SEMESTER 1 EXAMINATIONS 2018/2019

MODULE: MM453 - Manufacturing Automation

PROGRAMME(S):
ME B.Eng. in Mechatronic Engineering
CAM B.Eng. Mechanical & Manufacturing Eng
ECSA Study Abroad (Engineering & Computing)

YEAR OF STUDY: 4,X

EXAMINER(S):
Harold Esmonde (Internal) (Ext:5095)
Dr. William O'Connor (External) External
Dr. Gerard Ryder (External) External

TIME ALLOWED: 2 Hours

INSTRUCTIONS: Answer 4 questions. All questions carry equal marks.

PLEASE DO NOT TURN OVER THIS PAGE UNTIL YOU ARE INSTRUCTED TO DO SO.
The use of programmable or text storing calculators is expressly forbidden.
Please note that where a candidate answers more than the required number of questions, the
examiner will mark all questions attempted and then select the highest scoring ones.

Requirements for this paper:

1. Graph Paper
2. Log Tables

MM453 – Manufacturing Automation

Semester 1 Examinations 2018/2019 Page 1 of 6
QUESTION 1 [TOTAL MARKS: 25]

Q 1(a) [3 Marks]
Describe a systematic approach you would use when solving automation control
problems.

Q 1(b) [6 Marks]
Hot water is pumped around a system incorporating two plants and a boiler as
shown in Figure 1 below. Three simple valves, V1, V2, and V4 control the flow of
water which when switched on allow water to flow through them. There is also a two-
way valve V3 that allows water to flow from plant 1 to plant 2 when not switched on
and which allows water to return to the boiler when switched on. When temperature
thermostat T1 has not been tripped (T1=0) plant 1 requires heat. When temperature
thermostat T3 has not been tripped (T3=0) plant 2 requires heat. However plant 1
can dump excess heat to plant 2 if required when the plant 1 high temperature
thermostat has tripped (T2 = 1) in which case the boiler is off but the pump still runs.

Define the inputs and outputs for the control problem

Q 1(c) [8 Marks]
Construct a truth table for Q1b. Assume power is on at all times.

Q 1(d) [5 Marks]
Minimise the expressions for the logic defined in the truth table in Q1c.

Q 1(e) [3 Marks]
Are there any don’t care conditions in your solution Q1b and if so why?
[End of Question1]

MM453 – Manufacturing Automation

Semester 1 Examinations 2018/2019 Page 2 of 6
QUESTION 2 [TOTAL MARKS: 25]

Q 2(a) [9 Marks]
How are response diagrams constructed? With reference to the response diagram
in Figure Q2a, determine how the output relates to the input.

A
Y
B

0 5 10 15 20 25 30
Seconds
FigureQ2a

Q 2(b) [6 Marks]
A simple 3 second delay timer is used in conjunction with a two input off-dominant
memory in the circuit shown in Figure Q2b. The lower input on the memory acts as
the reset. How is the output Y related to the input A? Draw a response diagram to
illustrate the relationship between input A and the output Y.

A Tim
Mem
3s

Figure Q2b

Q 2(c) [10 Marks]

Design a logic network using simple delay timers, “and”, “or” and “not” gates to
switch two binary bits so that they repeatedly count from 0 to 3 in binary,
incrementing once per second.

[End of Question2]

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Semester 1 Examinations 2018/2019 Page 3 of 6
QUESTION 3 [TOTAL MARKS: 25]

Q 3(a) [7 Marks]
Explain the differences between logic and sequential control and give the merits and
drawbacks of each.

Q 3(b) [8 Marks]
A three-axis robot can pivot clockwise/anticlockwise around its waist, extend/retract
its arm and open/close a grip on the end of the arm. The outputs to be controlled and
Sensors on the robot monitor the state of the robot as follows:

Output Description Input Description

10 rotate base clockwise 00 base rotated clockwise

11 rotate base anticlockwise 01 base rotated anticlockwise
12 extend arm 02 arm extended
13 retract arm 03 arm retracted
14 close grips 04 grips closed
15 open grips 05 grips open

Starting from a position rotated fully clockwise with the arm retracted and grips open
the sequence of actions the robot completes are:

i) extend the arm

ii) close grips
iii) retract arm
iv) rotate anticlockwise
v) extend arm
vi) open grips
vii) retract arm
viii) rotate clockwise

Draw up a table showing the state of the inputs prior to each action.

Q 3(c) [6 Marks]
Generate the ladder logic to control the robot to perform the sequence of actions in
Q3b. Latch the outputs on until each action is completed and add an emergency stop
switch.

Q 3(d) [4 Marks]
Determine the minimum set of inputs required to initiate the first two actions in Q3b.

[End of Question3]

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Semester 1 Examinations 2018/2019 Page 4 of 6
QUESTION 4 [TOTAL MARKS: 25]

Q 4(a) [6 Marks]
Describe with the aid of a diagram how a vibration bowl operates.

Q 4(b) [8 Marks]
By considering a rectangular prism on a plane, derive the condition for forward
sliding to occur on the track of a vibration bowl. The track angle is , the coefficient
of friction between the prism and the plane is  and the vibration angle relative to the
plane is . See Figure Q4b.

N
mdw2


Ψ
F


θ mg

Figure Q4b

Q 4(c) [5 Marks]
What are the phases of motion of a part in a vibration bowl as the vibration amplitude
is increased? Which phase is considered optimal?

Q 4(d) [6 Marks]
A single part just begins to move on the track when the ratio of track normal
acceleration to gravitational acceleration normal to the track is 0.2. The track angle
is 4 and the track vibration angle is  = 27. Determine the coefficient of friction
between the part and the track. (Hint use your expression in Q4b).

[End of Question4]

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Semester 1 Examinations 2018/2019 Page 5 of 6
QUESTION 5 [TOTAL MARKS: 25]

Q 5(a) [6 Marks]
What is the difference between an indexing machine and a free transfer machine
and how does this difference affect downtime?

Q 5(b) [8 Marks]
Derive an expression for percentage downtime on an indexing machine in terms of
the cycle time t, the repair time T, the number of workstations n, the average
percentage defective parts x and the ratio of defective parts that cause machine
stoppage m.

Q 5(c) [7 Marks]
Derive an expression for the production rate on the indexing machine using the
same parameters as in Q5b.

Q 5(d) [4 Marks]
By studying the diagram in Figure Q5d what conclusions can be drawn with regard to
sorting out faulty assemblies on the production line?

Figure Q5d

[End of Question5]

[END OF EXAM]

MM453 – Manufacturing Automation

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