Automated Manufacturing Systems

• Automated manufacturing systems operate in

the factory on the physical product.
• They perform operations such as processing,
assembly, inspection, or material handling. In
some cases accomplishing more than one of
these operations in the same system.
• They are called automated because they
perform their operations with a reduced level
of human participation compared with the
corresponding manual process.
Automated Manufacturing Systems
(1) fixed automation.
(2) programmable automation
(3) flexible automation.
(1) Fixed automation.
• Fixed automation is a system in which the
sequence of processing (or assembly) operations
is fixed by the equipment configuration.
• Each of the operations in the sequence is usually
simple, involving perhaps a plain linear or
rotational motion or an uncomplicated
combination of the two
Features of fixed automation
• high initial investment for custom-engineered
equipment
• high production rates relatively inflexible in
accommodating product variety
(2)Programmable Automation.
• In programmable automation. the production
equipment is designed with the capability to
change the sequence of operations to
accommodate different product configurations.
• The operation sequence is controlled by a
program, which is a set of instructions coded
so that they can be read and interpreted by the
system.
• New programs can be prepared and entered
into the equipment to produce new products.
Features of Programmable Automation.
• high investment in general purpose equipment
• lower production rates than fixed automation
• flexibility to deal with variations and changes in
product configuration
• most suitable for batch production
(3)Flexible Automation.
• Flexible automation is an extension of
programmable automation.
• A flexible automated system is capable of
producing a variety of parts (or products) with
virtually no time lost for changeovers from one
part style to the next.
• There is no lost production time while
reprogramming the system and altering the
physical setup (tooting, fixtures, machine
settings).
Features of Flexible Automation.
• high investment for a custom-engineered system
• continuous production of variable mixtures of
products
• medium production rate
• flexibility to deal with product design variations
Three types of automation relative to production quantity and product
variety.
Numerical Control
• Numerical control can be defined as a form of
programmable automation in which the process is
controlled by numbers, letters, and symbols.
• In NC, the numbers for a program of instructions
designed for a particular work part or job.
Basic Components of NC System
• Part Program
• Tape Reader
• Machine Control Unit
• Machine Tool
Basic components of an NC system.
Part Program
• Part program is the most important element of
the NC system. It consists of step by step
instructions to the Machine Control Unit to
carry out the operations as per the plan.
• The program is written using standard codes
and symbols.
• The various media used to prepare the part
program are – Punched Card, Paper Tape,
Magnetic Tape.
Machine Control Unit
• MCU consists of the electronics and hardware
system which is either fitted to machine tool or
may be housed in a separate cabinet.
• The coded part program is used by MCU to
control the position of the cutting tool and the
work piece.
• MCU is the brain of the NC machine. It reads,
interprets and converts the input NC code into
signals, which control the various movements in
the machine tool.
• controls various non machining activities like tool
change, coolant on/off, loading unloading of parts
etc.
The MCU includes
a) Data Processing Unit (DPU)
b) Control Loop Unit (CLU).
• DPU reads the part program, interprets, processes
the information and passes it on to CLU.
• CLU converts the information to control signals
and the drive mechanism, receives feedback, and
instructs the DPU to read new instructions
Machine Tool
• The basic design structure of conventional
machine tool is not suitable for NC machine,
some constructional modification is necessary to
achieve the desired accuracy, repeatability and to
get additional features such as tool magazine,
loading unloading pallets etc.
NC machine tool consists of
• worktable, spindle and motors, controls necessary
to drive them.
• cutting tools, fixtures and other accessories
needed for machining.
Classification of NC machine systems
1. Based on motion type
a. Point to point NC system
b. Straight cut NC system
c. Contouring system
2. Based on positioning system
a. Incremental
b. Absolute
3. Type of feedback control system
a. Open loop system
b. Closed loop system
4. Based on Power supply
a. Electric
b. Hydraulic
c. Pneumatic
• Based on motion type
i)Point to Point System
• Point to point system (PTP) is also called
positioning system which represents the lowest
level of motion control between the tool and
the work-piece.
• The motion between beginning point and end
point is at maximum velocity. Machining
operations are performed only at specific
points.
• usually used for drilling, boring, reaming,
sheet metal punching, spot welding etc.
• Based on motion type
ii) Straight cut NC system
• The straight cut system is an extension of PTP control
system. In this system, the cutting tool can be moved
parallel to one of the major axis at a controlled feed
rate.
• NC machine capable of straight cut movement is also
capable of PTP movement.
• Example-Milling
iii) Contouring NC system
• This system generates a continuously controlled motion
of the tool and work piece along different coordinate
axis. This NC system is more expensive than other
systems. This system can also be used for straight line
and PTP operations also.
• Based on positioning system
i) Absolute Coordinate System
• Coordinates of all points are defined with respect
to same origin.
• The MCU (Machine Control Unit) uses this origin
point to position the machine during program
execution.
Advantages
• Very easy to correct and check a program when
written
• If there is any mistake in any block, only that
block will be affected. The remaining of program
will remain intact.
• Based on positioning system
ii) Incremental positioning system
• It is also called relative positioning system.
• The coordinate of a point is defined with respect to the
previous point. Each subsequent position is based on
the previous position.
Advantage
• For complicated components, this dimensioning is
more advantageous.
Disadvantages
• Positioning errors add up in incremental positioning.
• If error occurs at any line in the program, all the
subsequent lines will add up to the error.
• It is difficult to check a program written in incremental
system.
Absolute Vs Incremental Positioning System
Based on feedback control system
Open loop system
• In this Machine Tool control, there is no provision to compare
the actual position of the workpiece/tool with the given input
command instruction.
• There is no system to monitor whether the system is moving as
per the command given to it.
• Due to friction in mechanical parts and wearing of
components, there is a possibility that the actual displacement
will not match with the ideal displacement expected.
Open loop system
Advantages
• Less complex and less costly due to the absence of
monitoring devices
• Low maintenance cost
Disadvantages
• Control unit assumes that the desired position is achieved
when it really doesn’t
• No positioning compensation
Closed loop system
• In closed loop system, the actual displacement of the machine
slide is compared with the input signal by using feedback
devices.
• The position feedback device senses the movement of the table
and a signal is passed to the comparator. Comparator compares
the feedback from the transducer with input signal and slide
position is regulated by servomotor until the feedback signal is
zero.
.
Closed loop system
Advantages
• Error compensation allows for greater position accuracy
• DC motors gives the ability to reverse instantaneously
and to adjust for position errors.
Disadvantages
• Cost of the system is higher
• The system is more complex as feedback is to be
generated, compared, and compensation is needed to be
made.
NC Procedure
• Process Planning
• Part programming
• Tape preparation
• Tape verification
• Production
Numerical Control punched tape format
Advantages of NC
• Reduced Non productive time
• Reduced fixturing
• Reduced manufacturing lead time
• Greater manufacturing flexibility
• Improved quality control
• Reduced inventory
• Reduced floor space requirement

Disadvantages of NC
• Higher investment cost
• Higher maintenance cost
• Finding and training NC personnel
Computer Numerical Control (CNC)
• Computer numerical control is an NC system that utilize a
dedicated, stored program computer to perform some or all the
basic numerical control functions.
• Most of the CNC machines today use microcomputer based
controller unit.
Advantages of CNC
• The program tape and the tape reader are used only once to
enter the program into the computer memory.
• Tape editing at the machining site. The NC tape can be
corrected and even optimized during the tape tryout at the site
of the machine tool
• Metric conversion. CNC can accommodate conversion of
tapes prepared in units of inches into the international system.
• Greater flexibility –flexibility provides the opportunity to
introduce new control options with relative ease at low cost.
• Total manufacturing system – CNC is more compatible with
the use of a computerized factory wide manufacturing system.
Direct Numerical Control (DNC)
• Direct numerical control can be defined as a manufacturing
system in which a number of machines are controlled by a
computer through direct connection and in real time.
• The tape reader is omitted in DNC, thus relieving the system
of its least reliable component.
• Instead of tape reader, the program is transmitted to the
machine tool directly from the computer memory. In principle,
one large computer can be used to control more than 100
separate machines.
Components of a DNC system
•Central computer
•Bulk memory, which stores the NC part programs
•Telecommunication lines
•Machine tools
Advantages of DNC
• Elimination of punched tapes and tape readers
• Greater computational capability and
flexibility
• Convenient storage of NC part programs in
computer files
• Programs stored as CLFILE
• Reporting on shop performance
• Establish the framework for the evolution of
the future computer automated factory.
ANALYSIS OF NC POSITIONING SYSTEMS

(a)open loop and (b) closed loop.