1.

From this module and from general knowledge, list 5 modern

trends in production technology

1. Enterprise-wide/increased automation
2. Automatic data capture and parts tracking
3. Use of distributed numerical control machines
4. Increased use of industrial robots
5. Use of AI/Intelligent /machine learning systems in decision making
6. Emphasis on green/sustainable technology/manufacturing
7. Shortage of semi-conductor circuits due to excessive demand
8. Use of smart factories/IOT
9. Rising labour costs

1
As technology moves towards full enterprise-wide automation of
industrial processes using NC, robotics, RFID, and AI – is there a
future for humans in manufacturing? Articulate your response in 5
points
Humans will always be needed in the future to satisfy the following:
1. Even automatic intelligent equipment need maintenance – humans will like continue to do that
2. People will still be needed to supervise the programming and performance of AI systems
3. Plant management – humans are needed to supervisor and report on plant operations
4. Some operation outputs require human judgement – eg final touches and inspection of assembled vehicles
5. Where part of the product requires creativity – artistic creations
6. Some manufactured products need to be assessed for complying with human ethics – human beings will be
doing the assessments

2
List 10 types of process parameters/variables that sensors might
monitor in industrial control systems.
1. light, infrared, lidar, radar
2. temperature, thermal
3. vibration/sound,
4. chemical,
5. motion,
6. touch,
7. pressure,
8. position,
9. force, and
10. proximity

3
Briefly explain why we always need converters in industrial control
systems.

Some Input parameters and output variables of a process are continuous/analog (eg vibration,
temperature, mass, ). We need to convert these continuous signals from sensors into digital signals so
electronic circuits may be able to process them. We often then need to back-convert the processed
digital signals into analog so we can adjust process input parameters.

4
As a young trainee engineer at a company that is considering
investing in CNC technology, state 5 back-of-the-envelope talking
points to pitch to senior management why the company should go
ahead with the investment.
1. To increase the production volume
2. Reducing variability in the machining of components – consistency
3. Does not require highly skilled machinists
4. To produce expensive parts
5. Requires many operations on a single part
6. Cost-effective for producing parts that are required again and again (repeat orders)

5
Why should a machine shop doing jobbing processes avoid
investing in CNC machines? Give 5 reasons.

1. Jobbing processes result in excessive setup times

2. Higher investment cost -CNC machines are more expensive
3. Higher maintenance effort -CNC machines are more technologically sophisticated
4. Need for skilled programmers
5. Time investment for each new part
6. Higher utilization is required

6
Differentiate computer-assisted part programming and part
programming using CAD/CAM systems.
Computer-assisted part programming Part programming using CAD/CAM
Requires the programmer to provide part Only requires the user to provide a 3D solid model of
geometry, tool path, tool offsets and other component from a CAD/CAM file (such as Autodesk
machining functions like feed rate, depth of cut Inventor) – and the software package does the rest.
and speed, tool type – the software package such User may manually edit/adjust final Part
as APT does the rest programming to suit.
Requires a good appreciation of the machining Does not require any experience in machining
processes and steps on manual machines
Works only for parts with moderate details and Is ideal for parts with complex geometries
complexity
Does not involve visual feedback of machining Involves visual feedback of machining steps while
steps while programming programming

7
Manual Data Input

• Machine operator does part programming at machine

• Operator enters program by responding to prompts and questions by system
• Monitor with graphics verifies tool path
• Usually for relatively simple parts
• Ideal for small shop that cannot afford a part programming staff
• To minimize changeover time, system should allow programming of next job while current job is running

8
What are the six degrees of freedom of robot dynamics?

• Three linear translations along the X, Y and Z axes, and

• Three rotational motions about the X, Y and Z axes

9
Sketch body-and-arm robot configurations that sweep a spherical,
cylindrical and rectangular volume

• Spherical – twisting, rotation, and translation joint motion

• Cylindrical – twisting, orthogonal and translation joint motion
• Rectangular – translation, orthogonal and orthogonal joint motion

Joint motion is given from the base to the end-effector

10
Sketch body-and-arm robot configurations for jointed-arm and
SCARA configurations

• Jointed-arm – twisting, rotation, and rotation joint motion

• SCARA – revolving, rotation and orthogonal joint motion

11
What are some 5 typical industrial uses of a SCARA Robot?

1. Placement of electronics circuit components on

board
2. Filling/packaging of open containers
3. Drilling/painting/welding on flat work surfaces
4. Pharmaceutical processes
5. Stamping/3D-printing

12
Select all the joint movements we can have on a robot wrist
configuration

• Linear (L)
• Revolve (V)
• Rotate (R)
• Twist (T)
• Orthogonal (O)

13
Joint Drive Systems

• Electric
• Uses electric motors to actuate individual joints
• Preferred drive system in today's robots
• Hydraulic
• Uses hydraulic pistons and rotary vane actuators
• Noted for their high power and lift capacity
• Pneumatic
• Typically limited to smaller robots and simple material transfer applications

14
If a robot has a two-finger gripper, what will be the main function of
the robot?

• WIP handling, manipulation, transportation & picking and placing

15
For a precision CNC servo-grinding machine, what are some of the
sensors that could be used to control the process? Give 4 types and
a reason for each.
Thermal sensor – to measure and regulate the temperatures of WIP or grinding surface during operation
Vibration sensor – to measure and regulate amount of vibration to attain precision in grinding
Position sensor – so that workpart does not shift position
Force sensor – to measure and regulate the amount of spindle/workpart deflection/deformation

16
Provide 5 reasons for adopting the use of robots in a typical
production company

1. Hazardous work environment for humans

2. To handle repetitive operations
3. Tasks that are too complex for humans – eg precision working in low light
4. Minimizing machine operator inconsistencies
5. When high production volumes are required

17
Explain how a courier/ parcel delivery company may use robots

1. Inspection/scanning for prohibited substances and explosives

2. Sorting/labeling/packaging
3. Tracking device installation and shelving/storage
4. Transportation to different facilities for local and international freighting
5. Drone delivery

18
Give 5 challenges that could discourage the adoption of robots in a
manufacturing company in South Africa? -

1. Limited availability of local programmer/maintenance skills for the robots

2. High initial cost of robots require large demand of the products – which may not be there locally
3. Load-shedding may reduce robot utilization, which may result in prohibitively high cost-to-benefit ratio
4. Changes to labour needs brought about by using robots may be resisted by workers and unions
5. There may not be many other companies already using robots from which to learn and benchmark
6. There are no local manufacturers of robots – importation and maintenance costs may be too high

19
Explain to a non-engineer friend 3 differences and 3 similarities
between CNC and robotics technology
CNC ROBOTS

Differences WIP is usually processed from a fixed position WIP is usually moved and manipulated during processing

Operator usually needed to perform some manual Operator usually not needed during the entire process
steps during processing
CNC Machines have limited access and Robots can access hard-to-reach areas during processing
maneuverability on parts
Programming CNC machines is much easier – uses Programming robots takes much more time – usually requires
part programming codes some robot teaching/training techniques
Similarities Both require sensors and control systems

Both can attain high precision in operation

Can both produce high volumes of product

Have some PLC

20