undefined | unit 6 automation

Back to Study material

CAD

Unit 6

Q.1 Write the need for Automation

A1) NEED OR REASONS FOR AUTOMATION

1. To increase labor productivity

2. To reduce labor cost

3. To mitigate the effects of labor shortages

4. To reduce or eliminate routine manual and clerical tasks

5. To improve worker safety

6. To improve product quality

7. To reduce manufacturing lead lime

8. To accomplish. processes that cannot be done manually

9. To avoid the high cast of not automating

Q.2 What are the basic Automation Strategies?

A2)

Simplification

First strategy in automation is to look for simple solutions and avoid complex solutions. Simple solutions are cost effective, easy for operations, and easy for maintenance.

2. Specialization of operations

Special purpose machine should be developed for performing one operation with maximum possible efficiency.

3. Multiple operations

Multiple operation should be done at one machine or workstation. This reduces the number of machines required.

4. Simultaneous operation

Multiple operations should be carried out simultaneously. This reduces machining time.

5. Integration of Workstations

Many workstations should be integrated into a single integrated mechanism using automated work handling devices. This reduces work handling time.

6. Increased flexibility

A workstation should have flexibility to machine different products. This helps in maximum utilization of machine.

7. Automated material handling and storage systems

Non-production time can be reduced using automated material handling and storage systems.

8. On-line Inspection

In-process correction is achieved due to on-line inspection. This reduces scrap and improves quality of product.

9. On-line monitoring, Process Control and Optimization

On-line monitoring and process control helps in taking the corrective actions in case of deviation.

10. Control of Plant Operations

All the plants are networked using computers so that all the plant can be controlled and monitored at one place.

11. Computer Integrated manufacturing (CIM)

CIM integrates manufacturing operations and manufacturing support systems. CIM is complete integration of factory using computer network.

Q.3 Classify Automation.

A3) Three main classification are:

1. Fixed (hard) automation – involve hardware only

2. Programmable automation – involve software only

3. Flexible (soft) automation – involve hardware and software

Fixed (hard) Automation:

“Fixed automation is an automation system in which the sequence of operation is fixed by the layout of production equipment.”

Fixed Automation is a machine refer to totally hardware that can operate automatically without human interference.

Examples – door with spring load – watch, gravity machine, water-wheel, animal/wind – wheel.

Used in low and medium production manufacturing.

Special machine for production process efficiency at higher number/rate of product.

An Automatic machine and numerical control machine is an example of fixed automation because the inner construction and function can’t be change

2. Programmable Automation:

“Programmable automation is the automation system in which the production equipments are designed with a capability to change the sequence of operations so as to accommodate the different product configuration.”

Programmable Automation is a combination of hardware (machine) and software (programmable).

Example – Production line assemble, Air condition, screen saver, traffic light, radiator

Used when rate of production is small and there is a variation at the product.

An equipment can easily change their setup according to the product configuration needs after the first production is finish.

More different/variety and unique product can be produced economically in small amount.

One set of program controls the whole operation of product.

3. Flexible (soft) Automation:

“Flexible Automation is an automation system capable of producing products of design variation, continuously with little or no time loss for changeovers of one product to another.”

It is an extension of Programmable Automation.

It is combination of hardware and software (same as programmable) but can be easily changed during the operation without waiting the whole operation completed.

It can be programmed for different configuration product either at the beginning, middle or end of the production according to the production changes.

But usually configuration products are limited compare to the programming automation.

Allows combination of certain system.

In flexible automation, different product can be made in the same time at the same manufacture system.

Flexible Automation System mostly consist of series of workstation that is connected to the material operation and storage system, assembly line and control of operation of work by using a program for a different work station.

Example – Automobile assembly line

Q.4 What is FMS? Explain its need and give its application.

A4) FMS may be defined as “a highly automated GT machine cell, consisting of a group of processing workstations (usually CNC machine tools), interconnected by an automated material handling and storage system, and controlled by a distributed computer system.”

FMS employs a fully integrated handling system with automated processing stations.

Need of FMS

External changes such as change in product design and production system.

Optimizing the manufacturing cycle time

Reduced production costs

Overcoming internal changes like breakdowns etc.

Application of FMS

Metal-cutting machining

Metal forming

Assembly

Joining-welding (arc , spot), gluing

Surface treatment

Inspection

Testing

Q.5 Write a note on AGVS

A5)

An Automated Guided Vehicle System (AGVS) is a computer controlled, driverless vehicle used for transporting materials from point to point in a manufacturing setting.

An AGVS uses independently operated, self-propelled vehicles that are guided along pre-defined paths, and are powered by means of on-board batteries.

The AGVs are highly flexible, intelligent, and versatile material handling systems used to transport materials from various loading locations to various unloading locations throughout the manufacturing facility.

Types of AGVs

Guided Driverless Trains

The Guided driverless trains, also known as towing vehicles or automated guided tractors, are most commonly used for transporting large amount of bulky and heavy materials from the ware house to various locations in the manufacturing plant.

2. Guided Pallet Trucks

The guided pallet trucks are designed to lift and transport palletized loads. It is used for picking up or dropping off loads from and on to floor level. Thus, it eliminates the need for fixed load stands.

3. Guided unit load carriers

Guided unit load carriers have a deck that permits unit-load transport operation. They are used in settings with short/medium guide paths, high volume, and need for independent and versatility. They can operate in an environment where there is not much room and movement is restricted.

Application of AGV

Automated Guided Vehicles are used in a variety of areas to support processing and handling throughout a manufacturing facility.

Assembly

Kitting

Transportation

Staging

Warehousing

Order picking

Parts/just-in-time delivery

Transfer/shuttle

Q.6 Write a note on Group Technology

A6)

Group technology is a manufacturing philosophy in which similar parts are identified and grouped together to take advantage of their similarities in design and production.

Similar parts are arranged into part families, where each part family possesses similar design and/or manufacturing characteristics.

For example, a plant producing 10,000 different part numbers may be able to group the vast majority of these parts into 30-40 distinct families.

The manufacturing efficiencies are generally achieved by arranging the production equipment into machine groups or cells, to facilitate work flow.

Grouping the production equipment into machine cells, where each cell specializes in the production of a part family, is called cellular manufacturing.

GT is most appropriately applied under the following conditions:

The plant currently uses traditional batch production and a process type layout and this results in much material handling effort, high in-process inventory, and long manufacturing lead times.

The parts can be grouped into part families. This is a necessary condition. Each machine cell is designed to produce a given part family or limited collection of part families, so it must be possible to group parts made in the plant into families.

Q.7 Explain CIM

A7) CIM is the integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency.

The term CIM comprises three words – computer, integrated and manufacturing. CIM is the application of computers in manufacturing in an integrated way. CIM is an attempt to combine computer technologies in order to manage and control the entire business and manufacturing.

CIM is the computerization of design, manufacturing, distribution and financial/business function into one coherent system

There are four Islands of Automation in CIM:

CAD (Computer Aided Design)

CAMPC (Computer Aided Manufacturing Planning and Control)

CAM (Computer Aided Manufacturing)

Computerized Business System

Objectives of CIM:

More productive and efficient

Increase product reliability

Decrease the cost of production and maintenance

Reduces the number of hazardous jobs

Q. 8 Define Robot. What are the basic laws of Robotics?

A8) Robot is defined as, “A reprogrammable and multifunction machine designed to move materials, tools or specialized instruments, by programmed movements to carry out a variety of tasks.”

There are three basic laws of robotics as follows:

A robot can't damage a human being, nor allow this to be damaged.

A robot must obey a human order, except when these orders clash with the first law.

A robot must always protect themselves as long as this protection doesn’t clash with the first and second laws.

Q.9 Explain Robot Anatomy

A9) Robot anatomy consists of seven components:

Manipulator or Rover: Main body of robot (Links, Joints, other structural element of the robot)

End Effecter: The part that is connected to the last joint hand of a manipulator. End effectors may consist of a gripper or a tool. The gripper can be of two fingers, three fingers or even five fingers.

Actuators: Muscles of the manipulators (servomotor, stepper motor, pneumatic and hydraulic cylinder).

Sensors: To collect information about the internal state of the robot or to communicate with the outside environment. Sensors provide awareness of the environment by sensing things. Sensors are the core of robots. It is the system that alerts the robots

Controller: Similar to cerebellum. It controls and coordinates the motion of the actuators.

Processor: The brain of the robot. It calculates the motions and the velocity of the robot’s joints, etc.

Software: Operating system, robotic software and the collection of routines.

Introduction to robotics

Q.10 Give all the degree of freedom of a robot

A10) A total of six degrees of freedom is needed to locate a robot’s hand at any point in its work space.

The three degrees of freedom located in the arm of a robotic system are:

The rotational traverse: is the movement of the arm assembly about a rotary axis, such as left-and-right swivel of the robot’s arm about a base.

The radial traverse: is the extension and retraction of the arm or the in-and-out motion relative to the base.

The vertical traverse: provides the up-and-down motion of the arm of the robotic system.

The three degrees of freedom located in the wrist, which bear the names of aeronautical terms, are

Pitch or bend: is the up-and-down movement of the wrist.

Yaw: is the right-and-left movement of the wrist.

Roll or swivel: is the rotation of the hand.

Sign Up