Automation

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Outline
1. Introduction
2. Automation
3. Numerical Control
4. Adaptive Control
5. Material Handling and Movement
6. Industrial Robots
7. Sensor Technology
8. Flexible Fixturing
9. Assembly Systems
10. Design Considerations for Fixturing, Assembly, and Servicing
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 Introduction
• There is a need to reduce the labor cost, improve the
efficiency and flexibility of manufacturing operations
• Productivity defined as output per employee per hour
• To improve productivity, we need mechanization,
automation, and control of manufacturing equipment and
systems
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Introduction
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 Automation
• Automation is the process of enabling machines with little
human intervention and using specialized equipment
• Automation is implemented in:
1. Manufacturing processes
2. Material handling and movement
3. Inspection
4. Assembly
5. Packaging
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Automation: Evolution of Automation
• Major breakthrough in automation began with numerical
control (NC)
• In order of increasing automation as below:
1. Job shops
2. Stand-alone NC production
3. Manufacturing cells
4. Flexible manufacturing systems
5. Flexible manufacturing lines
6. Flow lines and transfer lines
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 Automation: Evolution of Automation
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Automation: Implementation of Automation
• Automation goals are:
1. Integrate manufacturing operations
2. Improve productivity
3. Improve quality
4. Reduce human involvement
5. Reduce workpiece damage
6. Economize on floor space
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 Automation: Implementation of Automation
Automation and Production Quantity
• Job shops produce small quantities per using stand-alone
machines or machining centers
• When parts involve a large labor component, the production
is called labor intensive
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Automation: Applications of Automation
• Decision to automate a new or existing production facility
requires some considerations:
1. Type of product manufactured
2. Production quantity and rate of production required
3. Phase of the manufacturing operation to be automated
4. Level of skill
5. Reliability and maintenance problems
6. Economics of the whole operation
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 Automation: Hard Automation
• In hard automation, or fixed-position automation, the
machines are designed to produce a standard product
• These machines are specialized and lack flexibility
Transfer Machines
• Machines can be arranged on the shop floor in linear,
circular or U-shaped patterns
• Used in automated assembly
• Transfer mechanisms are used to move the workpiece from
one station to another
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Automation: Hard Automation
Transfer Lines
• A transfer line can consist various operations : milling,
drilling, reaming, boring, tapping, honing, washing and
gaging
• Weight and shape influence the arrangement of the
individual machines
• Buffer storage features are incorporated to permit continued
operation
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 Automation: Hard Automation
Transfer Lines
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Automation: Soft Automation
• In soft automation, greater flexibility is achieved through the
use of computer control
• Can produce parts with complex shapes
• Can be reprogrammed easily and produce a part with
desired shape or dimensions
• Flexible manufacturing systems can have high levels of
efficiency and productivity
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 Automation: Programmable Logic Controllers
• PLCs eliminate the need for relay control panels, can be
reprogrammed and take less space
• Basic functions are :
1. On–off,
2. Motion,
3. Sequential operations
4. Feedback control
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Numerical Control
• Numerical control (NC) is controlling the movements of
machine components by coded instructions
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 Numerical Control: Computer Numerical Control
• 2 types of computerized systems were developed:
1. Direct numerical control (DNC)
- several machines are controlled directly
2. Computer numerical control (CNC)
- control microcomputer is an integral part of a machine
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Numerical Control: Principles of NC Machines
• The functional elements and the components involved are:
1. Data input
2. Data processing
3. Data output
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 Numerical Control: Principles of NC Machines
Types of Control Circuits
• Open-loop system: no feedback to check accuracy
• Closed-loop system is equipped with sensors that
accurately measure the position of the worktable
• Position measurement in NC machines is carried out
through:
1. Indirect measuring systems:
- convert rotary movement to translation
2. Direct measuring systems:
- sensing for linear movement
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Numerical Control: Principles of NC Machines
Types of Control Circuits
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 Numerical Control:Types of Control Systems
• 2 types of control systems in numerical control:
1. Point-to-point system
- each axis of the machine is driven separately by lead screws and at
different velocities
2. Contouring system
- positioning and operations are performed along controlled paths but
at different velocities
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Numerical Control: Types of Control Systems
Interpolation
• Movement of the tool along a path incrementally
• Some of the methods:
1. Linear interpolation
2. Circular interpolation
3. Parabolic interpolation
4. Cubic interpolation
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Numerical Control: Accuracy in Numerical Control
• Positioning accuracy is defined as the accuracy of the
machine to be positioned with respect to a coordinate
system
• Stiffness of the machine tool and the backlash in gear drives
and lead screws contribute to dimensional accuracy
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Advantages and Limitations of Numerical Control
• Advantages are:
1. Flexibility of operation
2. Machine adjustments are easy
3. More operations can be performed
4. Programs can be prepared rapidly
5. Operator skill required is less
• Limitations are high initial cost of the equipment, cost for
programming and maintenance required
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 Adaptive Control
• Adaptive control (AC) is a dynamic-feedback system where
operating parameters adapt themselves to conform to new
circumstances
• An adaptive controller continuously checks conditions and
uses feedback to refine errors
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Adaptive Control
Adaptive Control in Manufacturing
• Purposes of adaptive control are to:
1. Optimize production rate
2. Optimize product quality
3. Minimize production cost
• Response time must be short for AC to be effective
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 Adaptive Control
Adaptive Control in Manufacturing
• For adaptive control to be effective, quantitative
relationships is established and coded in the computer
software as mathematical models
• Computer software must reflect the relationships among
independent process variables and dependent parameters
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Material Handling and Movement
• Material handling is defined as the functions and systems
associated with the transportation, storage and control of
materials and parts
• Plant layout is important in the orderly flow of materials and
components
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 Material Handling and Movement
Material-handling Methods
Several factors must be considered:
1. Shape, weight, and characteristics of the parts.
2. Distances, position and orientation of the parts
3. Conditions of the path
4. Level of automation and the controls needed
5. Operator skill required
6. Economic considerations
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Material Handling and Movement
Equipment
• Types of equipment used to move materials and parts are
conveyors, rollers, carts, forklift trucks and self-powered
monorails
• Manipulators are controlled directly by the operator or
automated for repeated operations
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 Material Handling and Movement
Equipment
• Movements of automated guided vehicles (AGVs)
interface with automated storage/retrieval systems
(AS/RS) to utilize warehouse space and reduce labor costs
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Material Handling and Movement
Equipment
• Coding systems used to locate and identify parts in
progress, some of them are:
1. Bar coding
2. Magnetic strips
3. RF (radio frequency) tags
4. Acoustic waves
5. Optical character recognition
6. Machine vision
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 Industrial Robots
• Industrial robot is a machine having degrees of freedom to
hold a tool, a workpiece or an inspection device
• Applications for robots are described as dull, dirty,
dangerous, demeaning, hot, heavy, and hazardous
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Industrial Robots: Robot Components
Manipulator
• A mechanical unit that provides motions
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 Industrial Robots: Robot Components
End Effector
• End of the wrist in a robot is equipped with an end effector
• Compliant end effectors are used to handle fragile
materials or to facilitate assembly
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Industrial Robots: Robot Components
Power Supply
• Each motion of the manipulator is controlled and regulated
by actuators using electrical, a pneumatic or a hydraulic
power supply
Controller
• Communications that gives commands for the movements of
the robot
• Can be open-loop control or closed-loop systems
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 Industrial Robots: Classification of Robots
Classified by basic type:
1. Cartesian, or rectilinear;
2. Cylindrical;
3. Spherical, or polar;
4. Articulated, revolute, jointed, or anthropomorphic
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Industrial Robots: Classification of Robots
Fixed-sequence and Variable-sequence Robots
• Fixed-sequence robot movements are from point to point
and the cycle is repeated continuously
• Variable-sequence robot can be reprogrammed to
perform a different sequence of operations
Playback Robot
• The operator teaches the robot by showing it what to do
• Movements can be registered in the memory of the
controller and are re-enacted automatically
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 Industrial Robots: Classification of Robots
Numerically Controlled Robot
• It is programmed and operated like a numerically
controlled machine
• 2 basic types of controls: point to point and continuous
path
Intelligent Robot
• Capable of performing functions and tasks carried out by
humans
• Equipped with a variety of sensors with visual and tactile
capabilities
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Industrial Robots: Applications and Selection of Robots
Applications of industrial robots:
1. Material-handling operations
2. Spot welding
3. Deburring, grinding, and polishing
4. Applying adhesives and sealants
5. Spray painting
6. Automated assembly
7. Inspection and gaging speeds
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 Industrial Robots: Applications and Selection of Robots
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Industrial Robots: Applications and Selection of Robots
Robotic Deburring of a Blow-molded Toboggan
• Robotic Deburring of a Blow-Molded Toboggan
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 Sensor Technology
• A sensor is a device that produces a signal in response to its
detecting or measuring a specific property
• Actuators and switches have been used to set limits on the
performance of machines
• Sensors used to control intelligent robots and developed
with capabilities that resemble humans
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Sensor Technology
• Sensors classification as:
1. Mechanical
2. Electrical
3. Magnetic
4. Thermal
5. Acoustic, ultrasonic, chemical, optical, radiation, laser
and fiber optic
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 Sensor Technology
Tactile Sensing
• Involves continuous sensing of variable contact forces
• Effectors can sense the force
applied to the object being handled
• Anthropomorphic end effectors
are designed to simulate the
senses of human hand and fingers
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Sensor Technology
Visual Sensing
• Cameras optically sense the presence and shape of the
object
• Machine vision or computer vision utilizes a microprocessor
that processes the image
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 Sensor Technology
Applications
Selection of a sensor depends on;
1. Quantity to be measured or sensed
2. Sensor’s interaction with components
3. Service life
4. Sophistication
5. Usage difficulties
6. Power source
7. Cost
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Sensor Technology: Sensor Fusion
• Sensor fusion is the integration of sensors
• Individual data are combined to provide a higher level of
information and reliability
• Sensor validation: The failure of any one sensor is detected
and control system maintains high reliability
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 Sensor Technology: Sensor Fusion
Special Applications of Sensors
3 special applications of sensors:
1. Fiber-optic sensors are being developed for gas turbine
engines
2. Tire-pressure remote sensors developed and are installed in
some automobiles
3. Electronic sensors have been developed to distinguish basic
tastes
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Flexible Fixturing
• Clamps are simple multifunctional work-holding devices
• Jigs have reference surfaces and points for accurate
alignment of parts or tools
• Fixtures are designed for specific purposes
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 Flexible Fixturing
Modular Fixturing
• It is used for small or moderate lot sizes
• Modular fixtures are based on tooling plates or blocks
configured with grid holes or T-slots
Tombstone Fixtures
• They have two to six vertical faces onto which workpieces
can be mounted
• Used with workpiece that flips or rotates
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Flexible Fixturing
Bed-of-nails Device
• Consists of a series of air-actuated pins that conform to the
shape of the external surfaces of the workpiece
Adjustable-force Clamping
• Strain gage mounted on the clamp senses the magnitude of
the clamping force
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 Assembly Systems
• Assembly involves manual work and contributes to product
cost
• Total assembly operation can be broken into individual
assembly operations (subassemblies)
• Assembly method depends on the required production rate,
the total quantity to be produced, the product’s life cycle, the
availability of labor, and cost
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Assembly Systems
Methods and Systems of Assembly
• 3 basic methods of assembly: manual, high-speed automatic
and robotic
• Analysis of the product design must first be made to
determine an appropriate and economical method of
assembly
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 Assembly Systems
Methods and Systems of Assembly
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Assembly Systems
Methods and Systems of Assembly
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 Assembly Systems
Flexible Assembly Systems
• Set up for a specific product line and can be modified for
increased flexibility
• Flexible assembly systems (FAS) utilize computer controls,
interchangeable and programmable workheads and feeding
devices, coded pallets, and automated guiding devices
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Design Considerations for Fixturing, Assembly, and Servicing:
Design for Fixturing
Major design issues involved:
1. Work-holding devices must position the workpiece
automatically and accurately
2. Fixtures must have sufficient stiffness to resist
3. Avoid loose machining or grinding chips
4. Flexible fixture should be able to accommodate parts
5. Clamps and fixtures should have low profiles
6. Flexible fixturing must meet special requirements in
manufacturing cells and FMS
7. Workpieces should be designed so as to allow locating
and clamping within the fixture
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 Design Considerations for Fixturing, Assembly, and Servicing:
Design for Assembly
Design for Assembly
• Design for assembly (DFA) is the solution for continued
need to reduce assembly costs
• In manual assembly, humans can easily pick the correct
parts from bulk
• In high-speed automated assembly, automatic handling
requires parts be separated from the bulk, conveyed by
hoppers or vibratory feeders
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Design Considerations for Fixturing, Assembly, and Servicing:
Design for Assembly
Design for Assembly
General guidelines:
1. Reduce the number and variety of parts in a product
2. Ensure that parts have a high degree of symmetry
3. Designs should allow parts to be assembled without any
obstructions
4. Consider methods such as snap fits
5. Part designs should consider such factors as size, shape,
weight, flexibility
6. Parts should be inserted from a single direction
7. Products should be designed, or existing products
redesigned
8. Color codes should be used on parts
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 Design Considerations for Fixturing, Assembly, Disassembly, and
Servicing: Robotic Assembly
Robotic Assembly
Design guidelines for robotic assembly:
1. Parts should be designed so that they can be gripped and
manipulated by the same gripper of the robot
2. Assembly that involves threaded fasteners may be difficult to
perform by robots
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