How Automation is Transforming Mechanical Engineering

This article discusses automation's past and future impact on mechanical engineering with applications reshaping the industry. We also present AI in mechanical engineering and discuss the career prospects for students who seek employment by specializing in these aspects of the industry.

‍What is Automation in Mechanical Engineering?

Automation combines engineering expertise with advanced software and hardware to (1) monitor, (2) execute, and (3) control manufacturing processes.

Monitor: First, we collect data from sensors to understand the state of the process.

Execute: Based on the data, automation systems initiate actions or sequences in the process (for instance, starting a machine or moving materials).

Control: The automation system continuously adjusts parameters to optimize performance with a closed-loop performance (see figure).

Automation aims to increase efficiency and productivity and reduce errors in manufacturing. Its enablers are robotics, PLCs, CNC machines, and control systems.

• Robotic systems handle repetitive tasks. Robotics deals with speed and consistency of production and freeing up humans.

• CNC (Computer Numerical Control) Machines. CNCs control machining tools to perform tasks according to programmed instructions, such as cutting, drilling, and milling.

• Programmable Logic Controllers (PLCs) are computers managing automated processes such as assembly lines, conveyor systems, and automated testing.

Key Automation Engineering Applications

How is automation engineering research propelled by robotics, digital twins, IoT, and AI?

Robots and Automation Engineering

Robotic systems are the quintessential example of Automation Engineering principles in manufacturing.

A robot is a programmable machine designed to perform tasks (semi)autonomously. It can be equipped with sensors, actuators, and controls to interact with its environment, carry out tasks, and be adaptable. Industrial robots handle jobs from welding to assembly. Robots execute repetitive tasks, reducing human error. AI-powered controls on robots improve machine capabilities through learning algorithms.

How Do Robots Work (and AI Enhancements)

A robot follows steps involving hardware and software systems.

• First, our robot senses its environment with sensors.
• Then, algorithms analyze the information in the robot CPU or controller and decide the appropriate courses of action based on the robot’s programming.
• Finally, according to its program, the robot employs actuators, such as motors or hydraulic systems, to carry out tasks like moving limbs, picking up objects, or welding parts.

AI and Robotics are the perfect marriage. Artificial Intelligence or machine learning algorithms enable more advanced robots to learn from past actions. Thus, advanced robots have AI superpowers to adapt to their behavior over time!

Digital Twins and Automation Engineering

Digital twins are “digital replicas of physical assets.” They enable engineers to study mechanical systems in a virtual space. The digital twin (Industry 4.0) approach helps identify potential design flaws earlier in the product lifecycle. Once deployed, it optimizes performance and maintenance by providing real-time monitoring and predictive insights.

IoT and Automation Engineering in Manufacturing Processes

The Internet of Things (IoT) is  an Industry 4.0 feature that enhances automation by connecting machinery, systems, and sensors to enable real-time control and data collection. IoT devices track parameters across manufacturing processes, facilitating predictive maintenance and letting mechanical engineers improve asset utilization.

5G technology amplifies IoT with high-speed, low-latency device communication, allowing robotic systems in manufacturing to achieve greater real-time capabilities.

AI and Automation Engineering

Artificial Intelligence gives superpowers to automation engineering. Neural Concept Shape is an example of leveraging AI to optimize design for performance. It enables automated design iterations, allowing engineers to explore complex design spaces and reducing development time.  AI ensures that product designs meet engineering performance targets. A 3D deep learning application can assist engineers in automating the design process.

The Automation Engineer Job

Behind technologies are engineers who focus on designing, developing, and implementing automation across industries. Automation engineers design robotics, PLCs, and detectors to streamline companies’ manufacturing operations.

An example of automation engineers’ work is a human-machine interface (HMI) that displays  system status, alarms, and operational metrics while enabling direct interaction with machines. Automation engineers design HMIs to be user-friendly, ensuring ease of operation in complex environments such as manufacturing plants or power stations.

Mechanical Engineers’ Career

Automation is opening up career opportunities across various industries. Mechanical engineers specialized in automation technologies are sought after. Engineers seeking employment in industries prioritizing increased efficiency and productivity meet open doors. Job offers for graduates are not limited to sectors beyond machinery, e.g., automotive or aerospace industries.

For the mechanical engineer’s career, mastering automation means acquiring knowledge and experience with robotics and control systems. Students and recent graduates who seek employment or engineers who want to stay ahead in their career could focus on automation and robotics to gain a competitive edge in the job market.

Faster Development Cycles

By reducing repetitive tasks, mechanical engineers can iterate and test more ideas, focusing their career on intellectual productivity.

Robotics Career

CNC machines and robots offer career opportunities in the manufacturing process. For instance, a company’s robotics technical institutes install, troubleshoot, and repair robotic systems. Expertise in control systems  is vital in the automation industry, ensuring that machinery and processes operate efficiently.

Enhanced Safety: A Research Perspective

Research in automation highlights significant improvements in safety by deploying robots to perform tasks in hazardous environments. Research activities and jobs examples:

• analyze problems in robotic design for handling toxic materials
• improve components for extreme temperature environments.

Future Trends in Automated Systems

We will review automation trends to optimize real-time equipment operations, allowing mechanical engineers to develop smarter, adaptable devices.

Trends in Automation Technology: Cobots

Cobots, or collaborative robots, are the evolution of industrial automation. Unlike traditional robots, kept separate from human workers, cobots work alongside people on the factory floor.

Mechanical engineers increasingly use these collaborative robots to optimize manufacturing processes.

Cobots offer the automation engineer a flexible solution for adapting to tasks such as small-batch production or mixed-product assembly lines.

Cobots could assist humans with tasks such as tightening bolts or applying adhesives in an automotive assembly line.

Emerging Trends in Automation Technology: AI-Enhanced Automation

Artificial Intelligence in automation uses features like machine learning to improve the efficiency of automated systems.

What is the AI revolution in engineering?

Traditional automation follows predefined rules, while AI can adapt to changing conditions and optimize existing processes in real time. The automation engineer leverages AI to develop smarter control systems that predict equipment failures before they happen, optimize energy usage, and adjust production schedules on the fly. AI in product development plays a critical role here, enabling engineers to design machines and systems that are not only efficient but also highly adaptive, adjusting parameters based on real-time data.

AI can tap into new levels of efficiency and flexibility in the manufacturing process, making it a key driver of future industry automation engineering.  

Conclusions

We have seen how automation and robotics can help engineers optimize production, reduce costs, and enhance product quality by leveraging collaborative cobots, AI-enhanced automation, and advanced controls.

We reviewed what automation can do for mechanical engineers and vice-versa. The role of mechanical engineers is likely to expand, dedicating them to designing smarter, more adaptable systems that meet manufacturing demands.  

The future of engineering and mechanical engineers will be increasingly focused on automated systems!