Unit 6 Mechanism in Automation Systems 2
Unit 6 Mechanism in Automation Systems 2
UNIT 6
A cam maybe a robot that wants to transmit motion to a lover by direct contact. the driving
force is named the cam and also the driven member is named the follower. in an exceeding
cam follower combine, the cam unremarkably rotates whereas the follower might translate or
oscillate. a well-known example is the camshaft of the associate engine, wherever the cams
drive the pushrods (the followers) to open and shut the valves in synchronization with the
feeling of the pistons.
Cams square measure is accustomed to convert rotation into mutual motion. The motion
created are often straightforward and regular or complicated and irregular. because the cam
turns, driven by the circular motion, the cam follower traces the surface of the cam transmittal
its motion to the desired mechanism. Cam follower style is very important within the approach
the profile of the cam is followed. A fine pointed follower can additional accurately trace the
define of the cam. This additional correct movement is at the expense of the strength of the
cam follower.
Types of cams
a) Disk or plate cam: The disk (or plate) cam has an associate degree irregular contour to
impart a selected motion to the follower. The follower moves in an exceedingly plane
perpendicular to the axis of rotation of the camshaft and is a command in grips with the
cam by springs or gravity.
Figure.6.2. Disk or Plate Cam
b) Cylindrical cam: The cylindrical cam contains a groove cut on its cylindrical surface.
The roller follows the groove, and therefore the follower moves during a plane parallel to
the axis of rotation of the cylinder.
c) Translating cam: The translating cam may be a contoured or grooved plate slippery on
a guiding surface(s). The follower could oscillate (Fig.6.4. a) or reciprocate (Fig.6.4.b). The
contour or the form of the groove is decided by the desired motion of the follower.
Types of followers:
(i) Based on the surface in contact:
(b)Roller follower
(d)Spherical follower
Figure.6.5: Followers
(a) Radial follower: The lines of movement of in-line cam followers pass through
the centers of the camshafts.
(b) Off-set follower: For this type, the lines of movement are offset from the centers of the
Camshafts.
NOMENCLATURE OF CAMS
Trace Point The point at the knife-edge of a follower, or the center of a roller, or the center of
a spherical face.
Base Circle The smallest circle drawn, tangential to the cam profile, with its center on the axis
of the camshaft. The size of the base circle determines the size of the cam.
Prime Circle The smallest circle drawn, that can be drawn from the center of the cam and
tangent to the pitch curve.
Prime circle radius = Base circle radius for knife-edge and flat-faced follower
Prime circle radius = Base circle radius + radius of roller for a roller follower
Pressure Angle The angle between the normal to the pitch curve and the direction of motion
of the follower at the point of contact.
Lift of stroke: It is the maximum travel of the follower from its lowest position to the topmost
position. The maximum rise is called lift.
Pitch Circle: It is the circle drawn from the center of the cam through the pitch points.
Cam follower systems are designed to realize a desired oscillating motion. applicable
displacement patterns are to be designated for this purpose, before coming up with the cam
surface. The cam is assumed to rotate at a continuing speed and therefore the follower raises,
dwells, returns to its original position, and dwells once more through such as angles of
rotation of the cam, throughout every revolution of the cam. a number of the quality follower
motions are as follows:
Displacement diagrams:
It is discovered within the displacement diagrams of the follower with a regular rate that the
acceleration of the follower becomes infinite at the start and finish of rising and come strokes.
to forestall this, the displacement diagrams square measure slightly changed. within the
changed kind, the speed of the follower changes uniformly throughout the start and finish of
every stroke. consequently, the displacement to the follower varies parabolically throughout
the periods. With this modification, the acceleration becomes constant throughout the
periods, rather than being infinite a sin the uniform rate variety of motion. The displacement,
rate, and acceleration patterns square measure shown in fig.6.10.
Figure.6.10. Displacement, Velocity, and Acceleration
b) Simple Harmonic Motion: In fig., the motion executed by point Pl, which is the
projection of point P on the vertical diameter is called simple harmonic motion. Here, P
moves with uniform angular velocity ωp, along a circle of radius r (r=s/2).
A cycloid is a path generated by a point on the circumference of a circle, as the circle rolls
without slipping, on a straight/flat surface. The motion executed by the follower here, is
similar to that of the projection of a point moving along a cycloidal curve on a vertical line as
shown in figure.6.12.
Here, the displacement of the follower varies parabolically with respect to the angular
displacement of the cam. Accordingly, the velocity of the follower varies uniformly with
respect to the angular displacement of the cam. The acceleration/retardation of the follower
becomes constant accordingly.
Example:
Follower type = Knife edged, in-line; lift = 50mm; base circle radius = 50mm; outstroke with
SHM, for 60°cam rotation; dwell for 45°cam rotation; return stroke with SHM, for 90° cam
rotation; dwell for the remaining period. (2) Draw the cam profile for the same operating
condition with the follower offset by 10mm to the left of the cam center.
Cam profile:
Follower type=knife edged follower, in line; lift=30mm; base circle radius =20mm; outstroke
with uniform
velocity in 120°of cam rotation; dwell for 60°; return stroke with uniform velocity, during 90°of
cam
Displacement Diagram
Cam profile
We can draw and understand the cam profile for roller follower by the following example:
Follower type = roller follower, in-line; lift = 25mm; base circle radius = 20mm; roller
radius = 5mm; out stroke with UARM, for 1200 cam rotation; dwell for 600 cam rotation;
return stroke with UARM, for 900 cam rotation; dwell for the remaining period. Determine
max. velocity and acceleration during out stroke and return stroke if the cam rotates at
1200 rpm in a clockwise direction.
Displacement diagram:
Cam profile: Construct base circle and prime circle (25mm radius). Mark points
1,2,3 in a direction opposite to the direction of cam rotation, on the prime circle. Transfer
points a,b,c from displacement diagram. At each of these points a, bc draw circles of 5mm
radius, representing rollers. Starting from the first point of contact between roller and base
circle, draw a smooth freehand curve, tangential to all successive roller positions. This forms
the required cam profile.
We know o.k. that a (reciprocating)cam and follower is usually wont to attain mutual motion
within the vertical direction in any system. Example. (IC Engine Valve Operation) In most of
the cams like disc cams, plate cams, the cam is to blame for the upward movement of the
follower. however curiously the cam isn't to blame for the downward movement (return) of the
follower. rather than the cam, acceleration because of gravity “g” is to blame for the
downward motion. As we know, “g” is restricted by nine.81 m/s2. Here comes the matter, if
the motion speed of the cam is incredibly high, it results in accelerates the follower at a really
high rate. No downside regarding the upward acceleration of the follower, the cam can
lookout. we tend to cannot expect the cam to maneuver downward in Associate in Nursing
acceleration larger than “g”. It makes the follower lose contact with the cam. this is often
known as a jumping development.
Key Takeaways:
Cam and its followers, types of cams, types of followers, different types of follower motion like
follower motion with uniform velocity, modified uniform velocity, cycloidal motions, cam jump
phenomenon, cam profile for roller follower, UARM.
6.2 Automation
Introduction
Automation is that the use of management systems and knowledge technologies to cut back
the requirement for humans add the assembly of products and services. within the scope of
manufacture, automation may be a step on the far side of mechanization. Whereas
mechanization provided human operators with machinery to help them with the muscular
necessities of labour, automation greatly decreases the requirement for human sensory and
mental necessities further.
FIXED AUTOMATION
It is a system during which the sequence of process (or assembly) operations is fastened by
the instrumentation configuration. The operations within the sequence are sometimes
straightforward. it's the combination and coordination of the many such operations into one
piece of apparatus that creates the system advanced. the standard options of fastened
automation are:
a. High initial investment for custom–Engineered equipment;
The economic justification for fastened automation is found in a product with terribly high
demand rates and volumes. The high initial price of the instrumentation may touch an awfully
sizable amount of units, therefore creating the cost enticing compared to different strategies
of production. samples of fastened automation embody mechanized assembly.
PROGRAMMABLE AUTOMATION
In this, the assembly instrumentality is meant with the potential to vary the sequence of
operations to accommodate totally different product configurations. The operation sequence
is controlled by a program, that could be a set of directions coded in order that the system will
browse and interpret them. New programs are often ready and entered into the
instrumentality to supply new merchandise. a number of the options that characterize
programmable automation are:
Automated production systems that square measure programmable square measure utilized in
low and medium volume production. The elements or merchandise square measure usually
created in batches. to supply every new batch of a distinct product, the system should be
reprogrammed with the set of machine directions that correspond to the new product. The
physical setup of the machine should even be modified over: Tools should be loaded; fixtures
should be hooked up to the machine table even be modified machine settings should be
entered. This transformation procedure takes time. Consequently, the everyday cycle for the
given product includes an amount throughout that the setup and reprogramming come about,
followed by an amount during which the batch is created. samples of programmed automation
embody numerically controlled machine tools and industrial robots.
FLEXIBLE AUTOMATION
It is an associate degree extension of programmable automation. a versatile machine-driven
system is one that's capable of manufacturing a range of products (or parts) with just about no
time lost for changeovers from one product to consecutive. there's no production time lost
whereas reprogramming the system and fixing the physical setup (tooling, fixtures, and
machine setting). Consequently, the system will turn out varied mixtures and schedules
of the product rather than requiring that they be created in separate batches. The options of
versatile automation may be summarized as follows:
The essential options that distinguish versatile automation from programmable automation
are:
1. the capability to alter half programs with no lost production time; and
2. the aptitude to convert the physical setup, once more with no lost production time.
These options permit the machine-driven production system to continue production while not
the period of time between batches that's characteristic of programmable automation.
dynamic the half programs are usually accomplished by making ready the programs off-line
on a system and electronically transmittal the programs to the machine-driven production
system. Therefore, the time needed to try the programming for a consecutive job doesn't
interrupt production on this job. Advances in laptop systems technology square measure
mostly accountable for this programming capability in versatile automation. dynamic the
physical setup between components is accomplished by creating the conversion off-line so
moving it into place at the same time because the next half comes into position
for the process. the utilization of pallet fixtures that hold the components and
transfer them into position at the geographic point is a method of implementing this approach.
For these approaches to be successful; the range of components which will be created on a
versatile machine-driven production system is sometimes additional restricted than a system
controlled by programmable automation. The relative positions of the 3 sorts of automation for
various production volumes and merchandise varieties square measure pictured within the
following figure.
Figure.6.14. Types of Automation Based on Production Volume
Key Takeaways:
Automation definition with examples, types of automation, Fixed, programmable, and flexible
automation, comparison of automation by the diagram.
The transfer mechanism of the machine-controlled flow line should not solely move the partly
completed work components or assemblies between adjacent stations, it should conjointly
orient and find the components within the correct position for the process at every station. the
final strategies of transporting work items on flow lines will be classified into the subsequent 3
categories:
1) Continuous Transfer
These transfer systems square measure used for each process and assembly operations.
within the case of automatic assembly machines, we tend to square measure bearing on the
mechanisms that transport the partly completed assemblies between stations, not the feed
mechanisms that gift new parts to the assemblies at a selected station. The devices that feed
associate degreed orient the parts square measure usually an integral part of the digital
computer.
Continuous transfer: With the continual methodology of transfer, the work components
square measure moved incessantly at a constant speed. this needs the work heads
to maneuver throughout the process to take care of continuous registration with the work half.
for a few kinds of operations, this movement of the work heads throughout the process isn't
possible. it might be tough, as an example, to use this sort of system on a machining transfer
line owing to inertia issues because of the scale and weight of the work heads. In different
cases, continuous transfer would be sensible. samples of its use square measure in drinkable
bottling operations, packaging, manual assembly operations wherever the human operator
will move with ‘the moving flow line, and comparatively easy automatic assembly tasks.
Intermittent transfer: because the name suggests, during this methodology the workpieces
square measure transported with associate degree intermittent or discontinuous motion. The
workstations square measure mounted in position and also the components square measure
moved between stations then registered at the correct locations for the process. All work
components square measure transported at the identical time and, for this reason, the term
“synchronous transfer system” is additionally accustomed to describe this methodology
of labour half transport. samples of applications of the intermittent transfer
of labour components will be found in machining operations, press operating operations, or
progressive dies.
There are various types of transfer mechanisms used to move parts between stations. These
mechanisms can be grouped into two types: those used to provide linear travel for in-line
machines, and those used to provide rotary motion for dial indexing machines.
We will explain the operation of three of the typical mechanisms: the walking beam transfer
bar system, the powered roller conveyor system, and the chain-drive conveyor system. This is
not a complete listing of all types, but it is a representative sample.
WALKING BEAM SYSTEMS: With the walking beam transfer mechanism, the work parts are
lifted up from their workstation locations by a transfer bar and moved one position ahead. to
the next station. The transfer bar then lowers the parts into nests which position them more
accurately for processing. This type of transfer device is illustrated in Figure.6.15.
There are many strategies we want to index a circular table or dial at varied equal angular
positions appreciate digital computer locations. Those delineated below are meant to be a
representative instead of a whole listing.
RACK AND PINION: This mechanism is easy however isn't thought-about particularly suited
to the high-speed operation usually related to categorization machines. The device is pictured
in Figure.6.17. and uses a piston to drive the rack, which causes the pinion gear and
connected categorization table to rotate. A clutch or alternative device is employed to
produce rotation within the desired direction.
Figure.6.17. Rack and Pinion
RATCHET AND PAWL: This drive mechanism is shown in Figure.6.18. Its operation is simple
but somewhat unreliable, owing to the wear and sticking of several of the components.
Key Takeaways:
Methods of work part transport, Linear transfer mechanisms, rotary transfer mechanisms.
Automated Assembly Systems Assembly involves the change of integrity along with 2 or a lot
of separate elements to create a new entity which can be assembly or subassembly. machine-
controlled assembly refers to the utilization of mechanized and automatic devices to perform
the varied functions in an associate degree production line or cell. machine-controlled
assembly system performs a sequence of machine-controlled operations to mix multiple
elements into one entity which may be a final product or sub-assembly. machine-controlled
assembly technology ought to be thought-about once the subsequent condition exists.
High product demand and Stable product design: The assembly consists of no quite a
restricted variety of elements. the merchandise is meant for machine-controlled assembly.
machine-controlled assembly system involves less investment compared to transfer lines as a
result of 1. Work half created is smaller in size compared to transfer lines. 2. Assembly
operations don't have big mechanical forces and power demand.
Based on the type of work transfer system that is used in the assembly system:
The first three types involve the same methods of work part transport described
in the automated flow line. In the stationary base part system, the base part to which the other
components are added is placed in a fixed location, where it remains during the assembly
work.
In the dial-type machine, the base part is indexed around a circular table or dial. The
workstations are stationary and usually located around the outside periphery of the dial. The
parts ride on the rotating table and arc registered or positioned, in turn, at each station a new
component is added to the base part. This type of equipment is often referred to as an
indexing machine or dial index machine and the configuration is shown in Figure 1
and an example of six station rotary shown in the figure.
Figure.6.19. Dial Type Machine
An automated transfer line has consisted of several workstations which are linked together by
a material handling system where parts are transferred from one station to the next
The buffer storage system is a temporary storage location for goods being processed
It is located in between processing stations, whose processing times are significantly
different.
Car producing robots offer automotive corporations a competitive advantage. They improve
quality and cut back warrant costs; increase capability and relieve bottlenecks; and defend
staff from dirty, troublesome, and dangerous jobs. automobile assembly plants use robots
completely for spot fastening and painting, however, there are several alternative
opportunities to use robots throughout the availability chain. OEMs, Tier 1s, and alternative
half producers all stand to realize from victimization robots within the automobile producing
trade.
Car factory robots cut back part-to-part variability. extremely repeatable, they ne'er tire or
get distracted, therefore each cycle is performed similarly. Neither do they drop elements or
handle them in a very manner that causes harm. That reduces waste antecedent caused by
human error, which conjointly suggests that less variability in automobile assembly. Equipped
with vision systems, automotive robots even will observe variation in incoming materials and
adapt their programmed ways to suit. This, in turn, interprets to higher client satisfaction,
fewer mistakes, and lower warrant prices.
Example: Contemplate the assembly of a car: assume that sure steps within the production
line are to put in the engine, install the hood, and install the wheels (in that order, with
discretionary opening steps); just one of those steps are often done at a time. In ancient
production, just one automobile would be assembled at a time. If engine installation takes
twenty minutes, hood installation takes 5 minutes, and wheels installation takes ten minutes,
then an automobile is often made each thirty-five minutes. In the associate production line,
automobile assembly is split between many stations, all operating at the same time. once a
station is finished with an automobile, it passes it on to subsequent. By having 3 stations, 3
cars are often operated on at a similar time, every at a distinct stage of assembly. After
finishing its work on the primary automobile, the engine installation crew will begin
functioning on the second automobile. whereas the engine installation crew works on the
second automobile, the primary automobile is often moved to the hood station and fitted with
a hood, then to the wheels station and be fitted with wheels. once the engine has been put in
on the second automobile, the second automobile moves to the hood assembly. At a similar
time, the third automobile moves to the engine assembly. once the third car's engine has been
mounted, it then is often moved to the hood station; meantime, subsequent cars (if any) are
often moved to the engine installation station. Assuming no loss of your time once
moving an automobile from one station to a different, the longest stage on the production line
determines the output (20 minutes for the engine installation) therefore an automobile are
often made each twenty minutes, once the primary automobile taking thirty-five minutes
have been made.
AI refers to however pc systems will use vast amounts of knowledge to imitate human
intelligence and reasoning, permitting the system to be told, predict, and advocate what to try
to do next. Associate in Nursing AI capable of understanding selling KPIs will use numerous
algorithms that act collectively realize to seek out to search out the signal within the noise of
knowledge and find methods to solutions that no human would be capable of. Most AI these
days works in Associate in a Nursing helpful fashion, providing next best action
recommendations to humans UN agency then decide whether or not to trust them or not then
manually build changes.
When robotic method automation is combined with parts of AI like machine learning, the
result's called intelligent method automation (IPA). Associate in Nursing IPA tool as powerful
as a result of it permits US to reap each the advantages of automation inflated speed,
efficiency, time-savings, and skill to scale with the insights, flexibility, and process power of
AI. Marketers UN agency use IPA area unit ready to augment their capabilities, whereas off-
loading repetitive campaign management tasks to the machine. This will be totally different
from pure robotic automation therein the AI can begin, stop, or maybe alter what it's doing
supported the atmosphere within which it operates. What’s a lot of, as a result of the most
effective AI systems permit marketers to line guardrails, there’s no probability of unforeseen
events taking outcomes too so much wide.
Key Takeaways:
Automated assembly line, types of automated assembly systems, automated assembly line for
car manufacturing, artificial intelligence in automation.
Reference Books:
S. S. Rattan, “Theory of Machines”, Third Edition, McGraw Hill Education
(India) Pvt. Ltd.
Paul E. Sandin, “Robot Mechanisms and Mechanical Devices Illustrated”, Tata McGraw Hill
Publication