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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
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
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)
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.
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
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.
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
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.
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
Articulated Robots
Drilling Operation
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
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
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 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
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
To improve product quality To increase productivity in inspection process To increase productivity and reduce lead times in manufacturing
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
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.
NON-CONTACT INSPECTION
Optical Techniques Machine vision Scanning laser beam devices Photogrammetry etc. Non-Optical Techniques Electric field techniques Radiation techniques Ultrasonics
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
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
Increased
storage capacity Increased system throughput Reduced labor costs Improved product quality
Composed of a Microprocessor. Ability to be programmed by Human operator. A Display device to display geometry of the product.
Economic Objective.
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
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?
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
Machine 1
Tools
Machine 2
Computer
Tools
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.
Standard CNC machine tools Industrial Robots Special purpose machine tools Tools for maintenance of machines Special Inspection Probes used with the machine tools
Consists of:
Raw
Transferring:
Roller
Handling:
Robots
Storage
Automatic
Coordinates between Work Machine & Material Handling System Controls & Supervise FMS Responsible for both Flexibility & Automation in FMS
Machine Control Direct Numerical Control Production Control Traffic Control Shuttle Control Work Handling System Monitoring Tool Control System performance monitoring and reporting
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
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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