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

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

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 the Electronic 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

Schematics of NC Machine
PART PROGRAM

DPU

CLU

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.

Evolution of NC Controlled Machines

NC machines have evolved: CNC computer numerically controlled DNC direct numerically controlled (several machines controlled by a single computer) Examples: Grinding Machine Lathe

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 colocated 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-atthe-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 Services and the Use of Automated Equipment

Degree of Customer Contact

High

Manual Operations Mechanized Operations Automated Operations

Low Low
High

Capital Intensity

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) X Pallet

Transfer System X Workpiece in queue X X X X X X X X X
Tools

Machine 1
Tools

Machine 2
Computer
Tools

Pallet with workpiece X attached

Machine 3

Load Parts

X
Worker

Unload

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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