retroelectro
Here's a look back at some of the significant hurdles: ■ Relay Logic: Automation was primarily achieved through relay logic systems, where numerous relays, timers, and counters were wired together to control machinery. This approach was not only complex but also very expensive due to the high cost of relays and the labor-intensive wiring process. ■ Space and Maintenance: Large panels filled with relays took up significant space, and diagnosing issues or changing the control logic required extensive rewiring,
■ Scalability: Expanding an existing system or integrating new machinery was challenging. Each addition or change could necessitate a complete overhaul of the control system, making scalability a significant issue. ■ Manual Configuration: Without digital means, programming was essentially done through physical wiring. Wires would be wrapped around posts, changing the actions of the relay logic. Debugging required manual tracing of wires and logic, making it time-consuming and very prone to errors. ■ Lack of Documentation: Over time, as systems evolved, documentation often became outdated or incomplete, complicating maintenance and upgrades. The machines were built on-site by brilliant minds who left and moved to the next factory to do it over again. ■ Safety Concerns: The use of high voltage in relay systems posed safety risks for workers, especially during troubleshooting or maintenance activities. Factories were very dangerous for several reasons and electrocution was absolutely one of them.
■ Speed and Efficiency: The response times of relay- based systems were slower compared to what would become possible with digital technology. Every click- and-clack takes time that a transistor wouldn’t need. This limitation affected the efficiency of manufacturing processes, especially in high- speed applications. Globalization and labor shifts driving automation The late 1960s was a pivotal time for manufacturing. The rapid globalization of trade and rising competition from overseas manufacturers put pressure on American industries to increase efficiency and reduce costs. Labor unions were also growing in strength, leading to higher wages and benefits for workers. While these advancements improved worker conditions, they simultaneously drove the need for manufacturers to offset rising labor costs through automation. These factors underscored the necessity of a more flexible and scalable manufacturing process for companies like General Motors. While relay logic systems were serviceable, they were too slow, inflexible, and maintenance-heavy to keep
leading to downtime and maintenance nightmares.
■ Inflexibility: Once a control system was set up using relays, changing the sequence or logic of operations was a daunting task. It often meant redesigning and rewiring significant portions of the control panel, making the system highly inflexible to adapt to new processes or minor adjustments. ■ Mechanical Wear: Relays and other mechanical components were susceptible to wear, resulting in frequent failures. Consequently, the reliability of these systems was lower than desired, particularly in harsh conditions like dust, heat, or vibration.
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