based on the programmable logic controller (PLC). Early in its existence, thismicroprocessor-based hardware platform was sold as a "solid-statecontroller" to alleviate customer fears of using computer technology on thefactory floor. It brought a host of opportunities and benefits. One side effectfor many in manufacturing, is the fact that PLCs kept the IT departments out

of the production environment. While the PLC was an excellent tool in the1970s and 1980s, it was not designed with the commercial requirements of the 1990s and beyond in mind, nor could it take full advantage of themassive electronics and software changes that have transpired since itsconception.

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Modular Automation Likewise, being proprietary, these control systems demand high investment

by their users. Manufacturers usually standardize on a single brand, or evena single model in order to keep their training and spare parts burdenstolerable. This standardization also gives them some leverage in pricenegotiations with the vendor.

2. Custom Designed Software

Many times, a clever engineer will study the PLC approach to automationcontrol and conclude that the job can be done better in house. The engineer then uses C, C++, or Visual Basic to create a control system.

These custom-written control systems usually run on an embedded computer or a traditional PC platform. They are based on the services provided by a

real time operating system (RTOS). Typically, they require a very high levelof engineering support to maintain and/or upgrade.

Custom control systems usually end up being economical only for thoseOEMs who can amortize the high development and maintenance costsacross many units. These approaches each offer real business challenges for their respective users.

• Design costs are difficult to control in either scenario. Despite theavailability of Sequential Function Charts and State Logic processors,

PLC systems are usually programmed in languages like Relay Ladder Logic that were not created to handle the burdens of modernautomation systems.

• The RLL language, while very good at representing Boolean logic, isnot well suited to support modern needs for diagnostics,communications, data analysis, and record keeping. PLC makers haveresponded to these shortcomings with a bewildering array of special

purpose language elements, which only serve to make the programsharder to program and debug.

• Homegrown control systems are often the creation of a single person -the "wizard" - who is the only one who understands how they work.The wizard cannot be free of his creation and the company is still heldhostage by the wizard. If the wizard ever leaves the company, thecontrol system becomes a piece of black magic that can never beupgraded or maintained without great expense.

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Modular Automation These same effects limit how quickly new technology can be brought tomarket. Users of PLC systems struggle with the proprietary nature of thesesystems. Communications with the higher levels of the organization (MES,ERP, etc.) are difficult and expensive. PC based control systems can havedirect and immediate accesses into corporate databases, while PLCs must beconnected through expensive hardware and elaborate software. Customsystems suffer from an inability to add even simple features without major engineering efforts.

Together, this adds up to difficulty in providing customers withdifferentiating features at low costs - which reduces competitiveness all theway around. Using proprietary and/or custom control systems can limit theagility and flexibility that manufacturers depend on to survive in today'sworld.

The PC-Based Control Approach

Today's competitive environment calls out for a higher level of capability,and today's technological advances in computers, software technology, and

proliferation of development sources provide answers to that calling. Higher level solutions can enhance flexibility, improve human interaction, and

provide improved cost/benefit advantages over predecessor solutions.Examples of this are given in the next section of this paper.

These evolved control systems provide manufacturers and integrators withnew tools to leverage productivity - many that simply weren't available aslittle as five years ago. Some of these include:

• easy-to-use motion control• vision inspection systems• bar code and radio-frequency tags to identify and track components• graphical displays designed to interact with operators• multiple high speed serial port interfaces to connect smart devices• Ethernet connectivity to devices that can move a large amount of data

in a short time

Today's competitive automation solution must perform with at least thereliability and determinism of PLC systems, and should offer improvementto functions that the legacy systems cannot perform without great difficulty.High level programming languages like flow chart, automated diagnostics,

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Modular Automation increased integration flexibility, and enterprise data connectivity are easilyaccomplished with PC-Based control.

Case study

Modular Automation for the Aerospace Industry

Advanced techniques for manufacturing and assembly enable aircraftsuppliers to meet stringent cost targets and time constraints for massiveaerospace/defense programs. To meet the challenges of manufacturingairframe components for the F-35 Joint Strike Fighter (JSF) program,

Northrop Grumman Corp.’s (Los Angeles) Integrated Systems Sector in ElSegundo, CA, is developing a modular, moving assembly line at theAntelope Valley Manufacturing Center in Palmdale, CA, facility where thecompany assembles the F-35 aircraft’s center fuselage.

A major subcontractor to Lockheed Martin Corp. (Bethesda, MD) on the F-35 JSF program, Northrop Grumman builds composite components for theJSF center fuselage at its El Segundo Manufacturing Center and assemblesthe system at Palmdale before shipping the completed airframe subassemblyto Fort Worth, TX, where Lockheed Martin Aeronautics Co. performs the F-

35 aircraft’s final assembly. The JSF program is projected to be among thelargest military procurements ever, with approximately 3000 of the F-35multi-role fighters planned for the US Air Force, Navy, and Marine Corps,British Royal Air Force and Navy, and potentially several allied countries.The first production F-35, an Air Force version, is nearing completion atFort Worth and will fly later this year.

At the El Segundo facility’s composites center, Northrop Grumman buildsthe composite structures used on the JSF fuselage, as well as major composite airframe components for the US Navy’s carrier-based F/A-18aircraft. Besides the F/A-18 and F-35 programs, Northrop Grumman also

builds composite and metal components and subassemblies for variousaerospace/defense projects including the B-2 bomber, the T-38 training jet,the Global Hawk and the CEV (Crew Entry Vehicle) Space Shuttlesuccessor.

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Modular Automation Refining critical manufacturing processes can be more easilyaccomplished with collaboration among key players in theaerospace/defense industry. To solve vexing problems in aircraftmanufacturing, Northrop Grumman engineers have been working inconjunction with partners in the Aerospace Automation Consortium (AAC),a group coordinated through Purdue University’s (West Lafayette, IN)School of Technology, on projects to develop new processes includingautomated burr-less drilling, structural flexible robotic drilling, rapid low-cost tooling for composite fabrication, automated shim application and partloading, automated fastening on assembly systems, and real-time locatingsystems. Significant contributions have been made to changes in traditionalairframe assembly methods by strategic partners such as Comau Pico(Southfield, MI) and Nova-Tech Engineering Inc. (Edmonds, WA).

“Automation in the aerospace industry has been around a while, but more inthe fabrication side of the industry” notes Lance Bryant, director, productionengineering, Northrop Grumman Integrated Systems. “In the last 10 years or

so, it’s been more common in assembly. But to maintain the tolerances weneed, we ended up building large monuments, in order to maintain accuracyin the thousandths of an inch needed for military applications.”

Such investments are costly, and are cumbersome to switch tooling asfactory requirements change. For an aircraft like the F/A-18 E/F, there are

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Modular Automation some 40,000 OML holes to be drilled in Northrop Grumman’s section of theairframe, which can’t be easily done in an automated process.

Drilling airframe components constructed of composites with metalsubstructure such as titanium poses problems when trying to achieve

positional accuracy, which is exacerbated by thick material stack-ups.Drilling the composite F-35 engine inlet duct, a bifurcated, serpentinestructure, using advanced automation will improve quality and cost, so

Northrop Grumman is working on strategic alliances with other aerospaceconsortium partners such as Comau Pico to develop new automationsystems.

Automating airframe assembly meant adopting a more modular systemsimilar to the moving lines used by the automotive industry. At Northrop

Grumman’s Antelope Valley Manufacturing Center in Palmdale, the F-35integrated assembly line uses mechanized and automated systems for theaircraft’s center fuselage assembly, with a line that will become capable of

producing one complete assembly per day of any of the three F-35 variants.To do so, the production line significantly reduces the use of traditionaloverhead cranes and larger assembly jigs in favor of an innovativeSequential Universal Rail Fixture, or SURF system, that moves parts andsubassemblies between workstations within specific tool systems. ThePalmdale factory also employs automated drilling stations that increase

positional accuracy and throughput while solving worker-related ergonomic

issues.

“What was found, as we evolve, is that we start locking ourselves into acertain configuration of the assembly line,” Bryant adds,” because of hugemachines with their foundations. Then if you come back and say, “There’s a

better way of doing it now,” the nonrecurring cost of relocating a massivemachine with the foundation is too disruptive to the assembly line. It’s toocostly, and not only that, it’s very difficult to do. How do you keep

producing product, and make changes in the middle of everything, when

relocating automation machinery and assembly tooling is such a massiveundertaking?”

To create more modular automation, Northrop Grumman has createdalliances with automation integrators, such as Comau Pico and Nova-Tech,looking at automotive industry automation and other methods to see whatmay work best for aerospace environments.

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Modular Automation “The fact is that with the car industry, their rate is so high that it pays toautomate. Our production rate is not as high,” he adds, “so the nonrecurringcosts, at times, don’t have the ROI, because we’re not building a thousand aday like the automotive industry. But they have done an amazing amount of development, and we can, and are, using a lot of those innovations to help usautomate our assembly lines, and our fabrication houses, where it’sappropriate.”

With its integrator partners, Northrop Grumman has worked towarddeveloping future automated drilling, assembly, and paint systems. “They’reworking with us as an integrator to help us try to bring all the talent together to create more modular hole-drilling type of equipment,” Bryant says, “andthey’re also working with us to develop an integrated assembly line for theF-35. The idea there is to have a line that is integrated so that it goes from

position to position, without cranes, on a rail system, with health monitoringsystems that would communicate where the assembly process is from a cost,schedule, and quality view, by embedding the diagnostic equipment into theline. Therefore, you’re verifying that quality is being built in as you go, notinspected in after you’ve built the product, which is defect prevention versusdefect detection.”

Automated burr-less drilling, automated shim application, and structuralflexible robotic drilling are among the projects Northrop Grumman isworking on for future implementation. Drilling methods and technologies

may help eliminate burrs created when drilling composite-metal workpiecesfor many airframe components. Eliminating deburring on metalsubstructures and liquid shim repair would save time and cost of repairingholes.”If manufacturing can drill a burr-less hole in composite-metal stack assemblies without damaging the liquid shim material, it would save a lot of time and money,” Bryant says. “We’re in the early stages of developmentand at a low manufacturing-readiness level for burr-less drilling. Theindustry’s been attacking this for ages. Another way we are trying to tacklethis is with determinant assembly, which means that holes are drilled in the

skin and substructure separately, and then have to match perfectly whenassembled. In the end, determinant assembly might be the better way.”

Automated robotic application of high-tech coatings will enable aircraft likethe F-35 and B-2 to maintain a low radar signature, and the application of these coatings requires an automated solution in order to correctly apply the

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Modular Automation viscous materials at a proper thickness without requiring extensive manualre-work.

With the automated robotics developments, Northrop Grumman is designingsolutions before putting out competitive bids to suppliers. “These solutionsare still being developed,” Bryant says. “One challenge is to develop the

proper head design, packaged small enough so that it can get into tight areas.Kinematics routines are needed to attain the necessary motion analysis and

positional accuracy. We also need to overcome rigidity issues inherent inlightweight systems, to make sure they are capable of drilling through thick structures. We hope to have a solution that we can implement in the 2007timeframe”.

At the composites center in El Segundo, Northrop Grumman fabricates

most of the composite work pieces used in its aircraft programs. Thecompany also performs all of the drilling and assembly tasks for the F/A-18

program at the facility, as well as F-35 composite component fabrication.Automatic drilling machines from MTorres Group (Navarre, Spain) are usedfor holemaking on composite-titanium stacks of components for the F/A-18E/F aircraft. The systems require extremely high precision on a largequantity of holes, with 2600 holes required for the F/A-18 aircraft’s twinvertical stabilizers alone.

“In my opinion, this embodies all the elements of the aircraft,” notes Nick

Bullen, principal engineer, Northrop Grumman Integrated Systems,regarding the F/A-18 twin vertical stabilizers. “This part has elementsincluding composites, steel, aluminum, and titanium, it’s used for fuelstorage, and has hydraulics and electronics inside.”

Bullen adds. “It’s one of the most stressed components. The more critical thecomponent, the tighter the tolerances. Positional accuracy here is critical.This Automated Vertical Drilling Machine uses proprietary algorithms anddata on the speeds and feeds.

With a precision milling machine (PMM) from Droop+Rein (Bielefeld,Germany), a unit of D’rries Scharmann Technologie GmbH, the NorthropGrumman facility machines composite parts for the F-35 airframe assembly.“It drills, trims, and mills, to very tight tolerances in the low thousandths,over a large envelope, “says Bryant of the five-axis PMM.

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Modular Automation The gantry-mounted PMM is set up in a temperature-controlled room, andthe airframe parts are first put through a wash to normalize temperature towithin a couple degrees of ambient temperature, Bullen notes. The machinethen uses a proprietary volumetric compensation algorithm developed by themanufacturer and licensed for use by aircraft manufacturers to mill, drill,and trim the composite components.

Capable of cutting in X-Y-Z motion as well as pitch and yaw, the PMM has been producing parts at Northrop Grumman for about a year, Bullen adds.The system is outfitted with an advanced composite dust filtration systemfrom Valiant Cleaning Tech GmbH (Aachen, Germany). In order to meet

production requirements, the company may need as many as five to sevenmore of the PMM systems, which can cost $17-$20 million each.

CAD/CAM and simulation help Northrop Grumman engineers at all levelsof manufacturing process planning, including toolpath planning simulation,Bryant notes”. We are using CATIA V5 and Delmia in all programs acrossthe sector, which includes the advanced Hawkeye,” Bryant adds. “Our goal,especially in production engineering, is to “simulate twice, build once,” sowe’re trying to utilize simulation to design the airplane, designmanufacturability, design tools, and design the capacity requirements, andhow many tools we need. We use simulation for ergonomics development,to make sure people can reach up and access the aircraft from a tool.”

For toolpath planning, Northrop Grumman uses the Vericut NC verificationand optimization software from CGTech Corp. (Irvine, CA). “Vericut has

programmed into the simulation model the compensation system, and howthe machine will react to certain commands, “Bryant adds, “so when yousend the machine from one end to the other and drill a hole, you’ll knowhow the head is going to rotate and turn to get oriented for the next hole thatit’s going to go drill. With this system, you don’t have to go back in andreverse-engineer the path planning like we used to have to do for collision-avoidance. We do it all upfront, and then we download the program into the

robot and we’re ready to go.”

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Modular Automation

BIBLIOGRAPHY

1. http://www.sme.org/cgi-bin/find-articles

2. http://www.sme.org/manufacturingengineering

3. www.siemens.com/automation/newscentre

4. phoenixcon.com

5. http://www.cage.curtin.edu.au/

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http://www.sme.org/cgi-bin/find-articles

http://www.sme.org/manufacturingengineering

http://www.siemens.com/automation/newscentre

mailto:[email protected]

http://www.cage.curtin.edu.au/

http://www.sme.org/cgi-bin/find-articles

http://www.sme.org/manufacturingengineering

http://www.siemens.com/automation/newscentre

mailto:[email protected]

http://www.cage.curtin.edu.au/

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