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A

CASE STUDY ON

FMS

Presented by:

Saurabh Kumar BhartiCAD-CAM, SEM.,

MT09CDM015

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What Is A Flexible Manufacturing

System? A system that consists of numerous programmable

machine tools connected by an automated materialhandling system.

The flexible manufacturing system (FMS) is aconfiguration of computer-managed numerical workstations where materials are automatically handled and

machine loaded. It consists of CNC machines, a cellcomputer and a robot.

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Equipment of FMS Primary equipment

work centers Universal machining centers (prismatic FMSs)

Turning centers (rotational FMSs) Grinding machines

Process centers Wash machines Coordinate measuring machines

Robotic work stations

Manual workstations

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Equipment of FMS Secondary equipment

Support stations Pallet/fixture load/unload stations

Tool commissioning/setting area

Support equipment Robots

Pallet/fixture/stillage stores

Pallet buffer stations

Tools stores Raw material stores

Transport system(AGVs,RGVs,robots)

Transport units(pallets/stillages)

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FMS different approaches The capability of producing different parts without

major retooling .

A measure of how fast the company converts itsprocess from making an old line of products toproduce a new product .

The ability to change a production schedule, tomodify a part, or to handle multiple parts .

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FMS and FMC Early FMSs were large and very complex, consisting of

dozens of CNCs and sophisticated material handlingsystems.

Currently, the trend in FMS is toward small versions of thetraditional FMS, calledflexible manufacturing cells(FMC).

Today two or more CNC machines are considered aflexible celland two more cells are considered a flexiblemanufacturing system.

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The Cell Controller The cell computer (typically a programmable logic controller) is

interfaced with the microprocessors of the robot and the CNCs.The supervision and coordination among the various operationsin a manufacturing cell is also performed by the cell computer.

Control of each workstation

Distribution of control instructions to each workstation

Production control

Traffic control

Shuttle control

Work handling system monitoring

Tool control

System performance and monitoring

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The Cell Robot

In many applications, the cell robot also performs toolchanging, staging of tools in the tool changer, andinspection of tools for breakage or expressive wear.

When necessary, the robot can also initiate emergencyprocedures such as system shut-down.

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A case study on FMS

How Does It Work ?

-By implementing the components of robotics,manufacturing technology and computer integratedmanufacturing in a correct order one can achieve asuccessful Flexible Manufacturing System.

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Name of Device Quantity and description

5 Axis Robot 2

Personal Compute 3

Universal belt Conveyor 1

Flexible Conveyor 1

PLC device 2Sensors 9(4 Contact Sensors,3 Optical sensors,1 Metal detector and 1 Non-Metal Detector)

Motors 3(1 Emergency stop and run push button)

Other

Introduction

Concept : A flexible manufacturing system including different cells

Components:

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ROBOTS

First 5 axis robot is in charge of picking and placing parts which are scanned by the barcodereader, and transfer them to the left side for machining or throw it to the conveyor for

the other operations.This robot utilizes a vacuum gripper to pick the parts.

Pneumatic Robot which contained a few reed sensors, used to set the limits for thepneumatic cylinder motion. This robot is using a general griper which can be close or

open in each time.This robot just picks the parts which are detected by the Metal Detector sensor, placedbefore it.Hence, the duty of this robot is to pick the Metal-Coated parts, chosen by the sensorplaced near it.

Second Five axis robot which has the same specifications as the former one, used to pickthe Non-Metal parts (which are detected by non-metal detector sensor on the bigconveyor) from the flexible conveyor and place them into a rail way for the next definedoperations.This robot placed on a special Nut and Screw system which is connected to a Motorusing to turning the screw in case of moving the robot across the Big conveyor .

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second robot

pneumatic robot

First robot

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COMPUTERS AND SOFTWARES

First Robot is controlled by a General PC, using a visual basic program to

read the barcodes and also control the robots motion. For each part theprogram decide Where to be placed according to the parts barcode.

The second 5-axis robot is controlled by a PC using special software whichis named Robotica.

Generally, this software has a GIU (Graphical User Interface) which canbe used for programming the robot remotely. After writing theprogram, by pressing the Run Button on the program screen, each linetransferred to the robot using a general RS-232 cable.

Also we have another PC which is used to monitor the Main PlC , placedin an anti dust cabin for safety.

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CONVEYORSWe have 2 Conveyors, one general belt conveyor and one big flexible conveyor

which are driven by two different Motors . The specifications of these twoconveyors are as below:

11Cm

97Cm

63Cm

176Cm

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PLCs

Two different PLC devices :

A Siemens S7-200 PLC with 5 inputs and 5 outputs , which is used assecondary plc device , just to transfer the fire signal to the second five

axis robot.A Telemeqanic PLC with inputs and output , used as main PLC device

for controlling the motors, conveyors, sensors and all other feedbacksignals.

Telemeqanic Micro TSX PLC SIEMENS S7-200 PLC

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REVIEWING THE SCENARIO To run the system three parts are designed for three different operations. At

the first cell the scenario is collaboration of the barcode reader and the first

robot. After inserting the part in the input place , the small conveyor startswitch pushed down and the small conveyor runs.

After this the parts moves across the barcode reader for reading the partsbarcode, after that the conveyor stopped when the part reached the opticalsensor on the belt conveyor.

The Barcode reader Device 3 parts(1 Metal and 2 Non-metal with different barcodes)

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Regarding to the parts barcode, two different operations may have done.Parts with barcode going to the box 1, other parts must thrown to thesecond flexible conveyors , these parts including metal and non-metalparts. Throwing parts into the f lexible conveyor, they switch the optical

sensor on which caused the big conveyor to turn on.

After a while the parts reach the metal detector sensor, in this case if thepart was non-metal, it passes the sensor and continue it out, otherwise

the metal detector sensor send a signal to the main PLC and main PLCsend signal to the pneumatic robot to catch the metal part.

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The non-metal parts continue their route until they reach the non-metalsensor, at this time, the sensor send a signal to the main PLC and themain PLC send the required signal to the robot and also to the screwmotion control, so the screw starts turning and the robot get close to the

part which is in the conveyor waiting to be caught by the robot. Duringthis operation, the PC which is used to control the second robot must berun and ready to send the program to the robot.

The robot catches the part and after that the signal from the non-metalsensor goes off, so the screw starts in reverse direction by receiving a

signal from the main PLC , and the robot throws the parts into a specialrail at the end of the rout.

Metal Detector

Sensor

Non-Metal Detector

Sensor

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Part Flow monitoring

It must be considered that by detection of any part (metal or non-metal) by the special sensors ,the big conveyor stopped and waiting forpart-received signal from the first sensor of big conveyor.

Beside this an alarm system designed to warn the operator if the part is

going to reach the sensor in improper position (if it stands vertically) .When the alarm optical sensor detected the part which stood verticallythe alarm beep starts and warn the operator to correct the partsituation(it must lays on the width of the part) and after that push startbutton for resuming the conveyor cycle.

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Computer integrated manufacturing andPLC

In todays manufacturing units several PLCs are used to switchon or off robots ,conveyer belts and other part ofmanufacturing systems. The advantages of PLC in automatedsystems made PLC one of the main component of anyManufacturing unit.

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An example of a simple and

modern manufacturing

1 2

Hostcomputer

RawMaterials

Area

Swarfdisposal

Universal MachiningCenter

AGV transport system 1

AGV transport system 2

Universal MachiningCenter Head

IndexingMachines

WashMachine

CoordinateMeasuringMachine

AssemblyCells1 & 2

FinishMachieCell

PiecepartBufferArea

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FMS ExampleOne Design + One Assembly Process = Multiple Models

When different models are designed to be assembled in the same sequence they can bebuilt in the same plant.This maximizes efficiency and allows the company to respond quickly to changingcustomer

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FMS ExampleThrough the use of reprogrammable tooling in the body shop, standardized equipment

in the paint shop and common build sequence in final assembly, Ford can buildmultiple models on one or more platforms in one plant.

In the body shop, wherethe sheet metal comestogether to form the

vehicles body, flexibilitymeans more than 80percent of the tooling isnot specific to onemodel. It can bereprogrammed to weld a

car or a truck or a

Body Shop

In the paint shop,flexibility means roboticapplicators are

programmed to covervarious body styles asthey move through thepaint booth with equalprecision. This results inminimizing waste and

environmental impactwhile maximizin ualit .

Paint Shop

In the final assemblyarea, flexibility meansthe build sequence is

the same amongmultiple models on oneor more platformsallowing for efficientutilization of peopleand equipment.

Final Assembly

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Thanks