MNE3046

AUTOMATION TECHNOLOGY
Alexandar Djordjevich
(Y6617, [email protected], 3442-7776)

Course Aims:
to introduce concepts of
fixed, programmable and flexible automation,
their design, implementation, application and cost-effects.

Reading list:
S. B. Morriss, Automated Manufacturing Systems. McGraw-Hill
N. P. Mahalik, Mechatronics. McGraw-Hill
These notes
The objectives:
to understand the utilization of mechanization devices and
material handling systems;
to appreciate the need for the “design-for-assembly” principles
and understand the underlying reasoning;
to become familiar with the most common part and motion
sensing devices, including machine vision basics;
to gain conceptual understanding of programmable logic
controllers and motion controllers, with the emphasis on how to
build two-state on/off, combinational, sequential and
continuous control automation systems – by relying on case
studies, appreciate the maturity, versatility and effectiveness,
as well as limitations, of the technology involved;
to understand the construction, performance, programming
and application of robots and appreciate the cost effects
involved;
to develop the ability to anticipate, select and supervise the
implementation of flexible assembly systems in manufacturing.
Automation is
a technique that can be used to reduce costs and/or to improve quality.

Automation can lead to products having consistent quality

(consistently good quality)

Earlier dilemmas faced by manufacturers in developed countries when offshore

competitors produced goods more cheaply and of better quality:

“Automate, emigrate, legislate, or evaporate”

Some manufacturers automated or moved to countries with a lower labour cost
(emigrated), or both.
Many countries legislated trade barriers to keep high-quality, low-cost products out.
Manufacturers who did nothing have disappeared (“evaporated”),
often despite their government’s protective trade barriers (“legislate”).
While automation is not a magic solution to financial problems,
producing inexpensive, high-quality products is a good policy for any company.

But
How do you implement automation (where do you start)?
What automation and control technology is available?
What technologies should be used?
Should the current manufacturing process be improved before automation (how)?
Should the product be improved before spending millions on equipment to build it?
(if yes, how to redesign the product?)

Automating before answering these questions is foolish.

This course will either
provide direct answers to these questions, or
prepare you to answer them yourself
whether directly based on the particular situation in the company you would be working for, or
upon additional reading of the subject that would then be familiar to you (whereas without this
course, not only that such reading material would be much more difficult for you to understand, but selecting what to read
would be more of a challenge as well).
There is a communications gap between
specialists in narrow disciplines:

Automation is an interdisciplinary subject,

as you will soon find out.

J. Buur
 engineering

Manufacturing
Organization
Modern

Ideally, electronics, mechanics and controls subjects should not be studied in

isolation from each other but, rather, mutually intertwined

This allows the graduates to function better as designers and

technology integrators at the machine, workcentre or
shopfloor levels of modern manufacturing organizations.
Systems engineers should be able to
communicate with the technology specialists:
(you are lucky as you are taking
MNE3046 Automation Technology)
From the systems perspective,
a collection of equipment viewed
as a functional unit is called a
workcell.
The grouping of equipment into
workcells is facility dependent
(varies from case to case).
In the robot-centred cell illustrated
here, all equipment is located within
the reach of the robot. They are
controlled by one or more controllers.
There may be many "levels" of
workcell management within a control
hierarchy (workcell within a workcell).
For example, the soldering fixture
with its temperature controller could
be considered to be a workcell in
itself.
Automated workcells can be combined into automated systems.
Automated systems can be combined into automated factories.
Some automated workcells can have more than one purpose. If
the workcell function can be changed online, it is said to be part
of a Flexible Manufacturing System (FMS).
Agile manufacturing: manufacturing a variety of similar products
based on rapidly changing customer needs (short order cycles).
A workcell not exchanging information with other workcells is an
isolated island of automation.
Computers can accept
orders from customers’
computers. They can then
decide what to manufacture
and when, when and how to
store and ship goods.
When computers work with
each other to control
manufacturing, the system
that they are part of is said
to be a Computer Integrated
Fanuc Co Manufacturing (CIM)
system.
But,
let us begin with something simpler and purely mechanical:

MECHANISATION

Fanuc Co
A frequent problem in automation is how to start: small components are the most
numerous, but they are often supplied in bulk (such as a pile of screws).
How do we pick up a single screw from a pile of thousands?

We need FEEDERS

VIBRATORY BOWL FEEDER

is the most versatile of all hopper
feeders for small engineering parts.
The helical track passes along the
inside of the bowl. The bowl is usually
supported on sets of inclined “leaf
springs”. Resulting constraints couple
the linear vertical vibrations induced by
the electromagnet on the base with
torsional vibration.
Any part of the inclined track vibrates
along short, approximately straight path.
[5]
Typical part motion, including the hop [5].
The hop is usually eliminated by reducing
the intensity of vibrations.

Limiting conditions for various modes of conveying.

An is the normal track acceleration, gn is the normal
gravitational acceleration [5].
The vibration amplitude (hence the maximum
acceleration) increases as the bowl empties.
Result: the unrestricted feed rate increases [5]
1)

2)
2a)
2b)
RECIPROCATING TUBE HOPPER FEEDER
- Consists of a conical hopper with a hole in
the centre through which a delivery tube
passes. Either the tube or the hopper is
reciprocated [5].
The top of the tube is usually machined at an
angle so that parts resting across the opening
will fall clear and free the opening.
With too small hopper’s cone angle, there is a possibility of
parts jamming between the tube and the hopper. (45 degree
angle is usually satisfactory if the friction coefficient is less
than 0.414.)
Even for a given generic shape of parts (e.g. cylinder/disk), the performance of
reciprocating tube hopper feeder depends on the actual part features [5]. In the
examples shown, this feature is the aspect ration of dominant dimensions.

These examples show that the device suitable for cylindrical parts will not work
with disk-shaped parts, indicating the lack of flexibility.
Performance of a reciprocating tube hopper
feeder when feeding square prisms is shown [5]:

How do you expect this performance to change when

feeding prisms with the rectangular base 2WxW?
Centreboard Hopper Feeder
-- is a hopper in which the parts
are placed at random and a
blade with a shaped track along
its upper edge is periodically
pushed upward through the
mass of parts.
The blade will catch a few parts
on its track during each cycle.
When it is in its highest position,
the blade is aligned with a chute
and the parts will slide down the
track and into the chute. [5]
Load sensitivity of the “full
centreboard” hopper [5]

How does the “half centreboard”

help improve the performance?
 Reciprocating Fork Hopper Feeder
-- is suitable for feeding headed parts.
In its lowest position, the fork is horizontal and the rotation of the bowl (inclined at
~10 degrees) causes parts to be caught in the fork [5].
The fork then lifts a few parts by their heads to a height sufficient to cause the
parts to slide off the fork and into the delivery chute.

The analysis for the maximum fork inclination and the maximum rate of
reciprocation would be needed (the same also for the centreboard hopper).
 External Gate Hopper Feeder
-- is a rotating cylinder having slots in its wall for cylindrical parts to nest against
the wall of the stationary outer sleeve if oriented correctly [5].
The slots pass over a gate in the outer sleeve which allows the parts to drop one
by one into the delivery chute.
All mechanical feeders have a limit on the speed of their performance.
For example, in the case of the external gate hopper feeder, this limit is on the
maximum peripheral velocity of the inner sleeve of the feeder. At the limit, the time
for the horizontal motion of the part across some distance equals the time for
vertical motion for the part to drop its critical distance for jamming (sketch b).
Jamming occurs if this limit is reached or exceeded.
Critical when from the stage of sketch (a) follows (b):
t(vertical motion) = t(horizontal motion) (from sketch (a) to (b))

Sketch (c) is the desired performance

External gate hopper modified for feeding headed parts [5].
 Rotary Disk Feeder
-- includes a rotary disk with a number of slots machined radially in its face,
mounted at an angle, and forming a base of a stationary hopper [5].

Indexing or continuous drives are used for the disk motion.

(definition: indexing motion is moving into fixed position(s) precisely to within a
few hundredths of a millimeter.)
 Many designs and design variations have been used to suit specific part features.

Blade Wheel Hopper Feeder Rotary Centreboard Hopper Feeder

The blade only agitates the parts and The edges of the blade collect parts
pushes incorrectly oriented parts back with desired orientation and lift them
into the mass of parts [5]. up. Time must be allowed for parts to
slide down the blades, usually by
indexing drive [5].
 Tumbling Barrel Hopper Feeder
The cylindrical container has internal radial fins which rotate about a horizontal
vibratory feed track. Parts placed in bulk in the hopper are carried upward by the
fins until at some point they slide off the fin and cascade onto the vibratory feed
track. The feed track is shaped to suit the required orientation of the part being
fed and only retains and feeds those parts in this orientation [5].
Variation to suit the part shape

The rail is slanted or vibratory to assure conveying of parts to the left by

gravity or by compounded vibrations like in the vibratory bowl feeder.
 Elevating Hopper Feeder
An endless conveyor belt is
fitted with a series of selector
ledges that accept only correctly
oriented parts. [5].

MAGAZINES
Parts are stacked into a container which
constrains the parts in the desired
orientation. The magazine is then
attached to the workhead of the
assembly machine. Magazines are
usually spring loaded although gravity
or compressed air may also be used for
part delivery.
 ORIENTATION OF PARTS
It is necessary that parts be fed to workheads correctly oriented.
Most non-vibratory feeders provide at least some part-orientation function.
Two groups of orienting devices for bowl feeders: “in-bowl” and “out-of-bowl”.

In-bowl Tooling:
part of the track of the bowl
feeder is modified.
In this example, the first
two devices are passive in
that only the parts which
(by chance) are correctly
oriented pass through the
device; others are rejected,
then re-fed. The third
device is active in that it
actively reorients parts with
no reduction in the feed
rate.
In addition to its orienting function, the pressure break also returns excess parts if
the delivery chute becomes full (since feeders must overfeed).
Wiper blades usually lie at an acute
angle to the bowl to help prevent
jamming of parts resting on top of others.
This piling-up is common in vibratory
bowl feeders due to the pushing of the
parts circulating at different speeds.

The above illustrates that what works for some parts will not for others:
it is often necessary to seek alternative methods.
The following is an alternative solution to the wiper blade for machined washers.

accepted rejected
 A cutout (a portion of the track
is cut away) makes use of the
difference in shape between the
top and the base of the part.

Two schemes:
orienting of cup-shaped parts
and truncated cones:
A cutout (a portion of the track
is cut away) makes use of the
difference in shape between the
top and the base of the part.

Narrowed track.

Wall projection and

narrowed track.
 This was a passive
orienting scheme.

The resulting feed rate of correctly

oriented parts improves with the
application of active devices:
 Out-of Bowl Tooling
-- is situated between the feeder and the workhead.
-- is usually of the active type as orientation by rejection is less practicable.

Assumption: the center of gravity

(CG) is close to one end of the part. Assumption: the hollow end will catch
Orientation is by gravity (CG goes onto the pin allowing the part to rotate,
first on either side of the “bridge”). whereas the round end will not.
Reorientation of shallow-drawn parts (bottle caps): the selector wheel
indexes, parts in one orientation rotate through just two indexes before
sliding through the centerpiece, while the parts in the other orientation are
held by retaining plugs until rotated upside down.
 FEED TRACKS
-- for transferring parts from feeders to workheads while maintaining orientation.

Gravity feed track arrangement can be for horizontal or vertical delivery.

A minimum number of parts is needed in the track for the horizontal delivery to work.
 Clearances between the part and the track must be sufficiently large to allow transfer
and yet must be small enough to keep the part from losing its orientation [5].
In the curved portions of the track, further allowances have to be made to prevent
the part jamming.

Headed parts will not slide if the Headed parts will also not slide if the track
track inclination is too small. inclination and the clearance above the
parts are too large.
 Various gravity feed track sections for typical parts [5].

Powered Tracks:
Common types
are vibratory and
air-assisted.
 ESCAPEMENTS AND PARTS-PLACING MECHANISMS
Parts feeders must overfeed slightly. Metering devices referred to as “escapements”
ensure that parts arrive at the automatic workhead at the correct intervals.
They can also take the function of the a parts-placing mechanisms
(to place the parts in the assembly).

Escapaments actuated by the work carriers.

 Escapaments actuated by reciprocating drives
(back-and-forth motion).

“Ratchet” escapements operated

by reciprocal linear motion
“Ratchet” escapements operated
by reciprocal rotary motion

A ratchet is a device that allows linear or rotary motion in only one direction while.
(parts are moved in only one direction by the reciprocation of the metering elements)
 Slide escapements supplying
a single feed chute.

Slide escapements supplying multiple

chutes from a single feed chute.
 Star-wheel and worm escapements
Drum-spider escapements

Escapements are often integrated into

parts placing mechanisms: parts placing
mechanism for automatic screwdriver
Pick and place units that Pick and place units that
lift and position vertically move along an arc
The ultimate in pick and place mechanisms consists of a computer system,
sensors and a mechanical arm (often with five or six degrees of freedom: robots

But if the pick-up and drop-off points are always the same,
using a simple pick and place mechanism is usually much more economical.
(What do you think makes the difference? To be explained later.)
 TRANSFER SYSTEMS
Individual assembly operations are generally carried out at separate workstations.
Partly completed assemblies are transferred from/to workstations.
The transfer system must prevent the workhead/assembly relative motion.
Classification according to the system adopted for transferring the work carriers:

Continuous Transfer: Intermittent Transfer:

Work carriers move at constant speed Work carriers are transferred
while the workheads index back and intermittently and workheads remain
forth. Assembly is carried out whle the stationary. Transfer of all work carriers
workheads are moving forward, keeping occurs simultaneously. Carriers remain
pace with the work carriers. stationary to allow time for the operation
 Examples of mechanisms for achieving intermittent transfer:
(this is now better done by microprocessor motion control).

Walking Beam: a transfer rail picks up

carriers and deposits them farther Pawl Transfer: Reciprocation in increments
along the rail. Must return somehow. of the spacing of the carriers.
 Examples of Mechanisms for rotary indexing:
Geneva Mechanism (left) and Crossover Cam (right)

Nowadays, we can control drives !! (no need for complicated transmission elements)
The functionality is provided by microprocessors.

The burden to provide functionality is

transferred from mechanical,
to the electronics and software domains (i.e. mechatronics).

“Motion controllers” have been developed for those

Robert
not familiar with mechatronics Garner’s
(covered camera [source]
later).
[E.Huby, “Assembly Machine Transfer Systems”,
Conference on Mechanized Assembly, July 1966]
Consider again this orienting system as a “mechanisation” example:

System components are tailor-made to suit features of the specific part.

Not flexible to accommodate design changes.
Automation types according to the flexibility level:
Fixed, Programmable, and Flexible.
Fixed and Programmable concepts are illustrated on a nearly identical task:
parts with the same generic shape (lids for medicine bottles) are presented to
some device in a unique orientation.
With a product redesign (e.g. larger lid diameter), the fixed automation device
must be replaced. The programmable only needs one time constant changed.
(allows you to easily switch from one product to another and back – package
a number of medicines on the same line).
Definite reflective switch

Fixed Programmable
Automation Automation
Because fixed automation requires custom made devices, it may cost more to
implement it than the programmable automation.

Time charts are often used to record and analyse input and output signals.
The top chart is from the definite reflective switch, taking the “high” state for
elevated surfaces.
Used for synchronization, the separate type switch (middle chart) indicates
presence of parts.
When required, a delayed output signal is generated to push the part off.

Definite reflective switch

Programmable
Time axis
Automation
 Could we redesign the setup to
need just one sensing device?
However, the second sensor is usually needed anyway for the
synchronisation of the subsequent operation with the part arrival.

Definite reflective switch

Programmable
Time axis
Automation
 Reference: http://vsd.pennnet.com/Articles/Article_Display.cfm?Section=Articles&Subsection=Display&ARTICLE_ID=196803

Robot

Camera
Robots supplemented with vision systems
(perhaps also with the autonomous
guided vehicles -- AGVs) are often at the
base of flexible automation.

Flexible Automation
Many different operations can be performed depending on the program
instructions.
The evolution to an automated manufacturing environment often involves three steps:
•Simplification of the manufacturing process
The current product and manufacturing process should be re-examined and redesigned
before attempting to automate them.
Many manual operations are too complex to automate.
Simplifications are usually possible.
As the process is simplified, goods will be produced less expensively, and tighter quality
control will be possible (the understanding of the processes results in the quality improvement).
•Automation of individual processes (by forming “islands of automation”)
During the redesign stage, processes where automation is desirable will become
evident. Automating less complex ones firsts allows for a smooth learning curve within
the organisation.
•Integration of these islands of automation into a total manufacturing/business system
After building a few independent “islands of automation”, one should think about how
these and future islands can be integrated to work together.
The manufacturing system must be examined as if it consists of discrete functional
blocks (some may have to remain manual processes).
Essential information flow between each functional block must be identified, and a
computer system for handling it.
The components of the computer-integration system can be acquired and installed one
piece at the time as they are required and as personnel gain experience.
The simplification stage is particularly significant for the assembly automation.

Designing for Assembly

Reference: W.B. Heginbotham, Programmable Assembly

Redesigning the product is the most critical factor in the assembly automation:
individual operations must become sufficiently simple for a machine to perform them.

Could you develop a machine that would

1. insert this transformer into the product housing,
2. untangle the wires,
3. identify each wire, and
4. connect each wire to a corresponding connector?
In the redesign, the last three most difficult operations have been eliminated!
Product Design Guideline
1. Minimise the number of parts.
Product Design Guideline
1. Minimise the number of parts.
2. Provide a base part on which to build the assembly.
Product Design Guideline
1. Minimise the number of parts.
2. Provide a base part on which to build the assembly.
3. The base part should have features that locate it stably (prevent horizontal motion).
Product Design Guideline
1. Minimise the number of parts.
2. Provide a base part on which to build the assembly.
3. The base part should have features that locate it stably (prevent horizontal motion).
4. Build up the product in layers, each part being assembled from above and positively
located to prevent sliding.
Product Design Guideline
1. Minimise the number of parts.
2. Provide a base part on which to build the assembly.
3. The base part should have features that locate it stably (prevent horizontal motion).
4. Build up the product in layers, each part being assembled from above and positively
located to prevent sliding.
5. Provide chamfers or tapers for guiding the parts in the correct position.
Part Design Guideline
• Avoid projections, holes, or slots that tangle with identical parts when in bulk.
Part Design Guideline
• Avoid projections, holes, or slots that tangle with identical parts when in bulk.
• Attempt to make the parts symmetrical to reduce the need for orienting devices.
Part Design Guideline
• Avoid projections, holes, or slots that tangle with identical parts when in bulk.
• Attempt to make the parts symmetrical to reduce the need for orienting devices.
• If symmetry cannot be achieved, exaggerate or add additional asymmetrical
features so that they could be used to orient the parts.
Product Design Guideline
1. Minimise the number of parts.
2. Provide a base part on which to build the assembly.
3. The base part should have features that locate it stably (prevent horizontal motion).
4. Build up the product in layers, each part being assembled from above and positively
located to prevent sliding.
5. Provide chamfers or tapers for guiding the parts in the correct position.

Part Design Guideline

1. Avoid projections, holes, or slots that tangle with identical parts when in bulk.
2. Attempt to make the parts symmetrical to reduce the need for orienting devices.
3. If symmetry cannot be achieved, exaggerate or add additional asymmetrical
features so that they could be used to orient the parts.
The process of manual
assembly of this product
would be difficult to
automate.