ROBOTICS AND AUTOMATION

RAT 282 INTRODUCTION TO INDUSTRIAL AUTOMATION CATEGORY L T P CREDIT

VAC 3 1 0 4

Course Outcomes: After the completion of the course the student will be able to

CO 1 Understand the basic concepts of automation methodologies and trends in manufacturing

automation.
CO 2 Understand the working principle and applications of different types of sensors.
CO 3 Study the design aspects of modern CNC machines.
CO 4 Study the basic principles and operation of different types of material handling devices.
CO 5 Develop different pneumatic circuits based on their applications.
CO 6 Familiarize the basic concepts of PLC programming.
CO 7 Understand different automated inspection methods.

Mapping of course outcomes with program outcomes

PO 1 PO 2 PO 3 PO 4 PO 5 PO 6 PO 7 PO 8 PO 9 PO PO PO
10 11 12
CO 1 3 2 2 1 2 3
CO 2 3 2 2 1 2 1 2
CO 3 3 2 2 2 2 1 3
CO 4 3 2 2 2 1 1 2
CO 5 3 3 2 2 2 1 2
CO 6 3 3 2 2 2 2
CO 7 3 3 2 2 2 2 2

Assessment Pattern

Bloom’s Category Continuous Assessment Tests End Semester Examination

1 2
Remember 10 10 10
Understand 25 25 30
Apply 15 15 60
Analyse
Evaluate
Create

Mark distribution

Total Marks CIE ESE ESE Duration

150 50 100 3 hours

Continuous Internal Evaluation Pattern:

Attendance : 10 marks
Continuous Assessment Test (2 numbers) : 25 marks
Assignment/Quiz/Course project : 15 marks
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End Semester Examination Pattern: There will be two parts; Part A and Part B. Part A contain 10
questions with 2 questions from each module, having 3 marks for each question. Students should
answer all questions. Part B contains 2 questions from each module of which student should answer
any one. Each question can have maximum 2 sub-divisions and carry 14 marks.

Module 1
Automation methodologies: Concept of Mechanization and Automation – Types of Automation
Detroit type Automation, Automated flow lines, Fundamentals of Transfer Lines.
Trends in manufacturing – GT and Cellular Manufacturing, Flexible manufacturing systems – features
of FMS, computer integrated manufacturing – need for AI and expert systems in CIM, Automated
assembly system – flexible assembly automation.

Module 2
Sensors and actuators for automation: Classification of position and motion sensors, inductive
type, electromechanical switches, rotary position sensors – resolver, encoders, integrated motion
systems, fundamental sensor methodologies, LVDT, RVDT, photo electric, thermo electric,
capacitive, magnetic detectors, impedance type gauging transducers, linear potentiometer, strain
gauges. Practical examples on design, selection and implementation of sensor systems, calibration
of sensors.
Electrical, Hydraulic and pneumatic actuators and their comparison, Examples - use of Electrical,
Hydraulic and pneumatic actuators in industrial automation.

Module 3
Elements of CNC systems: servomotor and servo system design trends, stepper motors and controls,
adaptive control, ball screws and guideways, spindle, bearings and mountings. Drive systems.
Automated tool changers and pallet changers. Accessories, and selection of drives for CNC machines.

Material Handling and Identification Technologies: Overview of Material Handling Systems,

Principles and Design Consideration, Material Transport Systems, Storage Systems, Overview of
Automatic Identification Methods.

Module 4
Pneumatic/Hydraulic Automation: control valves – direction, pressure and flow, sequential control
of single /multiple actuator systems, cascade and Karnaugh Veitch map methods, step-counter
systems.

Electro pneumatic/electro hydraulic automation: Symbols: Basic electrical elements – relay,

solenoid, timers, pneumatic – electrical converters, design of circuits and hands on models on
material handling systems.

Module 5

Automation Control: Sequence control and programmable controllers – logic control and
sequencing elements, ladder diagram, PLC, programming the PLC. Practical Examples on PLC ladder
programming.
Inspection automation: Inspection automation, off-line and on-line inspections, computerized
 ROBOTICS AND AUTOMATION
coordinate measuring machine – CMM construction, online inspection systems., laser
interferometer, non-contact inspection methods. Automatic gauging and size control systems,
thickness measurement, machine vision systems.

Text Books:
1. Automation, Production Systems and Computer Integrated Manufacturing, Groover M.P,
Prentice – Hall Ltd., 1997.

References:
1. Computer Control of Manufacturing Systems‖ YoramKoren, Tata McGraw-Hill Edition 2005.
2. CNC Machines, Radhakrishnan P., New Central Book Agency, 1992.
3. Mechatronics: A Multidisciplinary Approach, 4/E‖, W. Bolton. Pearson Education India.
4. Mechatronics, HMT, Tata McGraw-Hill, 1998. 6. ―Pneumatic Control for Industrial
Automation‖, Peter Rohner& Gordon Smith, John Wiley and Sons, 1987.
5. Standard Handbook of Industrial Automation, Onsidine D M C & Onsidine G D C, Chapman and
Hall, NJ, 1986.

Course Contents and Lecture Schedule

No Topic No. of Lectures

1 MODULE 1

1.1 Automation methodologies: Concept of Mechanization and Automation –

Types of Automation Detroit type Automation, Automated flow lines,
4
Fundamentals of Transfer Lines.

1.2 Trends in manufacturing – GT and Cellular Manufacturing, Flexible

manufacturing systems – features of FMS, computer integrated
manufacturing – need for AI and expert systems in CIM, Automated 4
assembly system – flexible assembly automation.

2 MODULE 2

2.1 Sensors and actuators for automation: Classification of position and

motion sensors, inductive type, electromechanical switches, rotary
position sensors – resolver, encoders, integrated motion systems,
fundamental sensor methodologies, LVDT, RVDT, photo electric, thermo
4
electric, capacitive, magnetic detectors, impedance type gauging
transducers, linear potentiometer, strain gauges. Practical examples on
design, selection and implementation of sensor systems, calibration of
sensors.
2.2 Electrical, Hydraulic and pneumatic actuators and their comparison 2
 ROBOTICS AND AUTOMATION
3 MODULE 3

3.1 Elements of CNC systems: servomotor and servo system design trends,
stepper motors and controls, adaptive control, ball screws and guideways,
spindle, bearings and mountings. Drive systems. Automated tool changers 5
and pallet changers. Accessories, and selection of drives for CNC machines.

3.2 Material Handling and Identification Technologies: Overview of Material

Handling Systems, Principles and Design Consideration, Material Transport
5
Systems, Storage Systems, Overview of Automatic Identification Methods.

4 MODULE 4

4.1 Pneumatic/Hydraulic Automation: control valves – direction, pressure and

flow, sequential control of single /multiple actuator systems, cascade and 5
Karnaugh Veitch map methods, step-counter systems.

4.2 Electro pneumatic/electro hydraulic automation: Symbols: Basic electrical

elements – relay, solenoid, timers, pneumatic – electrical converters, 4
design of circuits and hands on models on material handling systems.
5 MODULE 5

5.1 Automation Control: Sequence control and programmable controllers –

logic control and sequencing elements, ladder diagram, PLC, programming
6
the PLC. Practical Examples on PLC ladder programming.

5.2 Inspection automation: Inspection automation, off-line and on-line

inspections, computerized coordinate measuring machine – CMM
construction, online inspection systems., laser interferometer, non-contact 6
inspection methods. Automatic gauging and size control systems, thickness
measurement, machine vision systems.

MODEL QUESTION PAPER

APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

THIRD SEMESTER B.TECH. DEGREE EXAMINATION
Course Code: RAT 282
Course Name: INTRODUCTION TO INDUSTRIAL AUTOMATION
Max. Marks: 100 Duration: 3 Hours

PART A

Answer all questions, each carries 3 marks. Marks

1 Explain the concept of part family. (3 )

 ROBOTICS AND AUTOMATION
2 Write short note on expert systems. (3 )

3 Explain the term sensitivity of a measuring instrument. (3 )

4 Differentiate between RTD and thermocouple. ( 3)

5 Briefly explain the different functions of machine tool guide ways. ( 3)

6 Explain the stick slip effect in friction guide ways. ( 3)

7 Explain cushioning in pneumatic cylinders. (3)

8 Draw the ISO symbol for single pilot operated spring offset 5/2 direction control valve. (3)

9 What are the advantages of PLC over electromechanical relay control? (3)

10 With suitable example explain latching in PLC Ladder logic. (3)

PART B

Answer any one full question, each carries14 marks.

MODULE1

11 a) With neat sketch explain different types of automated transfer lines used in an (7)
industry.

b) Discuss the nature and role of CIM elements. (7)

12 a) Explain the significance of group technology in present manufacturing scenario. (6)

b) Explain different types of FMS layout. (8)

MODULE II

13 a) Explain the construction and working of LVDT. (6)

b) Explain the working of eddy current and capacitance type proximity sensors. (8)

14 a) With neat sketches explain the working of (8)

i) resolver ii) Synchros.

b) Illustrate the configuration of gray coded absolute encoder. (6)

MODULE III

15 a) Explain the preloading of ball screws in recirculating ball screw mechanism. (6)

b) With neat sketches explain adaptive control of machine tools. (8)

16 a) Explain the different types of industrial trucks used for material handling. (8)
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b) Explain the different types of conveyors used for automated material handling. (6)

MODULE IV

17 a) Design a pneumatic circuit for A+B+ B-A-.sequencing operation using (8)

Karnaugh-Veitch method.

b) With neat sketch explain basic components of a pneumatic system. (6)

18 a) With neat sketches explain the basic electrical devices used in electro pneumatic (8)
control.

b) With a neat sketch explain the use of an on delay timer in an electro pneumatic circuit. (6)

MODULE V

19 a) Design PLC ladder logic for operating two cylinders in the sequence A+B+A-B-. (8)

b) Develop a PLC ladder program to glow three lights in sequence with a delay of 15 (6)
seconds in between. The circuit has only one switch to control the sequence.

20 a) Briefly explain coordinate measuring machine. (7)

b) Explain the scanning laser optical measurement system with a neat sketch. (7)

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