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MISSING NOTES
BOOK- (M.P Groover)
UNIT-1
- OVER VIEW OF AUTOMATION IN INDUSTRY:
Some elements of the firm's production system are likely to be automated, whereas others will be operated manually or clerically. f-or our purposes here, automation can be defined as a technology concerned with the application of mechanical, electronic, and computer-based systems 10 operate and control production. The automated elements of the production system can be separated into two categories: (1) automation of the manufacturing systems in the factory and (2) computerization of the manufacturing support systems. In modern production systems, the two categories overlap to some extent because the automated manufacturing systems operating on the factory floor are themselves often implemented by computer systems and connected to the computerized manufacturing support systems and management information system operating at the plant and enterprise levels. The term computer-integrated manufacturing issued to indicate this extensive use of computers in production systems. The two categories of automation are shown in Figure 1.6 as an overlay on Figure 1.1.
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o Batch production:
Batch of an object is processed in a sequence of steps. Each step may possess a single machine or a multiple machine. Garment manufacturers, threading operations, sheet metal jobs, forging, book parts, paints, vegetable oil etc. Most common type of production. A batch of objects (of specified sizes) is produced. Division of labor is possible.
o Mass production:
Computers, mobile phones, automobiles, soft drinks, pharmacy products etc. Specialized (SPM) are used. Involve heavy fixed cost/modern plants. Little material handling. Plant layout is designed well.
o Continuous Production:
Plant layout/process equipment is different from manufacturing unit. Safety parameters have to be high. Semi-skilled/skilled workers are employed. Material handling is automatic. Via buckets, trolleys, belt conveyers, pipelines etc.
- AUTOMATION ACHIEVEMENTS:
Automation is the technology by which a process or procedure is accomplished without human assistance. It is implemented using a program of instructions combined with a control system that executes the instructions, to automate a process power is required, both to drive the process itself and to operate the program and control system. Although automation can be applied in a wide variety of areas, it is most closely associated with the manufacturing industries. It was in the context of manufacturing that the term was originally coined by an engineering manager at Ford Motor Company in 1946 to describe the variety of automatic transfer devices and feed mechanisms that had been installed in Ford's production plants (Historical Note 3.1), It is ironic that nearly all modern applications of automation are controlled by computer technologies that were not available in 1946.
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following section. An automation migration strategy (Section 1.5.3) might be implemented for a new product that has not yet proven itself.
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7. On-line inspection, Inspection for quality of work is traditionally performed after the process is completed. This means that any poorquality product has already been produced by the time it is inspected. Incorporating inspection into the manufacturing process permits corrections to the process as the product is being made. This reduces scrap and brings the overall quality of the product closer to the nominal specifications intended by the designer. 8. Process control and optimization. This includes a wide range of control schemes intended to operate the individual processes and associated equipment more efficiently. By this strategy, the individual process times can be reduced and product quality improved. 9. Plant operations control. Whereas the previous strategy was concerned with the control of the individual manufacturing process, this strategy is concerned with control at the plant level. It attempts to manage and coordinate the aggregate operations in the plant more efficiently. Its implementation usually involves a high level of computer networking within the factory. 10. Computer-integrated manufacturing (CIM). Taking the previous strategy one level higher. We have the integration of factory operations with engineering design and the business functions of the firm; CIM involves extensive use of computer applications, computer data bases, and computer networking throughout the enterprise.
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data base and convert it into a process plan for making the product, this conversion. being done automatically by the CAD/CAM system. A large portion of the processing might be accomplished on a numerically controlled machine tool. As part of the process plan, the NC part program is generated automatically by CAD/CAM; The CAD/CAM system downloads the NC program directly to the machine tool by means of a telecommunications network. Hence, under this arrangement, product design, NC programming, and physical production are all implemented by computer.
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Continuous path systems generally refer to systems that are capable of continuous simultaneous control of two or more axes. This provides control of the tool trajectory relative to the work part. In this case, the tool performs the process while the worktable is moving, thus enabling the system to generate angular surfaces, two-dimensional curves, or three-dimensional contours in the work part. This control mode is required in many milling and turning operations. A simple twodimensional profile milling operation is shown in Figure 6.4 to illustrate continuous path control. When continuous path control is utilized to move the tool parallel to only one of the major axes of the machine tool worktable, this is called straight-cut NC. When continuous path control is used for simultaneous control of two or more axes in machining operations, the term contouring is used.
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o Coordinate measuring machine. A coordinate measuring machine (CMM) is an inspection machine used for measuring or checking dimensions of a part. The CMM has a probe that can be manipulated in three axes and Identifies when contact IS made against a pan surface. The location of the probe tip is determined by the CMM control unit. Thereby indicating some dimension on the part. Many coordinate measuring machines are programmed to perform automated inspections under NC. o Tape laying machines for polymer composites. The work head of this machine is a dispenser of uncured polymer matrix composite tape. The machine is programmed to lay the tape onto the surface of a contoured mold, following a back-and-forth and crisscross pattern to build up a required thickness. The result is a multilayered panel of the same shape as the mold. o Filament winding machines for polymer composites. This is similar to the preceding except that a filament is dipped in uncured polymer and wrapped around a rotating pattern of roughly cylindrical shape. UNIT-3 PREPARATORY G-CODES, MISCELLANOUS M-FUNCn CODES, COMMON WORD PREFIXES.
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