AUTOMATED STAMPING PRESS

Stamping press on automatic cycle producing stampings from sheet

metal coil
 CNC MILL-TURN CENTER

“Machine tool capable of performing multiple

operations either with single point turning
tools or rotating cutters in one setup under NC
control”
 Typical operations:
 Turning, milling, drilling and related operations
 Enabling feature:
 Capability to control position of c-axis in addition
to x- and z-axis control (turning center is limited to
x- and z-axis control)
PART WITH MILL-TURN FEATURES

Example part with turned, milled, and drilled features

SEQUENCE OF OPERATIONS OF A MILL-TURN
CENTER FOR EXAMPLE PART

(1) Turn smaller diameter, (2) mill flat with part in programmed angular
positions, four positions for square cross section; (3) drill hole with
part in programmed angular position, and (4) cutoff of the machined
piece
LEAN MANUFACTURING:

 The method to allocate machines to a

worker is fundamentally different in Lean
manufacturing. In LM, the machines are
typically arranged in a U-shaped cell, and a
worker tends as many workstations as
allowed within the Tact time.
 Total service + repositioning time ≤ Takt
time AND
 Machine + service time ≤ Takt time

 In LM, the machines are not necessarily

 UNIT IV
INDUTRIAL APPLICATIONS
 UNIT IV
ASSIGNMET
 Unit-IV

1.

a). What are the principles of material handling system?

b). Describe the use of Material Handling Equipment in Machine Tools.

2. Explain the various problems encountered in interfacing handling and storage systems with
manufacturing units.

3. a)Describe the following automated guided vehicle system with the help of simple sketch:

(i) Driverless automated guided train (ii) Unit load carrier.

b) Enumerate the differences between asynchronous conveyors and continuous motion

conveyors.

4. Explain the importance of automated work-in-process storage systems. [6]

b) Discuss the automated Storage/Retrieval Systems (AS/RS) controls, and the special
features and applications of AS/RS.

5. a) Explain the role of AS/RS in material handling systems. [8]

b) With neat sketch explain about fork lift truck.

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT IV
SHORT ‘Q’ & TUTORIAL
 UNIT-IV

1. What is a material-handling system?

A material-handling system can be simply defined as an integrated system involving such
activities as handling, storing, and controlling of materials.
The word material has very broad meaning, covering all kinds of raw materials, work in
process, subassemblies, and finished assemblies.
The primary objective of using a material handling system is to ensure that the material in the
right amount is safely delivered to the desired destination at the right time and at minimum
cost.
The material handling system is properly designed not only to ensure the minimum cost and
compatibility with other manufacturing equipment but also to meet safety concerns.

2.What are the three parts of the material handling system?

These include:
 Automated storage and retrieval systems.
 Automatic guided vehicles (AGVs)
 Automatic identification and data collection.
 Casters and wheels.
 Controls.
 Conveyors.
 Dock equipment.
 Ergonomics
2. What is the function of a materials handling system?
Material Handling is the movement, storage, control and protection of materials, goods and products
throughout the process of manufacturing, distribution, consumption and disposal. The focus is on the
methods, mechanical equipment, systems and related controls used to achieve these functions.
4. What are the Principles of Material Handling ?
1. Orientation principle: study the system relationships thoroughly prior to preliminary planning
in order to identify existing methods and problems, physical and economic constraints, and to
establish future requirements and goals.
2. Planning principle: establish a plan to include basic requirements, desirable options, and
consideration of contingencies for all MH and storage activities.
3. System principle: integrate the handling and storage activities that are economically viable
into a coordinated system of operation including receiving, inspection, storage, production,
assembly, packaging, warehousing, shipping, and transportation.
4. Unit load principle: handle product in as large a unit load as practical.
5. Space utilization principle
6. Standardization principle
5. What are the different types of Material Handling Equipment and explain
briefly?

DEPARTMENT OF MECHANICAL ENGINEERING

 1. Industrial trucks include hand trucks such as two-wheeled, four-wheeled, hand lift, and
forklift and powered trucks such as forklift, tractor-trailer trains, industrial crane trucks,
and side loaders.
2. Conveyors such as belt, chute, roller, wheel, slat, chain, bucket, trolley, tow, screw,
vibrating, and pneumatic.
3. Monorails, hoists, and cranes such as bridge, gantry, tower, and stacker. Automated
guided vehicle systems such as unit load carriers, towing, pallet trucks, fork trucks, and
assembly line.
4. Automated storage and retrieval systems (AS/RS) such as unit load, mini-load, person-
on-board, deep lane, and storage carousel systems.

6. What is automated guided vehicle system?

An automated guided vehicle system is a battery-powered driver-less vehicle with
Programming capabilities for destination, path selection, and positioning.
The AGVS belongs to a class of highly flexible, intelligent, and versatile material handling
systems used to transport materials from various loading locations to various unloading locations
throughout the facility.

7. Why an AS/RS?
 An AS/RS is highly space efficient. Space now occupied by raw stock, work in process,
or finished parts and assemblies can be released for valuable manufacturing space.
 Increased storage capacity to meet long-range plans.
 Improved inventory management and control.
 Quick response time to locate, store, and retrieve items.
 Reduced shortages of inventory items due to real-time information and control.
 Reduced labor costs due to automation.
 Improved stock rotation.

8. What are the different Type of AS/RS and explain briefly?
1. Unit load AS/RS: is used to store and retrieve loads that are palletized or stored in standard-
size containers.
2. Mini-load AS/RS: is designed to handle small loads such as individual parts, tools, and
supplies.
The system is suitable for use where there is a limit on the amount of space that can be utilized
and where the volume is too low for a full-scale unit load system and tool high for a manual
system.
3. Person-on-board AS/RS: allows storage of items in less than unit load quantities.
4. Deep-lane AS/RS: is another variation on the unit load system. The items are stored in
multi-deep storage with up to 10 items per row rather than single or double deep. This leads to
a high density of stored items.
5. Automated item retrieval system
9. What are the Design parameters should be consider for an AS/RS?
1. Determining load sizes
2. Determining the dimensions of an individual storage space

DEPARTMENT OF MECHANICAL ENGINEERING

 3. Determining the number of storage spaces considering
Dedicated storage
Randomized storage
4. Determining the system throughput and number of S/R machines
Speed of S/R machine
Mix of single- and dual-cycle transaction
Percent utilization of the storage racks
Arrangement of stored items
AS/RS control system speed
Efficiency
10. What are the Functions of storage systems ?
Receiving, identification and sorting, dispatching to storage, placing in storage, storage,
retrieving from storage, order accumulation, packing, shipping, and record keeping for raw
materials, purchased parts, work in process, finished product, pallets, fixtures, tools, spare
parts, rework and scrap, office supplies, and so forth have traditionally been considered the
functions of storage systems.
An AS/RS attempts to achieve these functions by automating most of these procedures in a
cost-effective and efficient manner.

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT V
FUNDAMENTALS OF INDUSTRIAL CONTROLS
Objective:
 To know product families often consists of workstations comprising CNC machine
tools.

Outcome:
 Student gets exposure on portable power tools.

Fundamentals of Industrial controls: Review of control theory, logic controls, sensors and
actuators, Data communication and LAN in manufacturing.
Business process Re-engineering: Introduction to BPE logistics, ERP, Software configuration
of BPE.

UNIT-V
Fundamentals of Industrial controls:
Logic Control Systems
To begin the discussion of industrial logic control systems, consider the simple pneumatic
system shown in Figure LC-1. The pneumatic cylinder moves in a linear dimension until it
reaches the limit switch at the extended end. The cylinder is controlled with a simple two
position, four-way solenoid valve as shown. The solenoid valve shown is activated by an
electrical current passing through the solenoid coil. This type of simple ON/OFF
programming has traditionally been done by relay control systems.

A relay control system for the simple system of Figure LC-1 is also shown. This schematic
diagram represents a type of programming frequently referred to as "ladder logic" by
industrial electricians. The two parts of a relay are both shown in this diagram. Electrical
relays (Figure LC-2) have a control circuit and one or more sets of outputs. The coil of the
relay forms part of an electromagnet which activates a set of contacts (contacts similar to
"points" in an pre-70's auto). Electrical current passing through the coil of the relay (the
"control relay") closes one of these sets of contacts (CR-1B) which allows current to flow
through the pneumatic valve solenoid, SOL-A. Another set of contacts, CR-1A in Figure LC-
1, is used to "hold" the contacts closed once they have been energized, by providing an
alternate path for electrical current through the control relay. A momentary contact push-
button PB-1 (normally open or N.O.) is provided for initiating motion. When PB-1 is pressed,
current flows through the actuating circuit of relay CR-1, which closes the output contacts
(CR-1A and CR-1B). When PB-1 is released, these contacts remain closed due to electrical

DEPARTMENT OF MECHANICAL ENGINEERING

current path through the closed relay contacts CR-1A and the normally closed limit switch
LS-1. Relay CR-1 remains energized until the limit switch LS-1 activated by the cylinder.
Oncethis limit switch is activated, the current flow through the control relay CR-1 is
interrupted, and the contacts CR-1A and CR-1B both open. The solenoid SOL-A is de-
energized, therefore the spring shifts the solenoid back to the right position, which causes the
cylinder to retract. The circuit is inactive until a subsequent pressing of the push-button PB-1.
Figure LC-3 shows the most common components of ladder logic diagrams. Input elements
include limit switches, momentary contact push-buttons, pressure switches, manual switches,
and relay contacts. Typical outputs include solenoid coils, control relay coils, pilot lights, and
annunciators (or horns). Note that each of the inputs is available in both normally open (NO)
and normally closed (NC) configurations. This distinction is easily explained by observing
the limit switch configurations. A normally closed limit switch will carry current if it is not
activated (the "normal" state). If a normally closed limit switch is pressed, then it no longer
will carry current. A normally open limit switch is the opposite - it will not carry current
inactivated, it must be pressed to allow current to flow through it.

DEPARTMENT OF MECHANICAL ENGINEERING

Sensors
Sensor is a device that when exposed to a physical phenomenon (temperature, displacement,
force, etc.) produces a proportional output signal (electrical, mechanical, magnetic, etc.). The
term transducer is often used synonymously with sensors. However, ideally, a sensor is a
device that responds to a change in the physical phenomenon. On the other hand, a transducer
is a device that converts one form of energy into another form of energy. Sensors are
transducers when they sense one form of energy input and output in a different form of
energy. For example, a thermocouple responds to a temperature change (thermal energy) and
outputs a proportional change in electromotive force (electrical energy). Therefore, a
thermocouple can be called a sensor and or transducer.
Classification of Sensors

There are several classifications of sensors made by different authors and experts. Some are
very simple and some are very complex. The following classification of sensors may already
be used by an expert in the subject but this is a very simple classification of sensors.
In the first classification of the sensors, they are divided in to Active and Passive. Active
Sensors are those which require an external excitation signal or a power signal.
Passive Sensors, on the other hand, do not require any external power signal and directly
generates output response.
The other type of classification is based on the means of detection used in the sensor. Some
of the means of detection are Electric, Biological, Chemical, Radioactive etc.
The next classification is based on conversion phenomenon i.e. the input and the output.
Some of the common conversion phenomena are Photoelectric, Thermoelectric,
Electrochemical, Electromagnetic, Thermo optic, etc.
The final classifications of the sensors are Analog and Digital Sensors. Analog Sensors
produce an analog output i.e. a continuous output signal with respect to the quantity being
measured.
Digital Sensors, in contrast to Analog Sensors, work with discrete or digital data. The data in
digital sensors, which is used for conversion and transmission, is digital in nature.

DEPARTMENT OF MECHANICAL ENGINEERING

Different Types of Sensors
The following is a list of different types of sensors that are commonly used in various
applications. All these sensors are used for measuring one of the physical properties like
Temperature, Resistance, Capacitance, Conduction, Heat Transfer etc.
 Temperature Sensor
 Proximity Sensor
 Accelerometer
 IR Sensor (Infrared Sensor)
 Pressure Sensor
 Light Sensor
 Ultrasonic Sensor
 Smoke, Gas and Alcohol Sensor
 Touch Sensor
 Color Sensor
 Humidity Sensor
 Tilt Sensor
 Flow and Level Sensor
Temperature Sensor

One of the most common and most popular sensor is the Temperature Sensor. A Temperature
Sensor, as the name suggests, senses the temperature i.e. it measures the changes in the
temperature.

In a Temperature Sensor, the changes in the Temperature correspond to change in its physical
property like resistance or voltage.
There are different types of Temperature Sensors like Temperature Sensor ICs (like LM35),
Thermistors, Thermocouples, RTD (Resistive Temperature Devices), etc.
Temperature Sensors are used everywhere like computers, mobile phones, automobiles, air
conditioning systems, industries etc.
A simple project using LM35 (Celsius Scale Temperature Sensor) is implemented in this
project: TEMPERATURE CONTROLLED SYSTEM.

DEPARTMENT OF MECHANICAL ENGINEERING

Proximity Sensors

A Proximity Sensor is a non-contact type sensor that detects the presence of an object.
Proximity Sensors can be implemented using different techniques like Optical (like Infrared
or Laser), Ultrasonic, Hall Effect, Capacitive, etc.

Some of the applications of Proximity Sensors are Mobile Phones, Cars (Parking Sensors),
industries (object alignment), Ground Proximity in Aircrafts, etc.
Proximity Sensor in Reverse Parking is implemented in this Project: REVERSE PARKING
SENSOR CIRCUIT.
Infrared Sensor (IR Sensor)

IR Sensors or Infrared Sensor are light based sensor that are used in various applications like
Proximity and Object Detection. IR Sensors are used as proximity sensors in almost all
mobile phones.

DEPARTMENT OF MECHANICAL ENGINEERING

There are two types of Infrared or IR Sensors: Transmissive Type and Reflective Type. In
Transmissive Type IR Sensor, the IR Transmitter (usually an IR LED) and the IR Detector
(usually a Photo Diode) are positioned facing each other so that when an object passes
between them, the sensor detects the object.
The other type of IR Sensor is a Reflective Type IR Sensor. In this, the transmitter and the
detector are positioned adjacent to each other facing the object. When an object comes in
front of the sensor, the sensor detects the object.
Different applications where IR Sensor is implemented are Mobile Phones, Robots, Industrial
assembly, automobiles etc.
A small project, where IR Sensors are used to turn on street lights: STREET LIGHTS
USING IR SENSORS.
Ultrasonic Sensor

An Ultrasonic Sensor is a non-contact type device that can be used to measure distance as
well as velocity of an object. An Ultrasonic Sensor works based on the properties of the
sound waves with frequency greater than that of the human audible range.

DEPARTMENT OF MECHANICAL ENGINEERING

Using the time of flight of the sound wave, an Ultrasonic Sensor can measure the distance of
the object (similar to SONAR). The Doppler Shift property of the sound wave is used to
measure the velocity of an object.
Arduino based Range Finder is a simple project using Ultrasonic Sensor: PORTABLE
ULTRASONIC RANGE METER.

TYPES OF THE ACTUATORS

DEPARTMENT OF MECHANICAL ENGINEERING

Actuator is something that converts energy into motion. It also can be used to apply a force.
An actuator typically is a mechanical device that takes energy — usually energy that is
created by air, electricity or liquid — and converts it into some kind of motion. That motion
can be in virtually any form, such as blocking, clamping or ejecting. An actuator is the
mechanism by which an agent acts upon an environment. The agent can be either an artificial
intelligence agent or any other autonomous being (human, other animal, etc.). Actuators
typically are used in manufacturing or industrial applications and might be used in devices
such as motors, pumps, switches and valves.
Energy Sources
Perhaps the most common type of actuator is powered by air and is called a pneumatic
cylinder or air cylinder. This type of actuator is an air-tight cylinder, typically made from
metal that uses the stored energy of compressed air to move a piston when the air is released
or uncompressed. These actuators are most commonly used in manufacturing and assembly
processes. Grippers, which are used in robotics, use actuators that are driven by compressed
air to work much like human fingers. An actuator also can be powered by electricity or
hydraulics. Much like there are air cylinders, there also are electric cylinders and hydraulic
cylinders in which the cylinder converts electricity or hydraulics into motion. Hydraulic
cylinders, which use liquids, are often found in certain types of vehicles.
Electrical Actuators

DEPARTMENT OF MECHANICAL ENGINEERING

Electrical Actuator is an electromechanical device that converts electrical energy into
mechanical energy. Most electric actuators operate through the interaction of magnetic fields
and current-carrying conductors to generate force. The reverse process, producing electrical
energy from mechanical energy, is done by generators such as an alternator or a dynamo;
some electric actuators can also be used as generators, for example, a traction motor on a
vehicle may perform both tasks. Electric actuators and generators are commonly referred to
as electric machines.
Applications
Electric actuators are found in applications as diverse as industrial fans, blowers and pumps,
machine tools, household appliances, power tools, and disk drives. They may be powered by
direct current, e.g., a battery powered portable device or motor vehicle, or by alternating
current from a central electrical distribution grid or inverter. Small actuators may be found in
electric wristwatches. Medium-size motors of highly standardized dimensions and
characteristics provide convenient mechanical power for industrial uses.
The very largest electric actuators are used for propulsion of ships, pipeline compressors, and
water pumps with ratings in the millions of watts. Electric actuators may be classified by the
source of electric power, by their internal construction, by their application, or by the type of
motion they give.
Fail Safe Actuators

DEPARTMENT OF MECHANICAL ENGINEERING

Fail Safe Actuator is for larger valves with higher torque requirements, requiring reliable fail
safe operation utilizing a unique in-built air reservoir giving fail safe action without the
torque losses inherent of spring designs. By using the time proven air accumulator system,
and modern design techniques, produces air chamber modules with all the pneumatic
circuitry safety protected within. Fail safe actuators maintains the highest seen air supply
pressure within the chamber modules, to be released upon control demand.
This design also prevents closure creeping when air supply pressures drop, which occurs with
all spring return designs. Torque output is constant in the powered stroke with only a small
drop off on the fail stoke. The available torques are proportional to the air supply pressure.
Spring changes for various air supply pressures need not be made.
The fail safe actuator operates as a double acting actuator in both directions until there is a
loss of supply pressure. When this loss occurs, the compressed air stored in the chambers
powers the actuator to close the valve. This makes the fail safe actuator series suitable for use
in ON/OFF and modulating control situations while still providing the fail safe requirement.
Applications
 Wellhead
 Flow line
 Header
 Pipeline system
 Casing relief blow down valve.
DATA COMMUNICATIONS
Data communications are the exchange of data between two devices via some form of
transmission medium such as a wire cable. For data communications to occur, the
communicating devices must be part of a communication system made up of a combination
of hardware (physical equipment) and software (programs). The effectiveness of a data
communications system depends on four fundamental characteristics: delivery, accuracy,
timeliness, and jitter.
1. Delivery. The system must deliver data to the correct destination. Data must be received by
the intended device or user and only by that device or user.
2. Accuracy. The system must deliver the data accurately. Data that have been altered in
transmission and left uncorrected are unusable.
3. Timeliness. The system must deliver data in a timely manner. Data delivered late are
useless. In the case of video and audio, timely delivery means delivering data as they are
produced, in the same order that they are produced, and without significant delay. This kind
of delivery is called real-time transmission.
4. Jitter. Jitter refers to the variation in the packet arrival time. It is the uneven delay in the
delivery of audio or video packets.
Components:
A data communications system has five components.

DEPARTMENT OF MECHANICAL ENGINEERING

1. Message. The message is the information (data) to be communicated. Popular forms of
information include text, numbers, pictures, audio, and video.
2. Sender. The sender is the device that sends the data message. It can be a computer,
workstation, telephone handset, video camera, and so on.
3. Receiver. The receiver is the device that receives the message. It can be a computer,
workstation, telephone handset, television, and so on.
4. Transmission medium. The transmission medium is the physical path by which a message
travels from sender to receiver. Some examples of transmission media include twisted-pair
wire, coaxial cable, fiber-optic cable, and radio waves
5. Protocol. A protocol is a set of rules that govern data communications. It represents an
agreement between the communicating devices.

Local Area Network (LAN):

LAN is usually privately owned and links the devices in a single office, building or campus
of up to few kilometers in size. These are used to share resources (may be hardware or
software resources) and to exchange information. LANs are distinguished from other kinds of
networks by three categories: their size, transmission technology and topology.
LANs are restricted in size, which means that their worst-case transmission time is bounded
and known in advance. Hence this is more reliable as compared to MAN and WAN.
Knowing this bound makes it possible to use certain kinds of design that would not otherwise
be possible. It also simplifies network management.
.

DEPARTMENT OF MECHANICAL ENGINEERING

Local Area Network Topologies
Business process re-engineering (BPR):
Business process re-engineering (BPR) is a business management strategy, originally
pioneered in the early 1990s, focusing on the analysis and design of workflows and business
processes within an organization. BPR aimed to help organizations fundamentally rethink
how they do their work in order to dramatically improve customer service, cut operational
costs, and become world-class competitors.
BPR seeks to help companies radically restructure their organizations by focusing on the
ground-up design of their business processes. According to early BPR proponent Thomas
Davenport (1990), a business process is a set of logically related tasks performed to achieve a
defined business outcome. Re-engineering emphasized a holistic focus on business objectives
and how processes related to them, encouraging full-scale recreation of processes rather than
iterative optimization of sub-processes.

Introduction to Logistics
Logistics is the management of the flow of goods, information and resources between the
point of origin and the point of consumption. It is a business concept that evolved during the
1950s due to the increasing complexity of supplying businesses with materials and
transporting products in an increasingly globalized supply chain. The complexity led to a call
for experts in the process who are called logisticians.
Logistics can be defined as “having the right item in the right place, at the right time, in the
right quantity, at the right price and in the right condition, for the right customer”.
There are two fundamentally different forms of logistics: one optimizes a steady flow of
materials through a network of transport links and storage areas, while the other coordinates
an effective sequence of resources in order to carry out a project.
Work in logistics involves the integration of information, transportation, inventory,
warehousing, material handling, packaging, human resources and sometimes security. The
goal is to manage the life cycle of a project from birth to completion. For example, a

DEPARTMENT OF MECHANICAL ENGINEERING

logistician would have to ensure that the supply chains work so that raw materials and/or
parts arrive at a factory or on site in time and in the correct order. It would be veryinefficient
and wasteful if the roof tiles were delivered before the foundations have been dug and the
walls built on a construction site, or, if large quantities of paper were delivered to a printer
who had nowhere clean and dry to store it. These are very simple examples of an extremely
complex and detailed process.
The main functions of a qualified logistician include inventory management, purchasing,
transportation, warehousing, consultation and organizing and planning of these activities.
Logisticians combine a professional knowledge of each of these functions to coordinate
resources in an organization.
Enterprise resource planning (ERP):
Enterprise resource planning (ERP) is business process management software that allows an
organization to use a system of integrated applications to manage the business and automate
many back office functions related to technology, services and human resources.
The need for enterprise resource planning (ERP) software grew with big business’ mandate
for a centralized solution to manage all information system requirements. An ERP may
consist of many different business modules, including:
 Manufacturing
 Human Resources/Payroll
 Sales
 Inventory
 Supply Chain/Partners
 Finance and Accounting
 CRM
In short, an ERP solution allows each department or business domain to be managed centrally
while operating independently. Advantages include interoperability of data, increased
communication and increased data reliability through the use of a single database.
ERP also enhances the quality of enterprise-wide decision making. For example, a
customized order may move from the sales department to inventory control, then on to
invoicing to finance and manufacturing. By using an ERP, this type of process is an efficient
and continuous series of events that allows for easy individual order tracking.
1. Business Process Engine (BPE):
A business process engine (BPE) is a software framework that enables the execution and
maintenance of process workflows. It provides business process interaction and
communication between different data/process sources spread across one or more IT
applications and services.
A BPE is a business process management (BPM) solution component used to oversee the
technical architecture of business process integration, interlinking and interprocessing. BPE
works with all of the different application infrastructure layers, including front end,
middleware, backend and external business applications. It facilitates the integration of their
processes, inter and intra system communication, process data routing, data transformation
and merging. A BPE dynamically monitors and adjusts changes applied to data, as well as
associated processes and process workflows.
A BPE also may be used to create new business processes, business rules and deployment
capability for all connected applications without disruption or downtime.

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT V
POWER POINT PRESENTATION SLIDES
AUTOMATION AND CONTROL TECHNOLOGIES IN
THE PRODUCTION SYSTEM
COMPONENTS OF MANUFACTURING SYSTEM

 Production machines, tools, fixtures and other

related hardware
 Material handling system

 Computer system to coordinate and control the

above components
 Human workers
1. PRODUCTION MACHINES
The machines can be classified as
(1) Manually operated: Directed by human workers

(2) Semi-automated:performs a portion of the work

cycle under some form of program control, and a
human worker tends to the machine for the
remainder of the cycle, by loading and unloading it
or performing some other task each cycle.
(3) Fully automated:has a capacity to operate for
extended periods of time with no human attention.
2. MATERIAL HANDLING SYSTEM

(1) loading and unloading work units

(2) positioning the work units at each station.
(3) transporting work units between stations
(4) Temporary storage function
TYPES OF ROUTING IN MULTIPLE STATION
MANUFACTURING SYSTEMS

(a) Variable routing (b) Fixed routing

 3. COMPUTER CONTROL SYSTEM
Communicate instructions to workers. In manually operated workstations that
perform different tasks on different work units, processing or assembly
instructions for the specific work unit must be communicated to the
operator.
Download part programs to computer-controlled machines ( e.g-, CNC machine
tools).
Material handling system control. This function is concerned with controlling the
material handling system and coordinating its activities with those of the
workstations.
Schedule production. Certain production scheduling functions are
accomplished at the site of the manufacturing system.
Failure diagnosis. This involves diagnosing equipment malfunctions, preparing
preventive maintenance schedules, and maintaining spare parts inventory.
Safety Monitoring. This function ensures that the system does not operate in an
unsafe condition. The goal of safety monitoring is to protect both the human
workers manning the system and the equipment comprising the system.
Quality Control. The purpose of this control function is to detect and possibly
reject defective work units produced by the system.
Operations management. Managing the overall operations of the manufacturing
4. HUMAN RESOURCES
In many manufacturing systems, humans perform some
or all of the value-added work that is accomplished on
the parts or products. In these cases, the human
workers are referred to as Direct labor
In manufacturing systems that are fully automated, direct
labor is still needed to perform such activities as
loading and unloading parts to and from the system,
changing tools, resharpening tools, and similar
functions.
Human workers are also needed for automated
manufacturing systems to manage or support the
system as computer programmers, computer
operators, part programmers for CNC machine tools
CLASSIFICATION OF MANUFACTURING SYSTEMS

(1) Types of operations performed,

(2) Number of workstations and system layout,
(3) Level of automation, and
(4) Part or product variety
1. TYPES OF OPERATIONS PERFORMED

1. Processing operations on individual units

2. Assembly operations to combine the
individual parts in to assembled entities
2.NUMBER OF WORK STATIONS AND SYSTEM LAYOUT
Type I Single station. This is the simplest case,
consisting of one workstation (n = 1), usually
including a production machine that can be
manually operated, semi-automated, or fully
automated.
Type II Multiple stations with variable routing. This
manufacturing system consists of two or more
stations (n > 1) that are designed and arranged to
accommodate the processing or assembly of
different part or product styles.
Type III Multiple stations with fixed routing. This
system has two or more workstations ( n > 1) ,
which are laid out as a production line.
3. LEVEL OF AUTOMATION
Manning level of a work station (Mi) is proportion of
time that a worker is in attendance at the station. If
Mi = 1 for station I, it means that one worker must
be at the station continuously.
The average manning level of multi station is equal

Mi = average manning level

Wu = number of utility workers assigned to the systems
Wi = number of workers assigned to I
W= total number of workers assigned to the system
AUTOMATION IN THE CLASSIFICATION
SCHEME
Type I M Single-station manned cell. The basic case is one machine
and one worker (n = l,w = 1).The machine is manually operated
or semi-automated,and the worker must be in continuous
attendance at the machine.
Type I A Single station automated cell. This is a fully automated
machine capable of unattended operation (M < 1) for extended
periods of time (longer than one machine cycle ). A worker must
periodically load and unload the machine or otherwise service it.
Type II M Multi-station manual system with variable routing. This has
multiple stations that are manually operated or semi-automated.
The layout and work transport system allow for various routes to
be followed by the parts or products made by the system. Work
transport between stations is either manual or mechanized.
Type II A Multi-station automated system with variable routing. This
is the same as the previous system; except the stations are fully
automated (n > 1, w; = 0, I M < 1). Work transport is also fully
automated.
AUTOMATION IN THE CLASSIFICATION SCHEME
CONT……
Type II H Multi-station hybrid system with variable routing. This
manufacturing system contains both manned and automated stations.
Work transport is manual, automated, or a mixture (hybrid).
Type III M Multi-station manual system with faxed routing. This
manufacturing system consists of two or more stations (n > 1), with one
or more workers at each station ( w>=1 ). The operations are
sequential, thus necessitating a fixed rout- ing, usually laid out as a
production line. Work transport between stations is either manual or
mechanized.

Type III A Multi-station automated system with fixed routing. This system
consists of two or more automated stations (n > 1, wi> = 0, M < 1)
arranged as a production line or similar configuration. Work transport is
fully automated.
Type III H Multi-station hybrid system with fixed routing. This system
includes both manned and automated stations (n > 1, wi> = 1 for some
stations, wi = 0 for other stations, M > 0). Work transport is manual,
automated, or a mixture (hybrid).
 Classification of Manufacturing Systems

( a) single station manned cell, (b) single station automated cell, ( c) multi-station manual system with
variable routing, ( d) multi-station automated system with variable routing, (e) multi-station hybrid sys-
tem with variable routing, (f) multi-station manual system with serial operations, (g) multi-station
automated system with serial operations, and (h) multi-station hybrid system with serial operations.
Key: Man = manned station, Aut = automated station.
4. PART OR PRODUCT VARIETY
Examples of possible variations that a manufacturing
system may have to cope with include:
 variations in type and/or color of plastic of molded
parts in injection molding
 variations in electronic components placed on a
standard size printed circuit board
 variations in the size of printed circuit boards handled
by a component place
 variations in geometry of machined parts
 variations in parts and options in an assembled
product on a final assembly line
 MODEL VARIATIONS

1. Single model: All parts or products made by the manufacturing systems are identical
2. Batch model: different parts or products made by the system, but they are made in
different batches because a changeover in physical setup and/or equipment
programming is required between models
3. Mixed model case: , different parts or products are made by the manufacturing
system, but the system is able to handle these differences without the need for a
changeover in setup and/or program.
 FLEXIBILITY IN MANUFACTURING SYSTEMS
Identification of the different work units. Different operations are required on
different part or product styles. The manufacturing system must identify the
work unit to perform the correct operation. In a manually operated or semi-
automatic system, this task is usually an easy one for the worker(s). In an
automated system, some means of automatic work unit identification must be
engineered.
Quick changeover of operating instructions. The instructions, or part program in
the case of computer-controlled production machines, must correspond to the
correct operation for the given part. In the case of a manually operated system,
this gener- ally means workers who (1) are skilled in the variety of operations
needed to process or assemble the different work unit styles, and (2) know
which operations to perform on each work unit style. In semi-automatic and
fully automated systems, it means that the required part programs are readily
available to the control unit.
Quick changeover of physical setup. Flexibility in manufacturing means that the
dif- ferent work units are not produced in batches. For different work unit styles
to be pro- duced with no time lost between one unit and the next, the flexible
manufacturing system must be capable of making any necessary changes in
fixturing and tooling in a very short time. (The changeover time should
correspond approximately to the time required to exchange the completed work
unit for the next unit to be processed. )
RECONFIGURABLE MANUFACTURING
SYSTEMS
Ease of mobility. Machine tools and other production
machines designed with a three- point base that allows
them be readily lifted and moved by a crane or forklift truck.
The three-point base facilitates leveling of the machine
after moving.
Modular design of system components. This permits hardware
components from dif- ferent machine builders to be
connected together.
Open architecture in computer controls. This permits data
interchange between soft- ware packages from different
vendors.
CNC workstations. Even though the production machines in
the system are dedicat- ed to one product, they are
nevertheless computer numerical controlled to allow jor
upgrades in software, engineering changes in the part
currently produced, and changeover of the equipment when
the production run finally ends
 UNIT V
INDUTRIAL APPLICATIONS
 UNIT V
ASSIGNMET
 Unit-V

1.

a). Explain the situations where adaptive control can be beneficially applied?

b). What are the limitations of adaptive control?

2.

a). Explain how various parameters such as cutting force, temperatures are controlled using
adoptive control concept.
b). Explain the process of adaptive control constraint (ACC).
3. Explain about Sensors and Actuators
4. Data communication and LAN manufacturing
5. Explain Business Process Re-engineering

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT V
SHORT ‘Q’ & TUTORIAL
 UNIT-V

1. What is a Sensor?
It is a device that converts signals from one energy domain to electrical domain. The definition of the
Sensor can be understood if we take an example in to consideration. The simplest example of a sensor is
an LDR or a Light Dependent Resistor. It is a device, whose resistance varies according to intensity of
light it is subjected to. When the light falling on an LDR is more, its resistance becomes very less and
when the light is less, well, the resistance of the LDR becomes very high.

2. What are the Different Types of Sensors?

The following is a list of different types of sensors that are commonly used in various
applications. All these sensors are used for measuring one of the physical properties like
Temperature, Resistance, Capacitance, Conduction, Heat Transfer etc.

 Temperature Sensor
 Proximity Sensor
 Accelerometer
 IR Sensor (Infrared Sensor)
 Pressure Sensor
 Light Sensor
 Ultrasonic Sensor
 Smoke, Gas and Alcohol Sensor
 Touch Sensor
 Color Sensor
 Humidity Sensor
 Tilt Sensor
 Flow and Level Sensor

1. What is an actuator and classify the types of actuators?

An actuator is a component of a machine that is responsible for moving and controlling a mechanism or
system, for example by opening a valve. In simple terms, it is a "mover".

An actuator requires a control signal and a source of energy. The control signal is relatively low energy
and may be electric voltage or current, pneumatic or hydraulic pressure, or even human power. Its main
energy source may be an electric current, hydraulic fluid pressure, or pneumatic pressure. When it
receives a control signal, an actuator responds by converting the signal's

4. What is LAN in manufacturing?

A local area network (LAN) is a computer network that interconnects computers within a limited
area such as a residence, school, laboratory, university campus or office building. Ethernet and Wi-
Fi are the two most common technologies in use for local area networks.

5. What do you mean by data communication?

DEPARTMENT OF MECHANICAL ENGINEERING

Data communications (DC) is the process of using computing and communication technologies
to transfer data from one place to another, and vice versa. It enables the movement of electronic or
digital data between two or more nodes, regardless of geographical location, technological medium
or data contents.

6. What do you mean by logistics?

Logistics management is the part of supply chain management that plans, implements, and
controls the efficient, effective forward, and reverse flow and storage of goods, services, and
related information between the point of origin and the point of consumption in order to meet
customer's requirements.

DEPARTMENT OF MECHANICAL ENGINEERING