AUTOMATION

Coined at Ford Motor Company in 1945 to describe

“ a logical development ” in technical progress where automatic handling between machines is combined with continuous processing at machines.

Automation:

Few Workers Involved Computer gives the instruction to the

machine for the repetitive works Robots , CMC and CAM has

revolutionalized the automation

In the past, automation meant the replacement of human effort with machine effort, to save labor costs.

Today, automation means integrating a full range of advanced information and engineering discoveries into operations processes for strategic purposes.

Today, automation is applied not only for labor cost savings, but also for: Improved quality Faster production and delivery of

products/services

AUTOMATIONAUTOMATIONAUTOMATIONAUTOMATION

Purposes of Automation

Reduction in direct labour costs Uniform quality with machines Safety Improves Shop efficiency Use of standard tools

Basic Principle in automation

Design of the part and the design of the process should be related as closely as

possible

- to avoid excessive costs

- to ensure maximum processing efficiency

Types of Manufacturing Automation

Numerically Controlled (N/C) Machines Robotics Automated Quality Control Inspection Automatic Identification Systems (AIS) Flexible Manufacturing Systems (FMS) Automated Storage & Retrieval Systems (ASRS) Computer Based Systems. ( CAD/CAM, CIM,

ERP)

Numerical Control (NC)

Definition:– The use of coded numerical information in the automatic control of equipment positioning

Principle : - Machine is controlled by the preset values loaded in punch tape and values will be referring physical

quantities like height, width etc.

Numerically Controlled (N/C) Machines Have a control system that receives/reads

instructions and translates them into machine operations

The standards set for NC is usually theElectronic Industries Association (EIA)

An NC Machine.

Hardware for NC Machining

Machine Control Unit (MCU) - Data Processing Unit (DPU) - Control Loop Unit (CLU)

Data Processing Unit (DPU) - Reads a part program - Decomposes instructions into CLU

commands - Passes CLU commands to CLU

Control loop unit (CLU) - Receives the CLU commands - Translates into control signals for machine

drive mechanisms

Data Processing Unit (DPU)

In the past, could be- Mechanical tape punch reader

- Mechanical card reader - Magnetic tape reader - Had no memory storage ability at all Today, - Has memory storage for program

storage - Some graphical preview display

capability - PLC (Programmable Logic Controller) or

PC based

Control Loop Unit (CLU)

- Still very much the same as when NC first began

- Electronic hardware, sending analog signals to

motors - One major innovation: CLU are now usually packaged integrally with DPU - Motor types

Stepper Servo

PART PROGRAM

DPU

CLU

NC Machine

Schematics of NC MachineSchematics of NC Machine

Part Programming

The part program is created to control - The tool path - The machine operating parameters Creation of part program requires knowledge

of: 1. part geometry. 2. path taken by cutting tool. 3.machine tool and control system. 4.part identification, tool tolerances,

etc.

NC machines have evolved:NC machines have evolved:

CNC – computer numerically controlledCNC – computer numerically controlled

DNC – direct numerically controlled DNC – direct numerically controlled (several machines controlled by a single (several machines controlled by a single computer)computer)

Examples:Examples:

Grinding MachineGrinding Machine

LatheLathe

Evolution of NC Controlled Machines

Computer Numerical Control(CNC)

Primary difference between CNC and NC– NC cannot store the program; CNC can

CNC is so prevalent now that it is difficult to separate from NC

CNC has ability to create programs on station, ie parallel programming.

DNC

A data communications system connecting a group of numerically controlled machines to a common computer

Requirements: Substantial memory for the storage of numerous

numeric control (NC) part programs Provision for on-demand distribution

(downloading) of NC Programs to the machines. Additional provision for the management, display

and editing of NC part programs.

System Control

Direct Numerical Control (DNC) – A single computer controls several

machines directly. – Prominent in era of expensive computers. Distributed Numerical Control (DNC) – Central (or network host) computer

connected to satellites for program download and control

– Satellite computers (or “nodes”) are co-located at individual cutting machines for CNC

Robotics and Robots

What is Robotics?

- Robotics is the science of designing , building, and applying robots.

What is a Robot?

- It means Slave in Czech.

- A reprogrammable, multifunctional manipulator designed to move material, parts, tools, or specialized devices through various programmed motions for the performance of variety of tasks.

Why Robots are Needed?

To increase the productivity. To improve product quality. To decrease product cost. To work under hazardous and monotonous

jobs.

Classification of Robots

Cartesian Robots Cylindrical Robots

Classification of Robots

Spherical polar Robots Articulated Robots

Applications of Robots in Manufacturing

Arc Welding Process Spot Welding Process

Applications of Robots in Manufacturing

Spray Painting Process Drilling Operation

Applications of Robots in Manufacturing

Material Handling Process Loading – Unloading Process

Types of Manufacturing Automation

Automated Quality Control Inspection Take physical dimensions of parts Compare measurements to standards Determine if parts conform to specifications Also check performance (ex. - electronic

circuits) Making 100% inspection economically

feasible

Types of Manufacturing Automation

Automatic Identification Systems (AIS) Sense and input data into computers Use bar codes, radio frequencies, magnetic

stripes, optical character recognition, machine vision

Data read from products, documents, parts, and containers

Used in warehouses, factory floors, retailing, wholesaling

Example – scanner at grocery store checkout

Types of Manufacturing Automation

Automated Process Controls Use sensors to obtain measures of

performance Compare measures to standards Might use “expert system” to determine

if/what process adjustment is necessary If necessary, change settings of process Long used in chemical processing,

petroleum refining, paper production

Automated Production Systems Automated Flow Lines

In-line, automated processing machines linked by automated material transfer

Perform without need for human attendance

Used to produce an entire component Also called fixed automation or hard

automation Used when product demand is high and

stable

Automated Production Systems Automated Assembly Systems

Automated assembly machines linked by automated material transfer

Operations are component insertion and joining

Produce major assemblies or complete products

Often use standard (lower cost) robots Product design appropriate for assembly by

humans is not fitting for automated assembly

COMPUTER AIDED QUALITY CONTROL

Objectives

To improve product quality To increase productivity in inspection

process To increase productivity and reduce

lead times in manufacturing

COMPUTER AIDED QUALITY CONTROL

ADVANTAGES: 100% Inspection Integration with the manufacturing

process resulting in time savings Automatic adjustment of process

variables Cost-effective Quality improvement

COMPUTER AIDED QUALITY CONTROL Quality Assurance QA Activities which maximise the profitability

that the product and its components will be manufactured within design specifications.

Quality Control QC Activities related to inspection of product

and component quality,detection of poor quality and corrective action necessary to eliminate it.

WHEN ?

Incoming raw materials At various stages during manufacturing At completion of processing Before shipping the final assembled

product to the customer

COMPUTER AIDED QUALITY CONTROL

Methods of Inspection

Contact Inspection : Parts or hardware such as rubber, silicon or thin wall parts that cannot be inspected with touch trigger probe technology are inspected with Non-Contact Inspection methods.

Non-Contact Inspection : If products or aspects of the product are too small or too soft, Non-Contact Inspection is the appropriate alternative over contact inspection techniques

CONTACT INSPECTION

Qualitative Inspection Go/No-go gauges :refers to an inspection tool

used to check a workpiece against its allowed tolerances. Its name derives from its use. A Go NoGo gauge is a measuring tool that does not return a size in the conventional sense, but instead returns a state.

Quantitative Inspection Vernier Pressure Gauge CMM etc.

NON-CONTACT INSPECTION

Optical Techniques Machine vision Scanning laser beam devices Photogrammetry etc.

Non-Optical Techniques Electric field techniques Radiation techniques Ultrasonics

SCANNING LASER BEAM DEVICE

NON-CONTACT INSPECTION

ADVANTAGES Eliminates need to reposition the work

part Faster than contact-inspection Eliminates mechanical wear Reduces potential danger to people Reduction of possibility surface damage

Automated Production Systems Automated Storage & Retrieval Systems

(ASRS) Receive orders for materials from anywhere in

operations Collect the materials from locations in warehouse Deliver the materials to workstations in

operations Three major elements of ASRS are:

Computers and communication systems Automated materials handling/delivery systems Storage and retrieval systems in warehouse

Automated Production Systems Automated Storage & Retrieval Systems

(ASRS) Main benefits of ASRS are:

Increased storage capacity Increased system throughput Reduced labor costs Improved product quality

Computer Control System.

Composed of a Microprocessor.

Ability to be programmed by Human operator.

A Display device to display geometry of the product.

Economic Objective.

To achieve efficiency of mass production for batch production.

Automation in Services

Example Airlines – air traffic control, passenger

reservation Banks – ATMs, computerized bank statements Gas Stations – automated payment (pay-at-the-

pump) Health Care – MRI system, AGVS for waste

disposal Grocery Store – self-service checkout stations Real Estate – web based house-for-sale tour

video

Degree of Customer Contact in Servicesand the Use of Automated Equipment

Degree of Degree of Customer ContactCustomer Contact

CapitalCapitalIntensityIntensity

HighHigh

HighHigh

LowLow

LowLow

Manual OperationsManual Operations

Mechanized OperationsMechanized Operations

AutomatedAutomatedOperationsOperations

Automation Questions

What level of automation is appropriate? How would automation affect the

flexibility of an operation system? How can automation projects be

justified? How should technological change be

managed? What are some of the consequences of

implementing an automation project?

Flexible Manufacturing System

A manufacturing system in which there is some amount of flexibility that allows the system to react in the case of changes, whether predicted or unpredicted.

Flexibility in FMS

Machine Flexibility Ability to produce new product types Ability to change the order of operations

executed Routing Flexibility

Ability to use multiple machines to perform the same operation

Ability to absorb large-scale changes, such as in volume, capacity, or capability

FMS System

Work Machine Material Handling System Control Computer System Human Labor

Flexible Manufacturing System (FMS)

Machine 1Machine 1

ToolsTools

X X

Machine 2Machine 2

ToolsTools

X X

Machine 3Machine 3

ToolsTools

X X

ComputerComputer

WorkerWorker

X

X

X

X

X

X

X

UnloadUnloadLoadLoad

PalletPalletTransferTransferSystemSystem

PartsParts

Pallet withPallet withworkpieceworkpieceattachedattached

WorkpieceWorkpiecein queuein queue

Work Machine

Performs processing, inspection and testing or assembly tasks

The processing could be: cheap removal, casting, plastic molding, forging, sheet metal processing, heat treating, welding, painting, flame cutting, washing, etc.

Work Machine Tools and related equipment

Standard CNC machine tools Industrial Robots Special purpose machine tools Tools for maintenance of machines Special Inspection Probes used with the

machine tools

Material Handling System

Consists of: Raw Material Parts in different stages of processing Tools

which have to be stored, transferred and handled

Material Handling Equipment Transferring:

Roller Conveyor Towline Cart Automated Guided Vehicle (AGV)

Handling: Robots

Storage Automatic Storage and Retrieval System

(AS/RS)

Computer Control System

Coordinates between Work Machine & Material Handling System

Controls & Supervise FMS Responsible for both Flexibility &

Automation in FMS

Computer Control System

Machine Control Direct Numerical Control Production Control Traffic Control Shuttle Control Work Handling System Monitoring Tool Control System performance monitoring and

reporting

Human Labor in FMS

System Manager Electrical technician Mechanic/Hydraulic technician Tool setter Fixture setup and lead man Load/unload man Rover operator

Challenges

Rapid Programming Ability to set up tools and parts offline Technological problems of exact

component positioning and precise timing necessary to process a component

Expensive, costing millions of dollars

Types of Manufacturing Systems

Productivity

Flexibility

Benefits of FMS

Increased machine utilization Reduced direct and indirect labor Reduced manufacturing lead time Lower in-process inventory Scheduling flexibility

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