MCE 439 Computer Integrated

Manufacturing
Assignment # 3
1. Prepare an NC part program for the part shown. The dimensions given in the
figure are in mm. The tool diameter is 20 mm. (3 pts)

2. The positioning table for a component insertion machine uses a stepping motor and lead screw
mechanism. The design specifications require a table speed of 0.4 m/s and an accuracy = 0.02 mm.
The pitch of the lead screw = 5.0 mm, and the gear ratio = 2:1 (2 turns of the motor for each turn of
the lead screw). The mechanical errors in the motor, gear box, lead screw, and table connection are
characterized by a normal distribution with standard deviation = 0.0025 mm. Determine (a) the
minimum number of step angles in the stepping motor and (b) frequency of the pulse train required
to drive the table at the desired maximum speed.
3. Using the notation scheme for defining manipulator configurations , draw diagram of the following
robot: (a) TRT:R,
4. The linear joint (type L) of a certain industrial robot is actuated by a piston mechanism. The length
of the joint when fully retracted is 600 mm and when fully extended is 1000 mm. If the robot's
controller has an 8-bit storage capacity, determine the control resolution for this robot.
5. A flexible manufacturing system is being planned. It has a ladder layout as pictured in Figure P10.1
and uses a rail guided vehicle system to move parts between stations in the layout. All workparts are
loaded into the system at station 1, moved to one of three processing stations (2, 3, or 4), and then
brought back to station 1 for unloading. Once loaded onto its RGV, each workpart stays onboard the
vehicle throughout its time in the FMS. Load and unload times at station 1 are each 1.0 min.
Processing times at other stations are: 5.0 min at station 2, 7.0 min at station 3, and 9.0 min at
station 4. Hourly production of parts through the system is: 7 parts through station 2, 6 parts through
station 3, and 5 parts through station 4. (a) Develop the from-to Chart for trips and distances using
1

MCE 439 Computer Integrated

Manufacturing
Assignment # 3
the same format as Table 10.5. (b) Develop the network diagram for this data similar to Figure
10.13. (c) Determine the number of rail guided vehicles that are needed to meet the requirements of
the flexible manufacturing system, if vehicle speed = 60 m/min and the anticipated traffic factor =
0.85. Assume reliability = 100%.
6. An automated guided vehicle system is being planned for a warehouse complex. The AGVS will be
a driverless train system, and each train will consist of the towing vehicle plus four carts. Speed of
the trains will be 160 ft/min. Only the pulled carts carry loads. The average loaded travel distance
per delivery cycle is 2000 ft and empty travel distance is the same. Anticipated travel factor = 0.95.
Assume reliability = 1.0. The load handling time per train per delivery is expected to be 10 min. If
the requirements on the AGVS are 25 cart loads per hour, determine the number of trains required.
7. A closed loop overhead conveyor must be designed to deliver parts from one load station to one
unload station. The specified flow rate of parts that must be delivered between the two stations is
300 parts per hour. The conveyor has carriers spaced at a center-to-center distance that is to be
determined. Each carrier holds one part. Forward and return loops will each be 90 m long.
Conveyor speed = 0.5 m/s. Times to load and unload parts at the respective stations are each = 12 s.
Is the system feasible and if so, what is the appropriate number of carriers and spacing between
carriers that will achieve the specified flow rate?
8. An AS/RS is used for work-in-process storage in a manufacturing facility. The AS/RS has five
aisles, each aisle being 120 ft long and 40 ft high. The horizontal and vertical speeds of the S/R
machine are 400 ft/min and 50 ft/min, respectively. The S/R machine requires 12 sec to accomplish
a pick and deposit operation. The number of single command cycles equals the number of dual
command cycles. If the requirement is that the AS/RS must have a throughput rate of 200 S/R
transactions per hour during periods of peak activity, will the AS/RS satisfy this requirement? If so,
what is the utilization of the AS/RS during peak hours.