AUTOMATION IN MANUFACTURING

AUTOMATION
INTRODUCTION Is an technology by which a process or procedure is done without human assistance. Implemented by using an program or instruction with control system which executes instruction.

REASONS FOR IMPLEMENTING AUTOMATION IN MANUFACTURING

INCREASE THE PRODUCTIVITY RATE OF LABOUR

TO DECREASE COST OF LABOUR

SHORTAGE OF LABOUR IMPROVES WORK SAFETY

TO RESUCE MANUFACTURE LEAD TIME

TO AVOID HIGH COST OF NON AUTOMATION TO IMPROVE WORKER SAFETY

PRODUCT QUALITY IMPROVEMENT

TO REDUCE MANUFACTURING LEAD TIME

TYPES OF AUTOMATION

1 . F I X E D A U TO M AT I O N 2 . P R O G R A M M A B L E A U TO M AT I O N

3 . F L E X I B L E A U TO M AT I O N

FIXED AUTOMATION
o sequence of processing or assembly operations to be

carried out are fixed by equipment configuration

o difficult to automate changes in design product o high production rates o time taking o during process new products cannot be processed

PROGRAMMABLE AUTOMATION
Production equipment is designed with the capability to change the sequence of operations Controlled by an program consists of set of coded instructions can be read and implemented by system New program or codes can be entered to produce new products High investment Low production rates, low & medium volume production Suitable for batch production Example: numerical control machines(nc)

FLEXIBLE AUTOMATION
Extension of programmable automation

Developed to minimize time loss between change

over of batch production from 1 to another No loss of production in reprogramming & altering Very high investment Continuous production with variable products Example: CNC Machines

ADVANTAGES OF AUTOMATION
High rate of production

Requires less number of workers

Produces high quality of products Production time period is low General working conditions are improved Heavy jobs can be handled easily

Adaptability to CAD/CAM
Shorter lead times

DISADVANTAGES OF AUTOMATION
Initial cost is very high Maintenance cost Requires several complex control systems Skilled workers Break down stops whole production Substantial preplanning is required

STRATEGIES IN AUTOMATION
1. 2. 3. 4. 5. 6. 7. 8. 9. SPECIALIZATION OF OPERATIONS COMBINED OPERATIONS SIMULTANEOUS OPERATIONS INTEGRATION OF OPERATIONS INCREASED FLEXIBILITY IMPROVING MATERIAL HANDLING ONLINE INSPECTION PROCESS CONTROL & OPTIMIZATION PLANT CONTROL OPERATIONS

10. COMPUTER INTEGRATED MANUFACTURING (CIM)

Automation is the technology by which a process or procedure is accomplished without human assistance. Basic elements of an automated system : 1. Power - to accomplish the process and operate the automated system 2. Program of instructions to direct the process 3. Control system to actuate the instructions

BASIC ELEMENTS OF AUTOMATION POWER

PROGRAM OF INSTRUCTIONS

CONTROL SYSTEM

PROCESS

Electricity The Principal Power Source

Widely available Can be readily converted to alternative forms, e.g., mechanical, thermal, light, etc. Low level power can be used for signal transmission, data processing, and communication Can be stored in long-life batteries

 Power for the process

To drive the process itself To load and unload the work unit Transport between operations

Power for automation

Controller unit Power to actuate the control signals Data acquisition and information processing

Program of Instructions
Set of commands that specify the sequence of steps in the work cycle and the details of each step

Example: CNC part program During each step, there are one or more activities involving changes in one or more process parameters
Examples:
Temperature setting of a furnace Axis position in a positioning system Motor on or off

Control System Two Types

1. Closed-loop (feedback) control system a system in which the output variable is compared with an input parameter, and any difference between the two is used to drive the output into agreement with the input 2. Open-loop control system operates without the feedback loop

Closed loop control system

open loop control system

Example for closed loop control system

Temperature instructions

Example for open loop control system

Levels of Automation
1. Device level actuators, sensors, and other hardware components to form individual control loops for the next level 2. Machine level CNC machine tools and similar production equipment, industrial robots, material handling equipment 3. Cell or system level manufacturing cell or system 4. Plant level factory or production systems level 5. Enterprise level corporate information system

Levels of Automation

PNEUMATIC SYSTEM

Hydraulic system

Pneumatic system consists of

Motor driven compressor Air receiver Directional control valve (DCV) PNEUMATIC cylinder

PNEUMATIC SYSTEM
DIRICTIONAL CONTROL VALVE

WEIGHT

AIR RECEIVER

MOTOR
MOTOR CONTROL

HYDRAULIC SYSTEM
The basic hydraulic system essentially consists of a pump and a cylinder Hydraulic piston is lifted by a hydraulic pump driven by a electric motor System consists of a closed-loop piping network With a fluid transferred from a storage tank to one side of piston Pump converts a mechanical force to hydraulic power and fluid is drawn from the tank

HYDRAULIC SYSTEM
hydraulic system has significant advantage over pneumatic system in carrying loads Range from 35 to 200 mpa Main components are Hydraulic power supply Electro hydraulic servo valve Sump or tank Hydraulic motor

HYDRAULIC SYSTEM

WEIGHT

FILTER

Press ure

Control valve
PISTON

FLUID TANK

 A pressure regulation/relief valve protects the system from high pressure Is essential to spill excess fluid back to tank The cylinder uses the moving oil to do work and the cylinder movement is controlled by a valve The control valve directs the oil to allow supply of oil from the pump to and from cylinder

AUTOMATION IN MACHINE TOOLS

 Machine tool is defined as the machinery used to obtain the desired properties or geometry of the metallic or non-metallic materials by performing various operations Automated machine tool is nothing but NC(numerical control) CNC (computer numerical control) Mostly used is CNC

Principle functions of CNC machines

MACHINE TOOL CONTROL IMPROVED PROGRAMMING AND WORKING FEATURES IN-PROCESS COMPENSATION DIAGNOSTICS

Machine tool control

This is important function of the CNC system Deals with steps and various functions of process which are used to convert the part program instructions into machine tool For this conversation process is done by using the computer interface and servo system TYPES 1. HYBRID CNC 2. STRAIGHT CNC

HYBRID CNC
Consists mainly 2 parts 1. Soft-wired computer 2. Hard wired logic circuits The hard wired circuits perform the machine tool feed rate generation and circular interpolation The remaining control functions and duties are associated by the computer

XYZ motion
Tape reader from initial program

input

interp olation

offsets feedback

Interfacing unit

HYBRID CNC

STRAIGHT CNC
Consists one computer to perform all NC functions The only hard-wired components are required to interface the computer with machine tool and operator task

STRAIGHT CNC

MOTION FEEDBACK

TAPE READER FOR INTIAL PROGRAM

I N P U T

COMPU TATION

OFFSETS

S E N S O R S

IMPROVED PROGRAMMING AND WORKING

Includes 1. Graphical display of tool path and verification of tape 2. Use of specially written subroutines 3. Manual data & input method 4. Local storage of more than one part diagram 5. Interpolation techniques 6. Editing the program

INPROCESS COMPENSATION
Recalculating and analysis of axis positioning Offset adjustments Accurate calculation of predicted tool life Use of specially written sub programs SI & METRIC units Large storage system having more than one part program

DIAGNOSTICS
This function is available in modern CNC machine It helps in maintenance and repair of the system Its functions are 1. To minimize downtime 2. Warn about forthcoming failure of a certain components

MECHANICAL FEEDERS
Used in automation are 1. Centrifugal feeders 2. Drum feeders 3. Barrel feeders 4. Rotary selector ring feeders 5. Elevator feeders 6. Blade feeders

MECHANICAL FEEDER

CENTRIFUGAL FEEDER

DRUM FEEDER

ELEVATOR FEEDER

AUTOMATIC TOOL CHANGING

M-TAB CNC

BED CNC

 A variety of machining process or operation may done for finishing a particular part So variety of tool are needed to do particular operation These tools are positioned on tool drum of the machine when a particular operation is done on the part Tool drum rotates to change the tool position by means of ATC mechanism This program helps to exchange the tool in the spindle and in drum

AUTOMATIC TOOL CHANGER

ADVANTAGES OF ATC
Reduces idle time Usually takes 5 to 7 seconds Identification of tool (done by codes) Tool transfer is done by the reciprocating motion

of spindle and magazine

CLASSIFICATION OF TOOL CHANGE

1. According to kind of cutting tools Single tool heads Multi tool heads Special tool heads 2. According to tool position Horizontal type Vertical type

SINGLE TOOL, MULTI TOOL

AUTOMATIC TOOL CHAGER HORIZONTAL

AUTOMATIC TOOL CHANGER VERTICAL

 According to system tool exchanger 1. Without tool change arm 2. With tool change arm 3. With tool parking position According to position of axes of spindle 1. Parallel axes 2. Intersecting axes

CNC MACHINE TOOLS