MEE 2012

MANUFACTURING
AUTOMATION
MEE 2012 MANUFACTURING AUTOMATION 3 0 2 0 4
Automation
Introduction, automation principles and strategies, basic elements of advanced functions, levels
modeling of manufacturing systems, Introduction to CNC programming..
Automated handling and storage system - Automated material handling systems – AGV, Transfer
mechanism - Buffer storage – Analysis of transfer lines, Robots in material handling, Automated
storage and Retrieval Systems (AS/RS) – carousel storage – Automatic data capture – bar code
technology, Automated assembly systems.
Automated Control structures in Manufacturing systems - Group Technology, Part family, Sensor
technologies, Automated inspection and testing, Coordinate measuring machines, Machine vision,
Rapid prototyping.
Programmable controllers in Automation - PLC Architecture, Modes of operation, Programming
methods, Instructions, Instruction addressing, latches, timers and counters.
Advanced Control Strategies in Automation - SCADA, DCS, Integration of PLC, SCADA and DCS with
manufacturing systems, Man-machine interfaces, Introduction to PLM, Case studies.
Smart Factory and Smart Manufacturing-Industry 4.0- Standard, Real-time production monitoring
techniques with smart sensors, Configuration of smart shop floor, traceability and call back of
defective products
Intelligent Manufacturing Systems -Artificial Intelligence based systems, Virtual Business,
e-Commerce Technologies, Global Manufacturing Networks, Digital enterprise technologies, IOT in
manufacturing
MEE 2012 Manufacturing automation
List of Challenging Experiments
1. Industrial Robot Programming
2. Automation using PLC such as bottle filling, elevator control
3. Online inspection using machine vision system
4. Process automation simulation using SCADA
5. Interfacing HMI with PLC
6. Factory flow simulation

MEE 2012 Manufacturing automation

Automation - Technology concerned with the application of mechanical, electronic,
and computer-based systems to operate and control production.
Automated elements of the production system can be separated into two
categories:
(1) Automation of the manufacturing systems in the factory
(2) Computerization of the manufacturing support systems.
In modern production systems - the two categories overlap to some extent, because the
automated manufacturing systems operating on the factory floor are themselves often
implemented by computer systems and connected to the computerized manufacturing
support systems. The term Computer Integrated Manufacturing is used to indicate this
extensive use of computers in production systems.

MEE 2012 Manufacturing automation

Needs Met by Automation
Consistency
Quality
Cost-effectiveness
Automation also manages the following:
 Hazardous processes (nuclear, high voltage, toxic, etc.) where human intervention is
quite dangerous and is not desirable.
 Continuous, repetitive manual operations can lead to failure due to human fatigue.
 Sequential startup and shutdown of plants at each step with manual operation, with
safety and/or other conditions to be satisfied, is highly time-consuming and prone to
errors.
 Complex processes (decisions based on heavy computing such as aircraft tracking and
guiding) where manual computing and decision making within a short time is impossible.
Benefits of Automation
1.Minimize
Breakdown of the plant
Reconfiguring of the plant to adjust to new requirements
Reduction in unproductive time
2. Optimization of resources through substantial reduction of dependence on skilled
manpower
3. Higher safety for personnel and equipment, as they do not come in contact with the
working of the plant
4. Higher security and reliability in the operation of the plant
5. Faster response and result, as there is no human intervention required
MEE 2012 Manufacturing automation
Automated Manufacturing System
• Automated manufacturing systems perform operations such as processing,
assembly, inspection, or material handling, in some cases accomplishing more than
one of these operations in the same system which is automated to perform their
operations with a reduced level of human participation compared with the
corresponding manual process.
• In some highly automated systems, there is virtually no human participation.

Examples:
• Automated machine tools
• Transfer lines
• Automated assembly systems
• Industrial robots
• Automated material handling and storage systems
• Automatic inspection systems for quality control

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Fixed Automation
Sequence of processing (or assembly) operations is fixed by the
equipment configuration

Typical features:

• Suited to high production quantities

• High initial investment for custom-engineered equipment

• High production rates

• Relatively inflexible in accommodating product variety

MEE 2012 Manufacturing automation

Programmable Automation
Capability to change the sequence of operations through reprogramming to
accommodate different product configurations. New programs can be
prepared and entered into the equipment to produce new products.

Typical features:
• High investment in programmable equipment
• Lower production rates than fixed automation
• Flexibility to deal with variations and changes in product configuration
• Most suitable for batch production
• Physical setup and part program must be changed between jobs (batches)

MEE 2012 Manufacturing automation

 Flexible Automation
• Extension of programmable automation

• System is capable of changing over from one job to the next with little lost time

between jobs.

• No loss in production time while reprogramming the system and altering the
physical setup (tooling, fixtures, machine settings).

Typical features

• High investment for custom-engineered system

• Continuous production of variable mixes of products

• Medium production rates

• Flexibility to deal with soft product variety

MEE 2012 Manufacturing automation

Three Automation Types

MEE 2012 Manufacturing automation

MEE 2012 Manufacturing automation
 TYPES OF MANUFACTURING INDUSTRY
Continuous Process Industries
• Production process generally follows a specific sequence.
• These industries can be easily automated and computers are widely used for process
monitoring, control and optimization.
ex: Oil refineries, chemical plants, food processing industries.
Mass Production Industries
• Production lines are specially designed and optimized to ensure automatic
and cost effective operation.
• Automation can be either fixed type or flexible.
ex: integrated chips, automobiles, electronic products, bicycles, bearings
Batch Production (Discrete Manufacturing)
• Distinguishing features are the small to medium size of the batch, and varieties of
such products to be taken up in a single shop.
• Another important fact is that small batch size involves loss of production time
associated with product changeover.
Mass and batch production faces a number of problems as there are a large
number of support activities. So different automation is implemented.
1. Fixed Automation - Designed for a particular product and any product change will
require extensive modifications
2. Flexible automation –Programmable automation

MEE 2012 Manufacturing automation

Realities of Modern Manufacturing
• Globalization
Once underdeveloped countries (e.g., China, India, Mexico) are becoming
major players in manufacturing
• International outsourcing
Parts and products once made locally are now being made offshore (in China
or India) or near-shore (in Eastern Europe)
• Local outsourcing
Use of suppliers locally to provide parts and services
• Contract manufacturing
Companies that specialize in manufacturing entire products, not just parts, under
contract to other companies
• Quality expectations
Customers, both consumer and corporate, demand products of the highest quality
• Need for operational efficiency
Manufacturers must be efficient in in their operations to overcome the labor
cost advantage of international competitors

MEE 2012 Manufacturing automation

 CHALLENGES IN MANUFACTURING
Manufacturingindustries strivesto achieve the following objectives to be
competitive in a global context
• Reduction in inventory
• Lower the cost of the product
• Reduce waste
• Improve quality
• Increase flexibility in manufacturing to achieve immediate and
rapid response to
• Product changes
• Process change
• Equipment change
Automation is an enabling technology to meet the above challenges
to the manufacturing.

MEE 2012 Manufacturing automation

Automation Principle
1. Understand the existing process
• Input/output analysis
• Value chain analysis
• Charting techniques and mathematical modeling
2. Simplify the process
• Reduce unnecessary steps and moves
3. Automate the process
• Ten strategies for automation and production systems
• Automation migration strategy

MEE 2012 Manufacturing automation

PRINCIPLES OF AUTOMATION
1. Mechanization
• Straight forward task to perform
• Stable environment to ensure that the products produced will be
appropriate ones
• Produce exactly the same product again
• Precision is at a premium
2. Continuous process
a. Assembly line-Continuous flow process
Skilled worker moved from one job to another performing the same task
specialization
b. Innovations
Mass production technology
Automatic transfer machines
No human intervention
Control through remote electronic panel
Ex. automobile industry, bottling

MEE 2012 Manufacturing automation

 3. Automatic control
Automatic control/feedback
Input of machine regulated by its output till desired objectives met.
Machine can start, stop, accelerate, decelerate, count, inspect, test, remember,
compare, measure sound, temperature and other physical properties.
 If there are any production problems, the system intervenes and suggests
alternate course of action.
[

Ex. CNC controlled processing machines

MEE 2012 Manufacturing automation

Reasons for Automating

1. To increase labor productivity

2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish processes that cannot be done manually.
9. To avoid the high cost of not automating

MEE 2012 Manufacturing automation

Automation Strategies
1. Specialization of operations
Special purpose equipment designed to perform one operation
2. Combined operations
Production occurs as a sequence of operations. Complex parts may require
dozens, or even hundreds, of processing steps
3. Simultaneous operations
Two or more processing (or assembly) operations are being performed
simultaneously on the same work part, thus reducing total processing time
4. Integration of operations
Link the several workstations together into a single integrated mechanism, using
automated work handling devices to transfer parts between stations.
5. Increased flexibility
Maximum utilization of equipment for job shop and medium volume situations
by using the same equipment for a variety of parts or products.

MEE 2012 Manufacturing automation

6. Improved material handling and storage
Reducing nonproductive time exists in the use of automated material handling and
storage systems
7. On-line inspection
Inspection into the manufacturing process permits corrections to the process as
the product is being made.
8. Process control and optimization
Control schemes intended to operate the individual processes and associated
equipment more efficiently.
9. Plant operations control
Manufacturing process is concerned with control at the plant level.
Manage and coordinate the aggregate operations in the plant more efficiently
which involves a high level of computer networking within the factory.
10. Computer-integrated manufacturing
Involves extensive use of computer applications, computer data bases, and
computer networking throughout the enterprise.
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Automation Migration Strategy

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
• Power to accomplish the process and operate the system
• Program of instructions to direct the process
• Control system to actuate the instructions

FIVE LEVELS OF AUTOMATION & CONTROL IN MANUFACTURING

Device level - Lowest level it includes the actuators, sensors,
and other lower devices
Machine level - Hardware from device level is assembled into
individual machines

Cell or system - Group of machines or workstations connected

Level and supported by a material handling system,
computer, and other equipments needed for a
manufacturing process

Plant level - Receives instructions from the corporate information

system and translate them into operation plan for
production

Enterprise level - Highest level it is concerned with all functions

necessary to manage the company: marketing and
sales, accounting, design, research, aggregate
planning, and master production scheduling.

MEE 2012 Manufacturing automation

New control system platform that combines the recent advances in
information technology and industrial automation

MEE 2012 Manufacturing automation

 Conceptual/functional topology of an automation system

5 Planning, Statistics, Finances administration

4 Production planning, orders, purchase enterprise

3 Workflow, order tracking, resources (manufacturing) execution

SCADA =
2 Supervisory Supervisory Control
And Data Acquisition

Group control

Unit control
1
Field

Sensors A V T
& actuators

0 Primary technology

MEE 2012 Manufacturing automation

 CIM
• Encompasses the entire range of product development and
manufacturing activities with all the functions with the help of dedicated
software packages which reduces humans in manufacturing (i.e relieves
the process of its slow, expensive and error-prone component)
• The data required for various functions are passed from one application
to another in a seamless manner.
For example, the product data is created during design which has to
be transferred from the modeling software to manufacturing software
without any loss of data.
• It also associated with total quality management, business process
reengineering, concurrent engineering, workflow automation, enterprise
resource planning and flexible manufacturing.

MEE 2012 Manufacturing automation

 HISTORICAL DEVELOPMENT -CIM

• CIM - Evolution of CAD/CAM

• MIT, USA – Pioneer of CAD/CAM
Need to meet the design and manufacturing requirements of
aerospace industries after the Second World War for US air force.
• Major innovation in machine control is the Numerical Control (NC),
demonstrated at MIT in 1952.
- NC’s are Hard wired = paper tape + tape reader(Punched cards)
• Mainframe computers in 1960 – used to control group of NC (DNC)
• After 60’s - minicomputers used for CNC
• 1970 - controllers design for microprocessors = Compact CNC
-- Nowadays CNC are built with 32 and 64 bit processor.
• 1980 - Conversion of Geometric modeling into programming
• After 80’s – FMS, GT, CMS, Robots arises

MEE 2012 Manufacturing automation

 CIM

Structure of CIM
MEE 2012 Manufacturing automation
 CNC Machine tools & Programming
Numerically control (NC) machines were fully hardwired machines as the entire
control logic was implemented in hardware.

MEE 2012 Manufacturing automation

 NC & CNC
Procedures in NC Problems with NC
 Process planning  Part programming mistakes.
 Part programming.  Punched tapes.
 Tape preparation.  Tape reader.
 Tape Verification.  Controller.
 Production.  Management Information.
CNC
The above difficulties in the NC machines leads to non-reliability. Hence, designers of
NC machines achieved a major breakthrough during mid-six tees when integrating a
minicomputer with NC machine tool which was renamed as computer numerical
control.
Integration resulted in the following advantages:
• Increase in the memory for part program processing
• Increase in capacity for storing large part programs
• Easy editing of part programs on the control console
• Realization of control logic through software
• Significant improvement in the reliability of operation of the machines

MEE 2012 Manufacturing automation

 Benefits of CNC

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BRIEF HISTORY OF CNC

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ELEMENTS OF NC MACHINE TOOL OPERATION

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ELEMENTS OF CNC MACHINE TOOL OPERATION

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 Major elements of CNC
Hardware
• Microprocessors for various control action.
• Devices for data input , machine tool interfacing and machine tool monitoring.
• Feedback units like transducers , actuators etc.
Software
• Processing input and output instructions and control functions.
• Does the computation works needed for machining process.
• Co –ordinate the activities of the machine and its accessories.
Information’s in CNC machines
• Cutter location data.
• Machine data.
• Information regarding the dynamic characteristics of machine ( Tool
compensation , Offset etc ).

Components of CNC
• Program of instructions.
• Controller unit also called as MCU.
• Machine tool or other controlled equipment’s

MEE 2012 Manufacturing automation

 Components of CNC
Machine Control Unit - MCU, sends control signals to servomechanism
Servomechanism(s) - Amplify signals from the MCU, and send them to servomotors
Controlled element - Tool, turret, M/T table: the numerically controlled part of M/T
Feedback unit - Records the achieved tool movement and send them to the MCU

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CNC TRUNUNG CENTRE

CNC MACHINING CENTRE

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 GENERATION OF CNC MACHINES
First Generation
The control system of the first generation numerically controls machines was built
with vacuum tubes and associated devices which was bulky, consumed lot of power and
reliability was poor.

Second Generation
Second Generation machines were built with transistors. The size of the control
elements was reduced. However, all the functions had to be realized through electronic
circuits. The number of printed circuits boards was large. Since there were thousands of
components and connections involved, the reliability was again poor.

Third Generation
Third generation NC machines were built with integrated circuits with medium
scale integration improved the reliability of the system. Drive technology also made
considerable progress. Thyristor controlled DC drive become popular during this period.
Reliable and compact DC controllers were developed both for main drives and for the
control of servomotors for axes feed drive.

Fourth Generation
SMART CNC – Conversion of Cad Models into Part Programming

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 CNC OPERATIONS

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 CLASSIFICATION OF CNC

Absolute versus incremental

In absolute positioning, the move is specified by x = 6, y = 8
In incremental, the move is specified by x=4, y=5 for the tool to be moved from (2,3)
to (6,8)

MEE 2012 Manufacturing automation

 Axis identification in CNC machines
• Cartesian coordinate system and three axis of movement are identified as X , Y , Z
• Rotary movements about X, Y, Z axis are designated as A,B, C respectively.

Movements in CNC turning machine

Z axis  parallel to spindle.
X axis  perpendicular to spindle axis.
Movements in CNC milling machine ?
Z axis  Movement of tool.
X axis  Movement of work table ( horizontal )
Y axis  Movement of work table (Vertical)
Movements in CNC drilling machine
Z axis  Movement of tool.
X axis  Movement of work table (horizontal )
Y axis  Movement of work table (Vertical)

INTERPOLATIONS
• Done to execute contouring tool paths.
• It produces a series of intermediate data points between given coordinate positions and
computes the axial velocity of an individual axis along the contour path.

MEE 2012 Manufacturing automation

Linear interpolation:
• Tool moves from start point to the target point along a straight line.
• Programming command should indicate X, Y, Z coordinates of target point, and
feed rate.
Circular interpolation:
• To cut circular arcs in three principal planes; namely XY, YZ, ZX.
• Direction, target position, arc radius, cutting plane, and feed rate must be
specified in the program.
Helical interpolation:
Combines the two-axis circular interpolation with a linear interpolation in third axis.
Parabolic interpolation:
• Uses three non-collinear points to approximate curves that are of free forms.
• Mainly used in mold and die making

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 CLASSIFICATION OF CNC
Type of motion control system:

• Point –to-point/positioning system

• Contouring (or) continuous path

• Straight cut

Structure of control system

• Analog system
• Digital system

Programming mode
• Incremental PM
• Absolute PM
Type of control loops
Open loop CS & Closed loop CS
Power Drive
Hydraulic, Pneumatic & Electric system
Axis identification
2 axis, 3 axis, 4 axis
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 Open Loop CS

Closed Loop CS

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DIRECT NUMERICAL CONTROL /DISTRIBUTED NC (DNC)

DNC with satellite computers

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 DNC IN FACTORY
CNC machines together with robots, programmable logic controllers, and other
computer-based controllers have been integrated into DNC systems to enhance
automated manufacturing systems

MEE 2012 Manufacturing automation

 OBJECTIVES OF DNC
• Upload and download CNC programs to and from machine tools simultaneously
and directly from the CNC systems.
• Easy editing of the existing programs.
• Copy programs to and from the floppy discs and other media to the DNC
computer.
• Compare files edited at the CNC to the original program.
• Show pictures of set ups for graphic catalogue of set up and machining
operations.
• Pass word protection at different points of the CNC system wherever the
• Operator could cause damage to the NC code by overwriting.
• Tool length offsets from tool pre-setters can be transferred directly to machine
tool controls.

MEE 2012 Manufacturing automation