SAVE FUEL AVOID POLLOUTION

Advanced Manufacturing Technology

By
Dr.P. Mathiazhagan

Professor

Mikell P. Groover

DEPT. OF MECHANICAL ENGINEERING

PUDUCHERRY TECHNOLOGICAL UNIVERSITY
PONDICHERRY - 605104
Industry
In a general sense the term “Industry” is defined as follows.
Definition: Systematic Economic Activity that could be related to
Manufacture/Service/ Trade
 Automation
The word ‘Automation’ is derived from greek words “Auto”(self) and “Matos”
(moving). Automation therefore is the mechanism for systems that “move by itself”.

Definition: Automation is a set of technologies that results in operation of machines

and systems without significant human intervention and achieves performance
superior to manual operation

 Automation is a technology concerned with the application of mechanical, electronic, and

computer based systems to operate and control production

 This technology includes automatic machine tools to process parts, automatic assembly
machines, industrial robots, automatic material handling and storage systems, automatic
inspection systems for quality control, feedback control and computer process control,
computer systems for planning, data collection and decision-making to support
manufacturing activities.
TYPES OF AUTOMATION:
Automated production systems can be classified into three
basic types:
1. Fixed automation,
2. Programmable automation, and
3. Flexible automation
FIXED AUTOMATION
 It is a system in which the sequence of processing (or assembly) operations is fixed by the
equipment configuration.
 The operations in the sequence are usually simple.
The typical features of fixed automation are:

(a) High initial investment for custom–Engineered equipment

 The economic justification for fixed automation is found
(b) High production rates in products with very high demand rates and volumes.

(c) Relatively inflexible in accommodating product changes.

2. PROGRAMMABLE AUTOMATION
 In this the production equipment is designed with the capability to change the sequence of
operations to accommodate different product configurations.

 The operation sequence is controlled by a program, which is a set of instructions coded so that
the system can read and interpret them.

 New programs can be prepared and entered into the equipment to produce new products.
 Some of the features that characterise programmable automation are:

(a) High investment in general-purpose equipment;

(b) Low production rates relative to fixed automation;

(c) Flexibility to deal with changes in product configuration; and

(d) Most suitable for batch production.

 Automated production systems that are programmable are used in low and medium
volume production. The parts or products are typically made in batches.

 To produce each new batch of a different product, the system must be reprogrammed
with the set of machine instructions that correspond to the new product.

 The physical setup of the machine must also be changed over

 Tools must be loaded, fixtures must be attached to the machine table also be changed
machine settings must be entered.

 This changeover procedure takes time.

 Consequently, the typical cycle for given product includes a period during which the
setup and reprogramming takes place, followed by a period in which the batch is
produced.

 Examples of programmed automation include numerically controlled machine tools

and industrial robots.
3. FLEXIBLE AUTOMATION
 It is an extension of programmable automation.
 A flexible automated system is one that is capable of producing a variety of products (or
parts) with virtually no time lost for changeovers from one product to the next.

 There is no production time lost while reprogramming the system and altering the physical
setup (tooling, fixtures, and machine setting). Consequently, the system can produce
various combinations and schedules of products instead of requiring that they be made in
separate batches.
 The features of flexible automation can be summarized as follows:
 (a) High investment for a custom-engineered system.
 (b) Continuous production of variable mixtures of products.

(c) Medium production rates.

(d) Flexibility to deal with product design variations.
The essential features that distinguish flexible automation from programmable automation are:
(1) the capacity to change part programs with no lost production time
(2) the capability to changeover the physical setup, again with no lost production time.
These features allow the automated production system to continue production without the
downtime between batches that is characteristic of programmable automation.
 AUTOMATED FLOW LINES
 An automated flow line consists of several machines or workstations which are linked
together by work handling devices that transfer parts between the stations

 The transfer of work parts occurs automatically and the workstations carry out their
specialized functions automatically

 A raw work part enters one end of the line and the processing steps are performed
sequentially as the part moves from one station to the next

 It is possible to incorporate buffer storage zones into the flow line, either at a single
location or between every workstation

 It is also possible to include inspection stations in the line to automatically perform

intermediate checks on the quality of the work parts

 Manual stations might also be located along the flow line to perform certain operations
which are difficult or uneconomical to automate.
Configurations of automated flow line.

In-line type:
 The in-line configuration consists of a sequence of workstations in a
more or less straight line arrangement

An example of an in-line transfer machine used for metal cutting operations

Segmented In-Line Type

 The segmented in-line configuration consists of two or more straight line arrangement
which are usually perpendicular to each other with L shaped or U shaped or rectangular
shapes

 The flow of work can take a few 90°turns, either for work piece reorientation, factory
layout limitations, or other reasons, and still qualify as a straight-line configuration.
 INDUSTRY
Why it matters?
4.0
The bet t er t he quest ion. The bet t er t he answer.
The bet t er t he world works.
Industrial Evolution
4. Industrial
revolution
Based on cyber-physical-
systems

3. Industrial revolution
Through the use of electronics
and IT further progression in
autonomous production

2. Industrial revolution

Level of complexity
Introducing mass production
lines powered by electric
energy

1. Industrial revolution
Introducing mechanical
production machines powered
by water and steam
Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0
End of the Beginning of the Beginning of the Today
18th century. 20th century 70th
Source: DFKI/Bauer IAO
Phases of earlier 3 Industrial
Revolutions
1. 1760 to 1840 - Ushered in Mechanical production; railways and steam
engine

2. 1870 to 1940 - Mass production; electricity and assembly line

3. 1960 to 2010 - Computers; semi conductors, main frame computing,

personal devices, internet
Industry 4.0: Germany
Smart Manufacturing Leadership Coalition: USA
A collective term for technologies and concepts of value chain organization. Based on the
technological concepts of cyber-physical systems, the Internet of Things and the Internet of
Services, it facilitates the vision of the Smart Factory.
Within the modular structured Smart Factories of Industry 4.0, cyber-physical systems
monitor physical processes, create a virtual copy of the physical world and make
decentralized decisions.
Over the Internet of Things, Cyber-physical systems communicate & cooperate with each
other & humans in real time. Via the Internet of Services, both internal & cross-
organizational services are offered & utilized by participants of the value chain.

 Builds on the Digital revolution  Ubiquitous internet

 Smaller & powerful sensors  Artificial Intelligence (AI)

 Machine Learning  Labor & Energy Cost

Time to reach 100 Million customers

• Telephone 75 Years

• Web 7 Years

• Facebook 4 Years

• Instagram 2 Years

• Pokemon Go 1 Month
Cyber Physical Systems

A cyber-physical system (CPS) is a system of collaborating computational elements

controlling physical entities. CPS are physical and engineered systems whose
operations are monitored, coordinated, controlled and integrated by a computing and
communication core. They allow us to add capabilities to physical systems by merging
computing and communication with physical processes.
Today’s Factory
Tomorrow’s Factory
Industry 4.0
Six Design Principles
• Interoperability: the ability of cyber-physical systems (i.e. work piece
carriers, assembly stations and products), humans and Smart Factories to
connect and communicate with each other via the Internet of Things and
the Internet of Services
• Virtualization: a virtual copy of the Smart Factory which is created by
linking sensor data (from monitoring physical processes) with virtual plant
models and simulation models
• Decentralization: the ability of cyber-physical systems within Smart
Factories to make decisions on their own
• Real-Time Capability: the capability to collect and analyze data and provide
the insights immediately
• Service Orientation: offering of services (of cyber-physical systems,
humans and Smart Factories) via the Internet of Services
• Modularity: flexible adaptation of Smart Factories for changing
requirements of individual modules
Lean Manufacturing
What is meant by agile manufacturing?
Agile manufacturing is a term applied to an organization that has created the processes, tools, and

training to enable it to respond quickly to customer needs and market changes while still controlling

costs and quality. It is mostly related to lean manufacturing.

 Additive Manufacturing Processes
Additive Manufacturing refers to a process by which digital 3D design data
is used to build up a component in layers by depositing material. The term
"3D printing" is increasingly used as a synonym for Additive Manufacturing.
APPLICATIONS:
Stereolithography (SLA) is a 3D printing technique that uses a UV laser to create objects
layer by layer:
1.Resin: A liquid, photosensitive resin is poured into a vat.
2.Curing: A UV laser cures the resin layer by layer, starting from the bottom and working its
way up.
3.Cleaning: Once the part is finished, it's cleaned in a solvent to remove any uncured resin.
4.Curing again: The part is then cured in a UV oven.
The anatomy or the structure of a robot depends on the basic components such as the
wrist, arm, and body used to build it for a specific operation. An industrial
robot comprises a mechanical manipulator and a controller that allows it to move and
perform other tasks.

 The mechanical manipulator comprises joints and links that allow the
manipulator’s end to be positioned and oriented relative to its base. The
controller operates the joints in a coordinated manner at the same time to
complete a programmed work cycle.

 A robot joint is similar to a joint in the human body. It allows for relative movement
between two body parts. Industrial robots typically have five or six linear or rotating
joints.
 Robots are mostly divided into four major configurations based on their
appearances, sizes, etc., including cylindrical configuration, polar configuration,
jointed arm configuration, and cartesian coordinate configuration.