Manufacturing system Advantages of using electrical power in an automated system

A manufacturing system can be defined as a collection of

equipment and human resources which are involved in the • clean and green energy
process of producing the final product from the raw material. • Widely available energy
• Conversion of electrical energy to other forms is easier
• Controlling and monitoring electrical energy is easier
• Can be used at very low power levels for functions
The three basic components of an automated system • Can be stored in long-life batteries
(1) power
(2) a program of instructions Two types of control system
(3) a control system
(a) Closed loop system
(b) Open loop system
Examples of activities that require electrical power

(1) melting a metal in a casting operation.

(2) driving the motions of a cutting tool relative to a
workpiece in a machining operation.
(3) pressing and sintering parts in a powder metallurgy
process.
 The three basic types of automated systems

(1) Fixed automation :

processing or assembly steps and their sequence are fixed by the (2) Programmable automation:
equipment configuration. the capability to change the program of instructions to allow
production of different parts or products.
Advantages:
Advantages:
• high initial investment for specialized equipment • High investment in general purpose equipment that can be
• high production rates reprogrammed.
• Lower production rates than fixed automation.
• little or no flexibility to accommodate product variety. • Ability to cope with product variety by reprogramming the
equipment.
• Suitability for batch production of various part or product
(3) Flexible automation: styles.
extension of programmable automation in which there
is virtually no lost production time for setup changes and/or
reprogramming.

Advantages:
• High investment cost for custom engineered equipment
• Medium production rates
• Continuous production of different part or product styles.
 SENSOR
A device that converts a physical stimulus or variable of interest into a more
convenient physical form for the purpose of measuring the variable.
Types of sensors: Types of stimulus:
• Mechanical
1. Analog sensor : measures a continuous analog variable and • Electrical
converts it into a continuous signal such as electrical • Thermal
voltage. • Radiation
• Magnetic
2. Discrete sensor : produces a signal that can have only a • Chemical variables
limited number of values.

3. Binary sensor : can take on only two possible values.

4. digital sensor : produces a digital output signal, in the form

of parallel status bits.
 ACTUATORS

A device that converts a control signal into a physical action.

Types of amplifiers: Contact input interface:

(1) Electrical A device that reads binary data into the computer from an
(2) Hydraulic external source.
(3) pneumatic.
Contact output interface:
A device used to communicate on/off signals from the computer
to external binary components.

Pulse counter:
A device that converts a series of pulses from an external
source into a digital value.

Pulse generator:
A device that produces a series of electrical pulses based on
digital values generated by a control computer.
 Programmable Logic Controller (PLC)
A microcomputer-based controller that uses stored instructions in
programmable memory to implement logic, sequencing, timing,
counting, and arithmetic control functions, through digital or analog
modules, for controlling various machines and processes.

Components of a PLC:
• Input and output modules
• Processor
• PLC memory
• Power supply
• Programming device

Advantages of programmable logic controllers:

• Programing a PLC is easier than wiring a relay control panel.
• PLCs can be reprogrammed.
• A PLC can be interfaced with the plant computer system.
more readily than conventional controls.
• PLCs require less floor space than relay controls.
• PLCs offer greater reliability and easier maintenance.
The main components of an integrated manufacturing system Types of material transport equipment
(1) Workstations and/or machines. (1) Industrial trucks.
(2) material handling equipment. (2) Automated guided vehicles.
(3) Computer control. (3) Rail-guided vehicles.
(4) Conveyors.
MATERIALHANDLING (5) Hoists and cranes.
the movement, storage, protection and control of materials throughout the
manufacturing and distribution process.

The principal material handling functions in manufacturing

(1) Loading and positioning work units at each workstation. (2)
(2) Unloading work units from the station.
(3) Transporting work units between workstations.

Material handling equipment and methods (1)

(4)
(1) Material transport.
(2) Storage. Storage systems
(3) Unitizing. (1) Conventional storage methods and equipment.
(2) Automated storage systems.
Fixed routing:
All the work units are moved through the same sequence of stations. Types of plant layout
Variable routing: (1) Fixed position layout. (3) Cellular layout
different work units are moved through different workstation sequences. (2) Process layout. (4) Product layout.
Production line METHODS OF WORK TRANSPORT
(1) Manual Methods of Work Transport:
Consists of a series of workstations arranged so that the product Manual methods involve passing the work units between stations by
moves from one station to the next. hand.

(2) Mechanized Methods of Work Transport:

Powered mechanical systems are commonly used to move work units
along a production line.
How manual methods are used to move parts between
workstations on a production line
Types of product model lines: When the task is finished at each station, the worker simply pushes the
unit toward the downstream station.
(1) Single model line:
Produces only one model, and there is no variation in the model.
Types of work transfer systems:
(2) batch model line: (1) Continuous transfer: consist of a continuously moving conveyor that
Produces each model in batches. operates at a constant velocity.

(3) mixed model line: (2) Synchronous transfer: work units are simultaneously moved
produces multiple models, the models are intermixed on the same line between stations with a quick, discontinuous motion. also known by the
rather than being produced in batches. name intermittent transfer
Manual assembly line (3) asynchronous transfer: allows each work unit to depart its current
Consists of multiple workstations arranged sequentially, at which station when processing has been completed. Each unit moves
assembly operations are performed by human workers. independently, rather than synchronously.
n=number of workstations on the line (w=n if M=1)
w= actual number of workers
Tc= ideal cycle time on the line

Ts= the longest service time on the line

Tr= repositioning time; (s) (change to min)

Tsi= the service time at station (i)

Or
Td= average time the line is down when a breakdown occurs.
F= downtime frequency, line stops/cycle
Tp= the actual average production time; min

FTd= average downtime per cycle

Hourly production rate; Rp= 60/Tp; units/hr

The ideal production rate ; Rc= 60/Tc; units/hr

Da= annual demand for the product; units/yr

Sw= number of shifts/wk, Hsh = hr/shift , wmin= the minimum possible number of workers.

Twc= work content time; min

(E) The line efficiency, Eb= balancing efficiency

pi = probability or frequency of a failure at station i

 (c)
(a) 𝑤 47
𝑛= = =33 . 571 𝑤𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠
𝑀 1.4

(b) ,

42
¿ 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐼𝑛𝑡𝑒𝑔𝑒𝑟 ≥ =47 𝑤𝑜𝑟𝑘𝑒𝑟𝑠
0 . 9912 ×0 .92
 60 × 0.95
¿ =1.14 𝑚𝑖𝑛
50
-

25.9
¿ 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐼𝑛𝑡𝑒𝑔𝑒𝑟 ≥ =27 𝑤𝑜𝑟𝑘𝑒𝑟𝑠
1.04 × 0.93
 60
(a) ¿ =1.875 𝑚𝑖𝑛
32 (b) 𝑤 = 𝑀 × 𝑛=24 ×1.25=30 𝑤𝑜𝑟
60 60 𝑇 𝑟 =0.08 𝑇 𝑐
𝑇 𝑐= = =1.781𝑚𝑖𝑛
𝑅𝑐 33.684

1.781
¿ 47.8
1.875
(c) ¿
𝐸 =0.95 30 × 1.63852
 (a)

60
¿ 𝑇 𝑚𝑖𝑛
=1 𝑐 =𝑇 𝑝 × 𝐸 =1 ×
60
𝑇 𝑐 =0 . 95 𝑚
𝑇 𝑠 =𝑇 𝑐 − 𝑇 𝑟 =0 .95 − 0 . 15=0 . 8 𝑚
930 𝑤 1250
(b) ¿ 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐼𝑛𝑡𝑒𝑔𝑒𝑟 ≥
0 . 8 × 0 . 93
𝑛=
=1250 𝑤𝑜𝑟𝑘𝑒𝑟𝑠
𝑀
=
2.5
=500 𝑤𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛
 60 × 1
¿
(a) 30
(b)
𝑐 =2 𝑚𝑖𝑛
50
¿ 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐼𝑛𝑡𝑒𝑔𝑒𝑟 ≥ =28 𝑤𝑜
1 . 85× 1
𝑤 28
𝑛= = =19 𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠
𝑀 1 .5
 (a) (b)

¿ 1.5 + 0.16 × 10
𝑃 =3.1 𝑚𝑖𝑛
 (b)
(a)

¿ 0.41 + 0.0833
=0.4933 𝑚𝑖𝑛
¿ 0.4933 +0.075 × 3
=0. 7183 𝑚𝑖𝑛
 2
𝑚 −6 𝑚
𝑧 1 =100 𝑚 , 𝑧 2= 0 , 𝑔=9 . 8 2 , 𝑣 =10 , 𝐷 =0 . 3 𝑚 , 𝐿=1000 𝑚 , 𝜀= 0 . 0001 𝑚
𝑠 𝑠

1 . 𝐹𝑖𝑛𝑑 𝑄 𝑢𝑠𝑖𝑛𝑔 𝑡 h 𝑒 𝐷𝑎𝑟𝑐𝑦 −𝑊𝑒𝑖𝑠𝑏𝑎𝑐 h 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛

𝐴𝑠𝑠𝑢𝑚𝑖𝑛𝑔 𝑓 = 0 . 02

2 . 𝐹𝑖𝑛𝑑 𝑅𝑒
4 ×𝑄 4 ×0 . 383 6
𝑅𝑒= = =3 . 54 ×10
𝜋 × 𝐷× 𝑣 𝜋 ×0 .3 × 10−6

3 . 𝐹𝑖𝑛𝑑 𝑡 h 𝑒𝑛𝑒𝑤 𝑓 𝑢𝑠𝑖𝑛𝑔 𝑇 h 𝑒 𝐶𝑜𝑙𝑒𝑏𝑟𝑜𝑜𝑘−𝑊 h 𝑖𝑡𝑒 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛

𝑓 =0 . 01549
1 . 𝐹𝑖𝑛𝑑 𝑡 h 𝑒𝑛𝑒𝑤 𝑄

2 . 𝐹𝑖𝑛𝑑 𝑅𝑒
4 ×𝑄 4 × 0 . 435 6
𝑅𝑒= = =1. 846 × 10
𝜋 × 𝐷× 𝑣 𝜋 × 0 .3 × 10
−6

3 . 𝐶 h 𝑒𝑐𝑘 𝑓𝑜𝑟 𝑐𝑙𝑜𝑠𝑢𝑒𝑟

1
√𝑓
=−2 ×
𝜀
( +
2 .51
3 .7 × 𝐷 𝑅𝑒× √ 𝑓 )
, 𝑤 h 𝑒𝑟𝑒𝑡 h 𝑒 𝐿𝐻𝑆𝑖𝑠
1
√𝑓
𝐴𝑛𝑑 𝑡 h 𝑒 𝑅𝐻𝑆 𝑖𝑠 −2 ×
𝜀
+
2.
3 . 7 × 𝐷 𝑅𝑒× (
𝐿𝐻𝑆=
1
√ 0 . 01549
=8 𝑅𝐻𝑆=−2 ×
( 0 . 0001
+
2 . 51
)
3 .7 ×0 . 3 3 .54 ×10 6 × √ 0 . 01549
=8

3
𝑚
𝑐𝑙𝑜𝑠𝑢𝑒𝑟 = 𝐿𝐻𝑆− 𝑅𝐻𝑆=8 − 8=0 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒=0 . 435
s