Chapter No.

07

Computer Aided Quality

rr+ q"pr qbs-!qap!E$&r-qg4'E cglg-olg{ $gf

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rh

conrrol or cAQC. The tv,'o major Firu orqualiry conrrol are

and testing, which are traditionally performed manually with the hei;
measuring devices and the tesrihg appararus. The two .rjor pa:-ts of cori.rp
qualiry control are computer Aided Inspection (cAI) and computer Aida
(Uf),CAl and CAT are performed by using
-$g _la1es! compute! and sensor :e
-c-Al and CAT are.the standalone systems and without them the full potentlacannot be ach!eved.

The rnain cibjectives c'f the

C.a.QC

a:c

1. to improve the qualiry of the product,

2. to increase t}e productiviry in the.inspecrion process
3. to reduce the lead times in rnanufacturing.

and

1. Important Points and Advantages of CAeC

Here are the advantages and the highlights of the computer ajded qualiq.

process:

7.

lOAo/o

testing and Inspecdon:

In the traditional manual process the testing and inspection is dont

sampling process out of tJ:e hundreds and thousands of products ::
manufactured by the company since it is not feasible to chelk each a:::
producl lvith cAI and cAT hundred percent inspecfion and tesring :
acccmplished without much difficulry. with 1000/o inspection the compa--1
not have to depend on statistical quality control nrethod in which it is a..
that anything less than 1000/6 of qualiry is acceptable. tvith compurer cc::
inspectic'n. it is not necessary for the qualig,' conti-ol departrrrent tc sertle ::
than perfection.
2. Inspection integrated

r+'ith manufacturing process:

Jn the traditional process there is separate quatiry contr-ol department r4,h:-r

manufactured product is taken for the inspection and testing. In cAiinspection process js integratcri rvith ihe'manufacturing process and it is i
along the production line. Tirus as soon as the product is manufacture:
tested immediately by the computerized process without moving it to some
location. This helps in recucing the overall tirne requilec fc: manrifactun:
producL

3.

Use

ofnon-contact sensors:

In the traditional process the product or the pai-i to be inspected js ha:

manuall,v since it has io be positfoned properl-i, for inspection on the de:r

suitable location. In CAQC non-contact sensc:s are used fcr rhe rnsc:

purpcse and

th.f

inspect the prcduc: i..'ithour comin:

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Chapter No, rI

. Cunre Representatiuns

Represcntation of curve i:eomeiry can bc carricd out in

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points. rhe ro ur brendins

futing n = 3 into EqtraA.on

BEZajfu)

=(l -u)-'

BEZ'@)=3u(1 -u)2
BEZsfu)=3u2('l - u)

Q r"(ul

At:lul
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0.8
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lc)

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I

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The four Bzier blending functions

for cubic curves (n 3).,r,
=

the orrry nonzero bl."ndi"g'_lnctionis

,64r,v;hich

has

t,re varue i. At u
= I, the
u"il.;;;'";;ue!rt
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;'-'trr,ffi;i :ixi*Jil'l"f r;;idl:iH"

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p; ir,"

r,"..

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at intermediate

il;;'i;*ii*#il1*Jt':iie6'i",;;ls

.:"'""4iili-.;T:uf:'{ry:lJ n"'.
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th-t*jyr'-e i'jll uu.n"cJide to

do not ario* roi /..rrl

reposition an-r' one
of rl

NP

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CURVE

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td

We can write a general expression for the'calculation of coordinate

along a B+pline curve in a blending-function formulation as

ontrol
rubsti-

\r\u) = LPt
t-0

D17\u),

u-i"<uSu*r,

2<dSu+1

v"here the p1 are an input set of n + I conirol points. There

sevet'r,l ,l;:r. , ;-695
"=.rr:
beiween this B-spline formulahion and that for Bzier splines. fhe rai,r'e r,f iierameter lr now depends on how rt'e choose the Fspline parameters. ';iir I Bt.er
.spllne blending functions Bga are poll'nomials of degree d - l, r*h',:, lrr;
rJ can be chosen to be any integer value in the range from 2 up tc ti ;',i]:
cf
confrol poinls, n * 1,.(Actually, r+'e can also set the value o{ i al I, ;,t :i
u:-

"cun'e" is just a point plot of the control points.) l,ocal ccntrol fr'r'
,'
',.,
'
,'
achieved by defining the blenciing hrnctioru over subintervai:. t,I ti

lie

of u.

:he

,n

Blending functions for B-spline cun'es are defined bv tlre

:ursion formuias:

nr.,trt =
Btzfu)

ll'

u:r=1 (

Co>,. ijeii.;',

ur+r

othent'ise

[0,
u u^
-..

U1.4-1 - U1

Di.a-1(u)

+ uL*d- tt
HI*d - llt*t

81.,.a-1(rr)

x'here each blending function is defned over d subintervals af thr: totai

r;',,

Figure
desronstrates the local-control characterisfics of B*pl
rddition to local control, B-sBlirres allor+'us to vary the nurnbei (,1 coniro' ,,.,
used to design a curve without changing the degree of the polynomial. A!'r',
iunber of conh'ol poi.!',ts can be added or modfied to manipulaie cun'e s,;,iy:'i
r

a B-spline ctrn'e Changing on of the contlol pr'inl.r i:i i;.i

ro), rvhich is modified onif in the neighborhoo,i of the altered q6ptu6r| lrlirri

-.:.-:l r.cJification of

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Px*t

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Chapter No. tz

I,r-,i-rr

982i

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computer rntegrated. Manur,.a.rftrring

Conrputer integrated manufacturing includes all of the enginecrir' {::,:''sisp5 s1

CAD/CAM. but it also includes lhe firm's business functions that are rri...r -j i.'rnanufacturing.The idcal Cllr'l systcm applies computer andcommunicalions 1.,-:i; xr:r..;ty to all crf
'
the operational funclions and information processing functions in rr',, . -,:lring frorrr
order receipl. through design and producrion. to product shipment. i,,* , -,i-,- of Cf t'{.
cc mpared

u'ilh the more limited scooe of CAD/CAI',I. is depicred in Frg*re 1

'-

of CAD/CAM

)z fq
n

L'!'K

L,

L)

Eusiness
funct ions

h.'rVe cf.e^:

"q
Figure

ll.+

The scope of CAD/CAN{ and CI}v{.

The CIlrl concepl is that alt c,f the firm's operations

reiated to producrion are i'corporaled in an integraled cornputer svstem.
to
augment, and automate the oprdtions
Tlie computer sYstem is pervasive throughour"rrirt,
rhe firri, touching all activities thJt su;,port
n-'enufacturing' ln this integrared computer
system, the output of one activitv serves as
the
rnPUt to the next activity,through the
chain of events that slarts with the sales order
and
culrninates wilh shipmenr of the-product.The
components uiii,. in,.gr*ted cornpure!-svstem are i!lustrated in Fieure 2 .
custom:r orders are initially enteretj by the compir3ir,:,5
sales force or directrl'b;- rhe cusromer
into a computerized qrder entry s,isr:r.:,ri ;'h r:, ,rrrs
con(ain the specifications describing
rhe product. ri,. ip..iiications serr,c ;t, , .
i, , io
ihe product design department. Nei,producls
ar O"rign.J-on a CAD,s.!sl.;irr. l,j;, i,TtPonenls that comprise the product are designed, th bifr
of-materials is ccri.lr:,i!r:::1. ;,i as_
s:mbl-r dra*ings are prep3red..The
ourpur
.i.rig;;;;;;r."t
,.**,
;,
rnanufac.turing engineering. x'here
pro..r. "i,rr.
pranning, r"ror olrign, and sin"r;r
:
,
accomplished to prepare for pro,Juclion,
Many of these n,rnu?r.,rring eiii.,, ,
j.
,,
rrle s ai'e suop"oried b-v the
crh{ system. process pranning is performed usinl,
j,, },:
:jXtUredesignisdoneonaCADs,\'stem.makingu,.o7tn.p,oou.tmodell".

l:"["".::j5:':l'|"o1tpYtfrommanuf,.tuiing.ngin...,i.,g.i'"'li?.,'.
':uctron
planning and conrror, *'here rnareriar
fLnn;ng anc ir,
::' ic'rmed usinq the.computer system. And so ,.qiir.l..,.nl,
it goes, rhrough each step in th,.
ettt i;pt.re;ra
{ resutrs in rhe auromarion of the ini,:,rr, ,.
:ll:_:t':l:
-'rough sver) aspect
of the c_omp.n;* o

r'of. S;

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CAD
Gcomctric modcling
Enginccring analy:is

rnd evaluation
Autornatcddrrfiing
Dcsign review

CAM

Computcrizcd
Busi;css Systc m:
Ordcr cntry
Accounting
Pzytol)

Cost cstination

CAPP
NC part programming
Compulcrizcd uork stds
MRP. capacitv planning

Customcr billing

cdtrl

control
Proccss raooitoring
Shop floor oonnol
Cornputcr-rided inspcction
Procass

Computerizcd elements of a CIM system.

l-1otc,.ict - Hoc'Et,-.3 S5a tc-"'' s

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\J

Gttb t nc,te,d ft161 t c,t{ oL -hq r.,d lrrs s!Slc"^-s ahat

$ cr'cro r15 LrSc.d i n odvq ., ce d oront f actu ring

i R^b",_^;;J e.^r j_a v-",,;

CaG;;r)

1 aRobots
rii ftrrbor.\ated s toeogc g Q-tricwa t Sys
f

,cref. Sa,rrie,v'98f ? 74 .4SSC

f a
I
\
L;
-r'KsJ

are
q rc

| 9E2fir41855

Adrnission Details at

Automated Guidecl n'*taicle's

Chapter No, t3
An auromatcd guiaer! vehiclr

s.r'stettt

(AGVS)

is a

rnatcrill

h,rr..1

' ' .:', :,.n1 lltirl tr:cs

:

. . :.,.,.ii :...l-hc r.uhi_

dr'
indepcndc n t ty opera{cd. sel f-propc I lcd
clcs arc p<-i*'ered hy on-hoard baltcrics that;rlk'rw fltany htlttrs ^f '- I ,llrrn tS. ltr lrr is
. r" i\/5" i'1rtDp.rt
Crl
typical) hcforc nccding lo hc rcch;rrgcd. A Cistinruishirtg fcntul
!.'\'ii.\'{ ili(. unr .}h.
to raii-guidcr'l vchiclc systcnrs lrnd trtttsI d(]tlvcvr]rs]";lr-'nt-s. is tlt;r: .r
trusive. An ACVS is appropri;rtr: lr'hcre diiiercr:t nralcrittl.s aru mr)\ - ': {}r!1 \':lri(}us lu:trl
points to various unload points. Art A(iVS is thercforc suitlhlr: for.,., irritl;,11rtu tn:rlct r:rl
handling in batch produclion irnd nrirc:i n:udcl production
vefr iclc-s

fl)
-_-l

I
I

Types

of Vehicles. Aulorlrrlci.l

guidcd alottg

.:.:uitJc.l vchiclc-s c:tn

r.

;.

ht dilitJ.,',i ;trio thc

lhree cateqories: (l)drivcrluss trains. (;) p;ille t trucks. urd (.1) uitit lt'r:i
in Frgul'c 10.-5. F. rjii'.'erlcss train consisis of it lowing rchiclc (the A(,

r-,8.
sloJ.

'inl-l

li:llqru.i nt

ji fii.r-s. illustrlrt c.J

",1

irullinc ()n..' {!r

I
I
I

P;'llrt
Priicl f,rkr

0'\
Pi;.r

hunld

z-

DO

j--

Rrrllsr dcck for

srtjc Inadint

Dr;r a * naa,a
t.

(c)

L(s

iigure !0.5 ff,rrc lvp:s of iiirirrrrrtcd 1:rritl'-'tl ,,chiclc.s: {;r i J:i..'

i\ 1:.1i1q1 lrucl .;rn,j (c) urrri i,,,;; .,,r.

.-{1-rt(',;i;ri:ij:uiiir.d tr;irn. (h).A(

i-rrorc {;::rleis t()

qte
Qt6 :

':

fdrnt:r train. as in Fjeurc 10.-5(;r). lt r*,as the fi:.si i ,,

inlr.iiuccd arrJ is srillu'idcl; usctJ r.da\'.A c.r'n.r'r.n appricutiort ;.-, ,;,,
()!'dr Ioi,q distan;c.s in r-.arch<.iuss.J Li!- fitct()rie: with or s.ithoui !!:::. ,r,
(tr(ri)^1,11 fr.irls al<rng thc r,urc. For trains consisting .f
fi'c {. l()} ti::; :,
Cie nl tr;trisport s\'Slcn.l.
Ar.;t.n-rlrtcd guitJecJ pnllet irucks. [-lgure i(i.-)(il).,rc uscti lo I.i..,,,]
irirrir'1 F:.rJ.lcr;.-tilc:-l i-()ulcs. J:r tl-,u ii1:i;li appiicati<.rn the'r:iiici,i,rl:r.lc,J p.rll..'t h-r';, hurit::n rr'(r;-kcr'\\'h,.):ilccrs lhe tfucf: artd uSes rr.

|tl;i.Jsii.:itil-r'.l.iicltiherrtlr!ercrives{ircpal|eilruck|ol|ietuit.ict:.i
ii:: r'.iricic Di-{;,ae c(i,i i;ui,rntaticell! ti) ll:c desliirali,
C.l 1';:cri.' i;{ ,11,. ..\i-l\'5
l';rJi..t irr..rCii iiiii_!i('5 U;t t(l srtYcr;rJ lh0u:;iiiii.i n,. :1,.
iir.ri.'lii .ii-r c;lpai:ii oi h;rnJjint l'.r'.; plliic{s ratli,_.r lli;rii orrc. .A iiti.,i.
r':llrtr-i il ihr 1i::r'l r:Lrci. is il:c j.'.rri. li:'r ,i6it -[lris ve l:ii]i ciur l,ch,..-.,i-,,i.1,;
: -' ' ..1 ,,.
eicsiin:rtirrr:.li;rJ

Prcf. Sanjti, 9B1g 7t.ISS0

Ai, t/$ 111 5..

:' .. lta.r,loads
, i,ir i: up and
I l( rjrt ellt-

l:; ja,

i iO:dS

i',jo th3
il';r:i:11i3
;' i:iIliS ilS
'ii',,1 i'f,.
, ,ri : llitc
, ',i..1iilt
ri,.i:i-tiaill
1

A(iV unit lttari carricrs arc used to nrovc unit lu;rJs frurn tinc statlon lo z
-ihc1,@utomalic|oadinganrJunitladingofpa||ersorlotc:
mcens of pclwcrcd rollers. nroving bcltr:. mechanize,J Iilt plariurms, cr or.hcr
rJcrrc_
intothcvehiclcdcck.Atypical unirloadAG\/is jllusrrarcc! irrFigure it,).-5(c). \te.riz
urlil lo:rd curr.icrs jnclude light load AGVs and assenrblr, line aCt's.'fhe ligirr l'a_
is ;r.relai:r.cl.,'small vehicle *,ith Correspr_rndin3 liihr l,r;rJ capac;t,",{r;pi;il;;
2,.
lc_ss ).

Gqiaan.ce rechnotoov. The guidance sysrcrn is rhe rncrho,J hr

are defincJJnElEEllles are conrrolled ro follow rr,. p",n";".ri
sectionl'*'e ors'-rlss lhrec tcchnologie.s that are used in commcrcial
:ystcms for
guidance: (l) imb.ddcd guidc x,ircs. (2) painr srrios. and
{T scrf.guidcJ ,,..r.,j.i"the- jrnbcdded Euidc u'irc mct,lttfi, elcctriccl rrircs are pleccd
in a -.;n:alj .-h:r.-.tnto tire surf ace of the floor. Thc channcr is tpica,|iy 1-r2 nrn
{r|:'.*},2 in,r s 13. an,J 1i_
(1n-|.0 in) deep.After the guide x'ire is inirallcd, rhe channel is filied r.r,iih
cemenr tc
nate the discontinuity in the flcnr surface.The suide \aire is cr_rnnected
ro a frequenq ;
ator, $'hich emi6 a lo*'-vohagc, lo*'-currcnt signal wirh a frcquenc'in
rhe range l_i-<
This induces a magnetic iielcl along the pathway that can b,e foJlo*,ed
by sensors on '
each vchicle.The operation of a t;picat s1rt(rm is illrrstratedin
Figurc l0.6.Tr'o SCfisrrris i

l)^-.Y:ni/e
Acvs
Pathwa)'s

AvCJ

F-loor

(: ui.Je
u.jt c

E li:t'r rOt;ragnc

I,

fre iiJ

Figure 10.6 opcration of ihe on-boa:-<J Scnsors!.srein

coiis tc, tracl: tlre n-lignetic JiclC in the
ui:l

1fi;11

1i,...

1r, r,

-r:uirtc

.lrc nl()uiltccl ort ihc vchiclc c'n eitl:cr sidc of tirc guiC: rvrr.c \\'lrcn tltc vchiclr: is ltrrlcC :
ihat tlrc quirlc x'irc is dilccti-r, bct*,ccn thc t\4.o corl\ the irrc:isill cf thc nra!:i,:i jc lltiJ i.surctj by c:.rch coil is ccuaj. Jl'the vehjclc sira.\'s lo onc si.jc oi- th. oihc;-. or jl ihc r:ui:: .
f alh ch:lngcs ciirection. thc nrugnctic fielci intcnsit-v a( thc t!,.'o sensors rrill hrrcon:: ui':ecI'his diifcrcncc is uscd to control the steeiing nro-ior. *hich r:rakes lhe iequired chanie'
vehiclc direcriorr to cqualizc rhc trvo senscr signal{ lherebr lr:rcking thc guicie rrirc.

\\ritcn paint strips arc uscd lo dcfinc the path*'av. lhc i'ciriclc u.\cs an optical ser:..
slslcn! capiF.k-r-il1?Ifkirtl Lhe paint.Tl.:e sti-ips crrn bc Lirircrj.:p.rarr:d. ()j- f-.rilrtcd on r-.flc',-.,r.. Orrc :l'rlcin lscs a l-in-rvi,-ic paint sir-ip colrtainin.l iui-.:cscenr prirlicies ih.li rcii,::
litl [rlir;ir ioi.'1 iLr\ ; lighf 5()!rcu lrorn :irc *cii.'i:. ..\:i i':i ,.i..ri.i .c:r:].': .; r.l,-,;,i. :. .
reflcclcti iighl irr thc strip ;tncl cr.rntrols ll:c stc'r.rirr! n'e ( hrnirm (c f,-,llo,,,, ii. Prir..t .sli guidrncJ ia ul.rl[l in?nviicinme n-ii u:hAre c].'L-rnc;il iirr;ilr ilirtii:i-t iiil iurCt.-u iic ,s..si.
uirr.:iilihlc ',',:- rrhcn iitc in-stllllaliorr oi quiJc irii'cs ir iliJ 11,,)r\r- :uii:c!' is rro: p;altic:rl. ()
Pi!'hicm *'i;h this tuid;incc lricthod;s lh:i{ ihc pi.rilil .iri; J.irl()t:;i.'s',r.ilh:iin:. It rl
bc k e p t clc ir it :-l nrj i-r: rio.-.t iia l j i' :-cir la lcd.
.

l:: '' 11:';

Admission Details at

lo anciiotc pan: :
cr rccs
lctad
2.50

br

a!'s.

-;

AC.

ki

iffiffiG

iaffi;.'

y:d;, @!r"r

-,

b_

arraliont

-_----->

setf'Auided'vchicles ($cVs) rcprescnr rhc

Inrcsr A.VS gui i,.r,.. i i.lnorogy.
r *s u
i
ass-,g, .dc n qld
pathwars rnsrcad. thev usc a c'rnbination
"r'; : gof dEo
recirning an(, i!r-ec:,,, rocatcd
throughour rhc pranr rhar can bc idcnrified
rry nn-uoori ;;;;;;$", d
r". i.*{.t,!;,:}.ii: irers ro
rhe froor' M,r'crncnr orG. t[trtr.
-::,,thililn
rronfrnc rolir'EmFiEhe.d t. r,,:
ri4urrJnunrbcr of rvheej roratjons jn
;rgi*_
a ,1"qr"n... of .spccific.tr slcerrn*
irrrrji,i
purarions arr: pcrrorrned b.v rhe vchicle,s
on-tr.,,,r,t.";p;;;;.;, i,n. n,ur;" c!.; ,:: comrioning ar-curacy of dcad reckoning
cr. posio"....urar.ur*, irng distanccs Acc.rt:,:rgl.v.
locarion of rhc serf-gui<lcd vehicre
;;r;;;icrio,Jicaily ,".i,;"Jiy c.nips.-ips ,:e the
lated posirion u'irh .nc or rnr-lre
caicukn,*n pori'tionr. Th.cic kntrwn pJsit:ons
aie cr,:biishc,J
using beacorrs locatcd straregicalty
u

wh,_-

rt,rorg;r,

tn ::

lcir r,cli,:'

C)

rhc. Dlirnr.

aOVS

,a,pplications. Auromarcd guided vchicle

systcms irr
r'-'ffiu.r,i""r"""

harr-r..i . -

t -t-lb t:. :
tl lo clir:;
'rq gerlc-

' p"ile*-4jfi.3l-,rppliearL,ln
r r:'ucr:s

uscr.J

il-r

i ;; _rr*.ir:s

a,,

;rrc rvpicari.v

user.i;nEF.pplrc;rrionr u.hich invoii,e

mr.,, ";l (
r:r.unrf L:1ds. Jhr' appricati,ns
often interfacc thc ACVS rr,ith
sonre olnf i .(,,rof{
nt.,.,n.such as a,r auromirred sr.ragc/rr-.r.;.uri
ryr,.. {As/;;l)
,il',i;t,,l,t"til-t;.:.;

t*15 ki-.t;
on boai:
)i-: (c{"lil!

A(

i\,

s-l'sltn.is

lrc

,-

rend

is-

uscd irr itsscnlblV linc, rr;rptir..rIrop*

Another apolication are ;, for

AGVS technology is fiexible
nranuf;rctu,: \. i,.r:r5

,t#:;r?Tl';fJ;J:-:^,:;;il;;t';nn.,r"ningworkparrs

are piaced

rii

i;l;::l::i;lif;:: l;:";.J$*,ff.1',i:::illi:*jj
transferred from thc ueliiclc
;,;:
pt.rrorm'in-rh. si"rion
tool)
GuJ ;rii'" rv.rkr;rhlc
ua, u

oiks,a,;":

. :,\,' ,,1;

lorpl",i." ol,pro..rr;ng. a u.l.,iclerl:i*::,:"i.f :, ; :,,i:

*'ork and rransporr"ir,"
ro p,,, iij., :i1,.-.
rrr.1"ii]'.,lnil:ljlj:t:':"f'j,):!icle.rerurns
i,,,Jhns",-;;ffiJ*",j,h::1,,;'..',iJ;$;1il':l;f,
a vcrsa,irr: r,:;:i , ;: !
for

processine. Ar.rhe

.,

,i,iljp,");a.,

.4C\/S technologl, is still develooinp,

and rhe inrtr,"r.., i* ;);;; ; ;, ",'", o* ;'
H ?il;f : il :t" ,; ;.J ;,l ::jli, ,,i::f;i
"
"
"
that conrbines l'*'o technoiogies
in"ol".s'rie use of a rot,otic ma,rprlaror
n...ouorr.:,j rrr an
;1f".T?::x,::l;|,;j;:,;",:I,::,.';:re a mobire l.olor ri, p.,i",nr;"s conlp!ci, :,.,,,,,,j,n*
de

s i

cd slrc.i.J r;.c a.
i:

.{

.-;^l

"j.'t:.:

trL Yu.:,

nges ii.

)rof. Sanjay gBlg

744550

1;::;:#.:

Chapter No. t4

Automated Storage & Retrieval Syste

Ar: aul,n:atcJ srorage/rctricral sl'stm {AS/RS)'is a st()ragc s).stei-n rhat

F}crfo!-ms sto:
igqand retrie v;rl opcrations rvith speed and accuracy untJei a r}efincd deeiee of auioni:
lion, Figure I l.-5 sh'lu's rtne aisl,: rrf an AS/RS that hirndles antJ storcs unit ft'iads t;:r piiliel,
A widc rangc of aulomaliLrn is [ound in ccmrnc'rcially ar'ailabJc ASrRSs. Alrhc rnos
sophisticatcd lcrel. the operations arc tolally autolnaled. computer controlled, and fui...
rn::Sratcd *'ith factory andlor wareh<;use opcration-i. At the other extrcmc, human g,orr:crs c()ntrol the cr;uipmcnt and pe rform thc siorage/rctricval transactions. AutomatecJ slorage/rctricval s;'stems arc custorn dcsigned for cach application, alrhough rhe tjcsigns arc
based on slandard nrodular contponenls availablr from cach rcspcctive AS/RS supplier
Our dcfinition of AS/RS might be inlcrpretcd to include carousel srorage r.r:rt.r,
H.- ,'vcr. in thc rnaterial hrndling industn'. carousel.based sysrcms are dislinguishec
from t.S/RSs. 1'he biggest difference is in ihe consrrucrion of the equipmenr. Th1 bssic
AVRS cojr);ii: of a rach strucluic iur slorin-r lr:acjs and a.slorate'rel:-je'al riecianisr
r+'husc rntrtions are l.inear (.r-.y-r mctions), as picrured in Figure I l.-5 B,v conrrast,
the
carctuscl s-Ystern uscs storagc baskets suspcnded from an overhead conveyor lhal revolr,es

Stora-ec

rlruclur!'

{rlrcl fr;rnrcu'i,rl

Stor;1g(' rnotJul.

1p;rilct irtrJr i

S/R nachinc

ffi

I'ic[.:rrlri.tltl'

f
:
k-

r:r

rti)i;i)a

Figure I 1.5

arqllq

.an-c;1gi tral! 1111p t11 Cc!ygi_tlrr' i:;r\.lil-\ 11 :1 lqild,irllo,rri :l;r1ii'rn- ::s i-';'.:r:, r.,!
Fieurc I i.6 Thc cJil^fcrcnccs h.li',ic:i: ,r;r :\S RS a,:.J ;r ca;t,us,--l si(:i-:rti s\:.ii;.'; ,;;'-. riir'::
m2rrzcd;n lthlc il.j
\! :l ri - (l
.4n .{S RS a.',.:rir oi ilr-\ {rf nl.1.,j \:.):-::!-. it:slcs l'i;::l jlt
-.-.
siorase,'rt:;er.rl tS. i-l r r:.tcitiiri.
5 il ; -' ,;i,'\ ;ri- s('i:.Ji,:
Thc ilis.:r !:.r; -' . -i, I : - .--n' i
; - l;sJ Li l,ll \lL:iiu lli.:llitlilll ll; ,: F, l'. i:. l
.,tt'lii', l-i:-,^:i-,;.:ls.,'l'-'.I :. i,
r

t
:
F

tn34:1955

Adrnission Details at

'ste

s s(or.

iomaiilicls.
(-arouscl )l

rnost

aua(

.;t
..:i
2l

u(c

'.. J

I full_'
'r

ork

sI

.'i
t-j

l) :,

or-

--- J

'.V

s arc

(';;.ru:',-'l

rlier.

,i

:rr;l

ems-

shed

r:sic
:

isn":

the
l\'es
8in.

f,.,:

-(

Figure |

storlgc carousel.

+ ASjR,srvpes severar inporranl cale gories of aiiionilrrcij -:ror;:!'.::'r

can be distinguishcd.The following arc, rhc principal types:

rJult
r!'r

1.6 A horizorrlal

r'

2.

{.)ni.i load AJR-!. Thc unii rrrr,j AS.TRS is tvpicarrr.:r r;rrrc;r!, .r.r
dcsienctJ r,iltrn.li" unit lrrads st()r!-c' on
trallcts rrr in olhcr., .r.i,j;i:.j ,-,,,:i

sislc:l-j rs contuier controii,,J..:nd tl,,: siR rnachineS are aL.rtoineiad

i,:.
ri, handle rhe unit load con:ai;rr;-s. Thc,:^.s/RS pictured in Firurc
li.-i is
s'isiei'Ir Other s1'stems dcscribed |rciorv iepresent varialions of 1he unii l
The dccp-lai,:,\S.,RS is a nirh_densii,, unir lca.i si,.,
2!!L!!!:l!t;.
lirat is appropriate-when large quantities of srock are stored, but
thc

nLri.

_:llqj*!-1.] l)ffi]:KUs) is rc.larir c j-r snrail. Insread of srorinE each uii .,

,';i ;i t.t a.-,:essra Circcili f:.or: riie 3i.sic ias in a conr.enlion:ti
un;t I ..t:
.i':rp'lane sisiji: sio:-e-( lcir oi nj()r-c jr,a<js jir a singie racl:, onr- j.rd ..,.
3

- .\!;niloai."i5 t.! l-tr:s sioratc s\').i:n-. ij ,;.ctJ io handic sr_.i.:lllr,::.:.

-.','pelCsIiTr.r;e conraineiiri iri;s.r; tira,.rrrs in ihe srorasc sr
:s desrgneJ tt, ri'.r!?\'f the bi;r :n: ir:i,,3r tt io a p&D rtr,,nn
i, I ,,
ihat indiricjual rteins ca.r h3 rvirl.jriri.r fror, rhe h,ins Tirr r,,.
cp'cr a teij bt, a hunan *.trr'l:cr

;ls.i:le

\\'\iCli:

.-'rs-l'h'
.jcsign c iJ

';;iit load
J ASIR5.
r: s!'sterii

',f scpai that ir

.-\:rlir. rL
rli(

he ncxl
' :lil:i ira

:rh in c

't.

+.

:l:i:li:t.'.-:-it

!l-:t;.suf :.:r::,,:.. : ,ii:.- 1:1-;51p,',

i;:.1.;l-:..i:-::,r::a ::5i3it ih: ,.i ,:.i: ,--l ,.i:!.. t;..i:i i::;:l ile :-:t ,_
-t
, r. a I i,:rs. Ti :s c iiris : n a,r;. :: i :, :.. i
:
-::c:r-i: -(!.sicnt i lr :.r:;

,f
i

.\!an-on-bc'crt.,i,5.,'R.5..4 nrrr-c.r-3:-.3;i qais,: caileci n-ian-;rl

,i'. st3a-,. reFrcs3itl-\ :i;.: allcrrr:l j.,.r 3aririJci.t i,: thl
prohJcr;,
:lll:,. ficin sla.:r!3. t:: :his s.,s:,::1..?'ir;13:t ci,:aj-3ii.,: nicS r.:l
;,-::chine. \\'hc:::s:h: minil,rac -(\.siiii ,j: jir::r-s an crijrr: !,i:,

t'7't,[.

:,if

_9ortj,.t' yB I 9 -+.ijSt

:::

::ic

-qr-r

,,u:iii','
.r

Cx

',l-':-;I
.;'R
r

:,-

i'

,:i, li:,-.::-.-'

5'

6.

Autgmaled..ite!!.r.retrie.vo[ srstem. Thesc storage svsterns arc also

cjcsrenctJ r
i'etrieval of individual items or smali product {artons: ho!\e i,cr. thc
rtcnts
urc str.-f
;l^-^iL,
-^.L^in
lanes
ralLer
lhan
urdrr,.ttrrs
bins ur
or Ora\r'e
\t nen an tlern
dra*,ers.
rS. !\'hen
itern tS
is tClnc\.ad.
.;_j:j::)lqll!-s,
rctrievcd. it
is puShctj l-r()t: i
il;;;i
lane and drops on(o a conveyor for delircry to the pjckup sralion.Thc opcr:rtir;:
{ rpc r,ir I l(;: :r
rI
somewhat similar to a candv vcnding machins, cxcept thal ln rlcr.:1
rcinc\.:rl svs:__-r
has more st{Jra8e lanes and a conVc}'or t() transport jtcms to;t
c{jntral l,rcailon T-:
supply of items.in cach lane is pcriodicall-y rcple nished. usuall-v
fro6 g5" rc:rr of l-:
s)'stern so lhat there is flow-through of ilems.tlrus pcrrnirring
fi rsr-iaitirst-sut inrc--

tory rotation.
l/enicallift storage modutes (VLSNt)
ltLr].These are also callcd vcrrjcallilr aurornalc-l
storage/retricval s)'srems (\/L-AS/RS)
[7] All of rhe preceding A,SiRg lv,pgl a::.
3 horjzpni?l aisle. Tl: ::r:nc principle of usj:: r c:nlc.- a:=1. ;j,.j_
ii,':'iT4r'n:rnri
lcids is used cxcept ttrar rtre iisle is veriical.-\crrical lifr sr.)raec m6dujcs.
slrnc \\;,heights of i0 :n (3b n) oirnoi., ar. .rpibl" of holcing largc inr.cnrt-rrics
*.hilc s.ar,jr.

valuable floor space in the facrory,.

+'

ASiRS

APplicatiog

N'lost applications

of AS/RS technoloev har.c i^-cn assocjarc-

wtth \A'arehousing and distribulion operations An .AS/RS can

also be uscd to s{()rc 13;
materials and u'ork-in-F1rocss in manufacluring. Three application
areas can lt: distir
guished for aulomated storage/retrieval s,r,srems:
unir lo"d storrge and handling (2)

fl;
ordc,
picklng. and (3) x'ork-in-process storage ljnit load srorage and
rerrie,.,al applicarions arc rcf ,
resntec by the unit load AS/RS and deep-lane srorag sysrem! Thcse kinds
of applicarion..
are commonly found in warehousing for finished goods in a distribution
cenrer. rarell. in rnanu.
f*:tt"g Deeplane s)'stems are used in the food inclusrry As described above. order picking
involves retrieving materials in less than full unit load quanriries
Miniload- man-on-hoard. anil
item retrieval sl,sterns are used for this second applicaiion arca.
Work-in-process (wlP) storage is a more recent application
of automatcd sroragc
technclcgr:llhile it is desirahrtc to minimjze lhe amount of work-in-process. \\,1 p is
unavoid.
able and must bc effectively managed- Autoara{.cd gor-age systerns e,ithcr
a3.rromaiecl sror.

atelrctrie.''al systems

i:,->

,3

or

carr:usel s-\'s!cms, rpresenl an efficienr \^,;rv

lo slorc matclal)

;i. .),-

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rfC SIL
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orne

AJ Flv{S Cornponents

i3.

2
:;.
{.

r-qi!$-i

le sgr r:.

is of CNC
,1

2 sysfem,

Eleme;ts of FIriS :

i,lalerial HanCling and storage

s-\.siems
Ccnpurer Ccnf;-cl Sl,stem
IJunan Resaurces

7. ll:orkstations

soc.,itl,-':

()rc 13 .: distir2) ordc'

arc rei-

T:.:i:i:,:'1'j:::_,:.d in Fr"js js ovC- machine roors r,{;;; ;; ; : l,' l"",ii; ;,

::;! ::' :n,?"::,., :. : tira t !;,,r.',r'
-,
:;u i;;i:,,
::::::, :'^'j11'-.1 ; ; i ; ;;;r;, "'' iH;" ili: ""I:..:
tc n, a t irr::
gl
;;: li|,i,1l,?i", ;:,,
I :: : :
ir, " "
n oe ro ra ri on ia I I I : ::: : :"1 !;i::,,, ;; ;; ;E;;;;; ; J J iii',';X,'*,
r
r re q u re l, r,il"
i

icatic.r.

l manu.

bu

picking

2.

rrd. an.i
!tora:c

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stot'.

crial:

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he CNC
ing
:rcf uding

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:. iIiL^
,rfr

I mostll/

ic(

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Nlater-ial Handling and

storage sJ,stems

tt;iin::f

ir:i,;?,f,1;r:'l3,'"
bl secondary Handllnj si;;;n,

ravoid.
rt

'

A Fn{S systeln consists

of four major cornponents
as de tai
l. \lrerk_ctaticns

lvpcs l-j

ll{anufactu r"ing $3's;terns

'

FI exi bl e

Sysrcm (Fr.,,sl is a prodir*ion

susre:
*ffi:?:j1i:'y::::ii"g
*'
J t v'; ; ;i ;; ## ;'ji:
j
ili;';,
IT::::.:
l]
:
:':":"
and
"
confrolled b;,a central
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c:tr ()r
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u

Chapter No. rS

an FI'{s is orten shared

be*,'een ri,t'o s,. ,,

Q ) Pr.irnary handlr.ng s;,.siem

The primary t,"n-ating
,yr,"rn-. .r,
t.1e basic rayour
responsibre *;;;;;;"r'i;:"#:"::'ll5l::
or rhe i-,i;. and is
rnoving rvorkparts benveerutrtio*
lipe of rt,ts Jai
ir,l-rlre sr.sie r.r F.
-,n the
ha'diing equiprnen,
r.,t"nri"s

I
y:
rr.

il{o|t;lrlterial

Ccn,,.eyor s-\,stern
Fia:JGuiCeci re hicle

s-:.srnr

;11;.^pi3se6lGuideJi;;i;i;i.:rGvJsl,sterr
-'* \?,!
1..'. Iritilr-sir-i:i Illbct

'i
'i.

{
I

--

rrplrr;:y

used

,i

,lnar-v

iii] Ladder Layout:

1qlJ

The ladder Ia-yout consists of a loop with rungs ben,,,een ,ihe strai::.
sections ofihe !oop, on which r.,,orkstationsare located as shc.,.,.n ir Fi:r l-=

OOOO
5r:rtint

?trtD.n,

OOOO

Cmplctcd

prnt

figure

FMS laddcr layour. Kcy: l,ord = parts lo:Cing srarion,

UnLd = pans unloading station, Mrcb = machining sra!ion,

Man = manualnation,Aut = automatcdstation.

iv)

Cpen Field Layour:

The open field layout consists of multiple loops and ladders ancJ mai,
include sidings as rvell, as illustrated in ligure. This layout is senerall.,.
appropriate for processing a large family of parts.
Flgore
Opcn field FI{S lalc,ut. Kcy: Load = perts lca --:rq
UnLd = parts unloading, Itach = machining, Clng : clez;:::
Insp = insJ,ection.l'{an = nantral,.{ul = automaled,.4C\' =
ionatcd guided vehicie, Rechg = bsiteri recharging stati:r
AGVr t

?rrtt
*Oe

OOC
S:artirg
s'o;t F! r tJ

Benefits Derived from the Use of FMSare:

1.

Flr{ss achie'e a higher average utilization than machines in a

cor\;
producticn shcp.
2. Because of higher machine utilization, fer'ermachines are re,quire.;i
3 cornp:red ir'ith a job shop of equr,,'arent capaciil,, an Fl.is genera:r,
Itvvt

d,t ca.

. nn Fi'i5 inpi-oves Greater responsiveness

.
5
Lon'er manufacturing lead times.
6 . Reduced direct labor requirernents
T

::

rional batch

i-r'qu-ii-es iess

to change.

;. i'he high ievel of automation jn an Fl'{s allorvs

ir to operare fcrexti,r,,ied pericds
citi:ne rtiihcui human attenrion.

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Admission Details
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o\- ,o{ Chapter

r

.a_A,c}

No.

t6

at

98203478ss

Technolog;' Driven practices

A)Rapid Prototyping
1. Rapid Prorogping Defined

.q*.t'9;')"5

Rapid Proto4'ping (Rp) can be defned as ra1,er

- by - rayer fobriceti,:dimensional ph1,si6s1 moders directrl'frt m o computer
aided desig n (cAD)

This ad;itive manufacturrng process pro'ides designers

and engi;capabilig, to literalli'pririt out their ideas in three dimensions.

2. RapiJ Protoq,ping C1,cle

The basic methodorogl, for alr current Rp techniques
can be summ;::
follorvs :
CAD De,"igl

r---J\)

STL FrJe Ourpul

-r'/

Rapici
Post Processing

Protog'ping
Cycle

Preproces

si n

Tr ansl'er

a)

CAD Design

The first step is to buird a cAD mc,del. The final file must be in.ccli;
formar so as to allor,,,for successful protoq.pe build
bJ STL File Output
Fi-om the cF.D fire, an e):port forrnat called the.STr. i:le
is being crsaii:
'srl file, so nanred b-v 3D s;'siems fc* srereolirhographi., is cu,rer,-..
standarC file format foi- all p.p sJ,stems. STL files zre
irianE,
representations cf soljd models. The indir,iduai tri:neles
ar rp,-esanl::
simple coordinaies in a text file foi-mar.

cJ Preprocessing
Preprocessine incjuC:s r.eril-i-ing the.STL i:l:, and
creaiing,sliced l;...er,mcc'ei and'setup argorithms appried fol
ya;-ious rapid pro-toii-plng _qj,*cren.:

dJ File Transfer
.r.fter.STL

i-s b,einE p:-proces-sed, thc file i_c ir::t-sfef

it ,qp s-\._(t.i.ii. Fil: ti,_.
ceii J3;on: nianuaiii'L''_i'ir;nsierring thrlugir ri isi.l. iocal area
rai,,1.c:.
thicu:h irtei'ri.

I 9820311E5s

Adniission Details at
e) Build Proccss

af the physicat model, rhe model is tl;.'n lorvere'j

until compli:tion of the
b-t. cne layer thicl.ness, and the process ls repeated
but can r'''tr-'
rrrr.,del. l,lost F.P machines builC parts lvithin a felv hours'
unattended for several days for large parts'
Aftei- creating the

lar

c,'

n)

:*

il

tineer-.;

first

la.r,er

Post Processing
This jr,ctuCes re moval of rhe part from the machine, anC if tlere are any
and cleaned'
supDorts are removed; the sulface of tie model is then finished

Lhe frnished part meets the necessary requiremenE, rhe cycleis complete'
l--'::e ;-,'.:::, :::::ii::: c:n be implem:nierl ;n the r--Att flle and the cl'cle is repeated'

li

tte-erd t'roton'Pi

I
dt tLc

g Proc

5ttrq-alX.baeIarrt'-l
oiTi:e most commonly used process for rapid proioiyping is the stereolithograph.v
solidifY
p,iictolrthcgi-aph1'. These s)'stems build shapes using-'-lighi to selectiv'l-t'
phL)ro cui-able resins. Sterelithographv machinrr, .otffi.'rt three-dimensional CAI)
car; of ph;'sical objects into vertjcal siacls of slices.-A low'-powg ,.i1ri::"r9.19$!gr
liquid polyme r-, producing
be am is rhen carefully traced across a vat of photo curable
la-\,er of.solidified resin-the first slice of rhe object under constirrction. The

a single
la:,,:r h.,eam is guided across the surface (by servo'controlled galvancmeti'mirrors],
'l'he initjal
drarvlltg a cross-sectional paffern in the x-.v plane to from a solid sectiorl

l;.,,er is then lo'.r'ered incrementally by the height of the next slice, whereupon the
is
la',,cr is iecoated $itir resin and anothe:- is traced on top of it- This procedu:'e
r,jr,:atei until tlte entire part is faLrrjcated. Though this rfas the first prccss
ci;riiei-cialiseil, it is expensi,,,e and is linrited to r.onle oi the photo'curable plastinraterials onil".

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rc

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2. Selective

laser sinteri[g

In the selecti'e Laser sintering

[sLS) process originaily de'eroped ar th:
of Texas at Austin, a modurated raser beam
foilorvs the shape of a si,
generated object; it rraces the object across
a bin of special heat_fusir
heatins the ot'tislqs so rhey fuse o.
_1u1,,nt,,,n.
material is spread out and revered in the prane
rhe rayer is to be formed.
Sc;.nairg

^^^LdJEI

t-

li
l-J', ntered Povrcjer
ii l(r o Form Parts)

J[,
'it4

)L_
Schematic of Selective Laser Sinterin.g Det.ice
A coz laser then selectiveil'traces the la1'er- to fuse
to the bottom lar.er. The pi-r..,.
cen be joined b1'melting or surface bonding. The
unfused maieria! rernains ilr l
as the support structure. After the initial lai,er
is formed, portder is reat;rJie.;
the laser processes the next layer. some of tiie materiais
use d are, plastics \i,a.iir
lo".'' melting' temperature meta! allo-vs. Because
of the use of nretal po.....dt:r-r
pl-oCt'ss is greatll'used in applications
as
dire,^t tooline applicaticns
-such
rni'estment and dje casting applications.

,*
r

: .iD+nrrlins
m
1

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.r

-'
-fi

3-D printing can be compared to sLS; the difference

is ihat insteaci of laser L.e,iiauid binder is appried to lrond the por'der particlcs.;i
3D pr-intei- is oper;rei rn ::
follorving sequence. The printer spread,i
a la1,er of par,,.der frcm the feed Lrr)i: :
rn:.cr
n,,-a^--r.l
Lv'|
L' tlr^
t,rq ru'dLtr
.,r
rne DUrJc piailornr arrc then prints bindc;. s,:.ur:,_
i, :,i.,.
io':sc pov"Cer, formin!; the fiist crcss-sr;iion
oiihe pari. \i'iien ihe b;'der;s p:i:r..:_
the po*1{e{9 pq,rqicfes are.glued together. The
remainii,.g pc.,,,.riei- is lco-se;;:.,
suttcrts the parts as tt;s being orinied i,,'h:n file crc_cs_seitr::t
;s cc:i.:le .: :;.
iL;ilci platfcrrn is loi','e;-cd sligi:tll, ard a ne,,.,.ia,,.er._.f

:i':fait'

pc:.,,ier is srreaj cr.rr ir:,_

The pro':ess i-s r3pg;;eij i:iltjr r,':e ',r'ho,ie nrodej
is ccr,piered. -he ii:,r_

Admission lletails at

| 9820341855

platform is raised and lr'ose po"r'der

vacuumed a\tay, revealing

completed

Pdr r.

the L':.
:;i,.

,.

E,r,ae: q -. =':.1i:

?--t

',....-

sil;u
;: ,{
'---___.--.--{
i:t C.,'{
t.
l

F.at:c:':r

*-

Fov,'

it

Farls)

4,.-:

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Schematic of Three Dimensional printing Device

Fused Deposition ltlodelling

ln

filament is unn'ound from a ccil and suppl;, n,;, ::rials to ;n

eliirusion rtozzle. Tlie nozzle is heaied to melt the plasiic and as a rne: isrn r,.'hiilt
aliolr-eJ the l'lor', of the nielted plastic tc Le tu:-ned on and off .The no::.r, : moulLed
io a nlechaniral platfornr, tvhich can be moved in both horizontaj ,rj r.t_-rtical
dircction-s. As the r,uzzle is mo','ed o,.,e:'the table a required geometri,_ : reposir-s a
thin bead of t:<i;-udcd plastic to ironr ea:h l:,r'er. The plastic hardelr-.r ' riediarel,.,
aftc;- heing squirted fiom the nozzle and bonds to the la-yer belo.,v, se:, :n3terials
:rr'a',.ail3ble for tlre proces_s including inr.estrnent-casting \.,,a):. :.al FDi,,i
r;r:ici'i;ls are in th: eligin:;ring -c:r'elopmcnt stage, inclrrdrng J,',,- ;-ir;na'.e,
y;cli'prcp','l:n-, Pljl'iA Ioerl'"'l;t.:t]r.,.jnle tha;-cn.lateJ, an,J r.ai-iius pol1.es,.,.

frr-r',

s tit
I i --

'

il:'r-:

fl t-i*^-\
.

:''-'

rhi-s procss a plastic

'-n:

iil
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Prcf. Sanjo;,' 9519 714550

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Fiianren! from e Coil
Feeder

r-rrl

i rI
4rtr
i i't-.-,:i
i
/

-- --'-. ,r'
'.
'\i

Solicifred Fraste r

F-

I
i

..'

t,Aetier

\ \\r-----J

F"

- -1t'
Extrusion lJczzle
Piatf oin

'

--->r-1
!

Schematic of Fused Deposition lttodelling

5. Laminated

object manufactutigg

Larninate object manufacturing (LOlr{J machine ruorks b1,:ctuall;'cr:ning rhe ,.sljces,

of the object out of a sheet of paper foil and then bontJing theni rogether. The foil
comes off the ntaterial supply roll and the.laser then cut arounC the outline

oirhe

I)

F
t'

tr

hr
F
;r

d.-,,-E
E
I

layer, italso h:itches the foil around the edge so that this can be easily brrken
a\.,,a-\,
r.''hen all of the layers have been bonded together..After the
laserhas cu! our the top
Iayer, a heated rolier mo'es o'er the top of rhe foil to bond the la1,gr- to
the rst of
the object- A sensor is useci tc masure the thickness of ihe fcril as this carr ,,,ar-_i.and
the machine rviil automaticaill'adjusr the dimensions of the ial,er being cui to
acccuni for an-1'r'ariaiion. The resuli is a part that lool:s like laininated r,,'oor:.

Adrrrission Details at
Tcc View
t
--.

Laniraiing Rcller

Conlour of Actual
Cisss Seclicn of the
l,4.rdei

Scal.r-r,nq i.1

Lan:

rrar ,r)

2r--1-

Foller

L?rr;,:'lEi lvlOdel
i

if:ni o1' Euild

*-:
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PlalaAr-

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lice s'
ihe foii
of rhe
'l a tira-\l

Schcnatic of Lominoted Object lIanufactu;;,1.:

.tlgli,
Some of the uses of the rapid protoB,ping
are:

1. Cl,ecl.: the fea.sibiJitl of nei...de si;n concepis

2. CcnrJir:t li-rar!:ct tests/evaluation
3. As.-ce.s-s the fit oi compiex mechanisms
4. Prl:nc ir .ci. u rj-ent product dt.,.cl:i;ni en t
:6. i,.1;.1:e, ltian:. a.r:aai copies siriiultari::,usli..J
i.f al:: rnc;,;iiis ii,r !,.a,\ cure,,,
arr,,rn,

he rop

'est Of
r qll!f

'Lii to

Benefit-s of Rapid protog.ping

.i

)
_f

iri-;

:'ru

i' =i

ct der,elopnien i

:tr

Cesien

ni-,_,C

-!c,, -lC

.i*- Lltit:

ur:

ci:t,i l:.r: pa,-is

::-:-. ; in: hEl:s rr ri;:i-i: its aestheiic
,','j::

Frof,

Sa;tj,"t

>c,l >

app=al

:lr ni:i:ul;i:;:.

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,,

$. Virtual Protofvpinq
. l/irtual Prototyping also referred to as Digitol prototl.ping, is a :
generated digital3D model that can be manf pulated to exact specific:

o ic is used in the development of neiy items such as consumer e.:

rna:hinerr', cars, ships and aircraft or an e ntjre in;jusir-ial pi:,ress;r:g

t, la:

'l-he

virtual modelcan be as simple as a single pari (E.r;ampie: A bu:ter.i:can be a highli'detailed and complex model rviih thousands of asserrbji::
an entire aircraft.

- 'ii,:

soft.,','are use i l; dc',,clcp the 3D n;ie i is a l,i.f;r;i ci fipu:i- :

desi6;l [C.4DJ and cc,mputrr auicntateci er.g:n::rir.:g i,J:.r_ l i:l:rf :i-,:i

r*
FM
J
I

The softrtare is used to develop detailed 3D imagr-ri jn order t"r vaj.

er.plore rnultiple iterations oi a ccircepi pritt io ir,: cre;iion ci a s r.
rvorking proton'pe.

Besi-ln-Class nranufacturing organizations use digita) protc,tvping

cost of product development and shorten the tirne necessart' ro
product to markel

Applica tions of Virtual Prototlping

ii

1. l'irtual prototypes are used by industrial designers to apply and

test
rnaterials and finishes for aesthetic appeal..4lso they conducr Finite Element.:
(FEAJ and sinrulaie rhe product in real rt'orld applications

I-I

2. Engineering anC manufacturing teams appl-v Design for

ivianufactrrre
techniqrrss to iest the digital protot)'pe and assure it can be nra;iufaciureC.

?.

Designers break ccit'n the indiuidual sub a-<semblies of the 3D rnocel an:
geonrefric dinrensioning and tolerance to assure propr fit to other e.,
componeilts or products

The 3D r:iodcl is u:ed to crafe a photcrealistic ren,Jering c'f tite digital r:roJ.
renclcrlrgs are useC in markeiing effcrts to tregin pre-sclJirig ti:..'ne r.,'producr::
it even.gie-s inio production.

l5

ilr3

ilii
IFnn

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5. It is often uscd tc generate video simuiations ir

reaii-stic sefttngs. This :s a:

opticn for inventoi's and nlarl-:eters ',r'hc i.,'ani ic mal:e a pci,.'e rfulpresenlaiioir

Advantages of Yirtual Prototl'ping

1. \rirtual proict-r'ping enables incilidual in,.'entors anc pi'ccuii d,(iqlr j:irm-s tc a:
supe :-ici'rr3aj ita:s;t 1c.,,.'ei- co,(t to th: cr_;tsli:;

ii

tf-

aicjs in rapict'

prr.iuct Ce','elcplnent

It recuce-s ii,.:
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Admission [)etai]s at

C, $rc$'ledge
,isa:.

9g2A-1

Based En

(,"n\

peciftc::

l(noi'ledge Based Engineering syste;n aim ro capture procuct

an,i ;
,,,
and rhen
:lb:l::."::-s.. .to moaet eng;nerr

-l'tFr

a:r

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r'o.,1^-.;S
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xnci^"lerlse based engineering

{fiBE) is a discirrline r,,,ith roors
D:slgn fcAD] and knoFledge based s'r,srerns. Knov,ledge
based

::ter,t::rir

biit:

r.'ess

inforn:afion

, tiie mocel tr

jn ccmpurer

Airjecj

engineering is the
process of capturing the knou,ledge and can
be reused for design octit.ities to
enhance solutions for a product during its entire
Iife ca'cle. These knol..,lecge -.ase_.
ral e;.:st ir r:.:anr' fcrri-,s such as ,su.:eadshe:ts, hanJbo:|:s,
engrnee

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ri'g iorr r-:ias,

d;-ai"'ii,gs and cioc..:rnents, oi'in ru.|es ci rhumb

that are based ori hurnan judgment

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ph,,

'

trritai: all o;- parr of the process,

E.xanrple

o red:::
i r.t: il

ge

est

i' shov'in ti:e abo'e figure, KBE is utilized ro generate differenr

t1,pes olFlanges rvith
parameters such as thickness of flange,hub
length, no. of holes. etc.

|
I

1'a.-

rnt Ana

KBE

ir it.1
and

1. .-iuioinated'
2. (_aiculation

3.

a::

e.l:!s: i

5.
r.^'

-1;I

j.f be: i

:rn.

C=it.."

Applicatjons

creai jon of georni:tr-1,

of engineering p:rameiers
Pro:ess planning

Tool de_sign / ligand fixrure desicir

,i.ccLrrate ccsi es:i'tates for d=tarlsl
or cclnplt

dvari tages cf Kn

or,,.l

r;

products

edge Based Engin ceri n g

Kn:,',.,'Jtrige ceptu;-e cen be reused.

2. Cr:Je rr tire da..a fl-o:l the
dilfrr-ent soi.riCr:s
.1. i'iel ls lc iicntii. "Design,..jcJ:iions,,
.i. iieips i.
,,pi-cduct
reCuce

the
cosi,,
i'ie!p.s i,,. i-eju,:e the iin:e a;id
inci-ea,s:

ii,:

pi-.._,,Ji:itji.it.,.

liSE s','s:snrs prci.ide far rnore

Foi.,,.r. arC f =r:h jj;r;,.i" rt:e
.-. :+.^F.
-rrr*- _
-,.-r-

Ce

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[.

Reverse enqineerinq {LE}:

Engineering is the profession int'olved in designing, manufacturing, consrrucri:.:

maintaining of produccs, slrstems, and structures At a higher !ev,el, th:re aj-e t\.,.1
of engi neering: "fo rw a rd e ng i n ee ri n g " ana " rev erse engi n ee ri ng ".

:.:

Fonvard engineering is the tradirional Erocess of moving from high-lr','el abstra:t::

and logical designs tc the physicalimplementation of a system. ln sorne situarions, rh=
may be a pht'sical part r+ithout anv technical details, such as drau'ings. bills-cfor rvjthout engineering f

:t:. o'rh:< ihcrrneland

ne:t:

electi-ical nroperties.

/'\-----*---------

-,
(/,r,--ADstracUan

:\,s[em

\\
\

Re'verse Enoineerino

Abstraction

----

Foi'ward Engineerrno

Re-Implementation

c-r-\> \
Oid system

Delinition:
"The process of duplicating an existing component, subossembll', or produrct,
v'itltout the aiC of dro*'ings, documentation, or computer model is knos'n os reye rse
engineering".

0r

"lt can be defined as a s)'sternatic meiliodologl' fol' analyzing the de-sign of ;rrr
existing device or system, either as an approach ta studt'the desil]n or as a
prerequisite for rc:d_e5ign'.
Rer,rse engineering

c:n be vicrted

I rrlanrifi' tho c".f:n'S

aOrnnnnpnts e^ri

2. Create representations
e

as the prcce,ss of anal-r'zing a s,..,(in tc:

th:!f jnte:-foi6tjgn<:ir-.c

of the s1'stern in anctlrer fc:i: cr a higher lei':l cf

bstra cti o n.

3. Create th_e ph-r'sic_al repr:sentatrcn

lf rl:;i -s'. s::;;.

l:.':r-<e ;t.cin:pr::q :s uii-', coiTt:-.a:: i:. s i-:,

I it'!:

ii3

t;t lti

i. a I il:-1 af'"'?. :': n-.'_: ii-::-

::

:.: i::.-:::

itf

4,

ii

:tra

Admission l-)etall5

I e8;

31

t3)

ror exatnple, rvhen a new machine comes to rnarket, competjng

f7-;l
\-!!2
rnanufaclut-e:s r";'r!-;'i,it;-n;cl:in* ai:d disassemble it to learn hc,r,. it i'as
buiJt an,J
rnechanjcal 'i:siqns

hcr..,'it r,,'cri<s

cheri:icai cornpan-i,n.lav use reverse engineering to cefrat a patent

on a
cornpetiror's n;3rir;r.iuring p':ocess. in cii il engineering, bridge a:.:,J building
designs
.+

are ccpied ,rr';,::t F:st suacc-sses so ih3:e rt'ill be less chance of catastrophjc
faiJur:. j;i
-tofn^,'are engiir ecri::g , S..od sou rce code is often a variation of other good source code.
Follcr*ing ai-e:ca:.i::s fcr rei,ers: engineering

part or product:

1.1-he orrg:nai manufactu;-er oia prociuct no longer produces that;::-r,,iluct.

2. There js iiac:;:'..:a:: .J:,cum:;liaticn cf :he orjelnai design.

3. ]-he

criEjn;lrn;i,::;,tir:ir n3lcr:lc;- e,;:i-qis, but a cusrcmei- neei: . .

4. Tire ci-jeinald-:sian'ic':'Jinsnrat:cr h:s

ri.JCt

lost or nei,er e.tisted.

L,een

5. some bad featu*s cf a prc,Jucr ne-t'd to be desig.,ed out.

For exar:

n:ight ii;dicate v,'he;-e

6.

:,.r-eSSiVe i.,'ea

i-

product should be improved.

l'c

strengthen rhe rc'od features

proou cI.

cf a prcduct based on lc,ng-tr:-r.

' To analvzc the good and bad feaiures of competitors' procuct.

B. To gain c0inpetii!r e berrchrr:ari:ilre nrethcds io undersranci
conir,.

:lsage

cf

the

ur's prdducrs

and develop bener- products.

C{
,s:

9' The original supprier is unabre or un',.,.ilring to provide additionar par:

10.Th.: original eqrrip;lent rndlui;.tri!-rirs are either unrt,illing
or
r!irJacerrsni prit_(.,:rr derranJ inil:ted costs for sole-,.ou,-ce
Darts.

:a r-,
-,,-^1..
p/_\
'u rw _\-l

,:i:turing the

'?nempring
i','sis shculC
r, is

ti'nicail;r'

:nt Oi ilill
':iiltac i/eit

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;

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"I

F, Green Manufacturinq

What is green

manufacturing?

il_

Green 14anufacturing is a method for rnarrufacturing that minimizes r";as::

pollution achieved through product and prccess desiqn

concept of Green

{
;

Manufacturing

fl

Green rnanufacturing is a term used to describe rnanufacturing practices tha:l

not harm the environment during any part of the manufacturi,,; prcces: J
emphasizes the use of processes that do not pollute the environmer.i or r{
consurners, employees, ar other fi'lrnbers nf tne c:n-imunit1,. G +
manufacturing addresses a nunrber oi nrenufacturino rrrar-iets, ircl-: I
recycling, conservation, vraste rnanagement, rvater supply, envii-onn-{
protection, regulatory compliance, pollution control, and a variety, of c:{
related issues.
L
Experts predict that green manufacturing rvill be the most popular trend in d
next five years.

Steps to Green Manufacturrng

1. Identify the wastes

The first step toward going green is finding all the rvastes in :-*
manufacturing process. Manufacturers should lock closely at the harn'-

wastes and emissions their company may be producing. Many manufacturer

have made a switch to solar or wind energy to cut dorvn energy costs. -additicn chbnging to organic materials ca n also cut dorryn on herm'ernissions.

2. Recycle materials
The simplest way to go green is to start recl,cling. Manufacturino compani=shbuld take a look at the products their company uses and find ones thai ca'
be re-used at the facility. t-or example: if you have emptl,plastic container-.
you can find other places to use them.

3. Set up recycling stationr

Another vital aspect of going green is to have access to rec;'cling staii.rns. /easy solution is to place bins around ihe facility rvhere ernployees cen eaSi;.
access them to toss_products thet can be r-ecycied. Rervards anc ir,cenliv-:
can encourage them to use the bi.,. incfe:'1 nf irrcl- tossino there used iiern.
into the garbage.

4. Hold regular training meetings

It

ia

tit;i

rhtr itafl memberi neei io

-.lur;,9 Li =c!j crru

^^;F^

^-^^-

-.-;

ofierinc inceniir
n,rinn n.aaa

f:'r:1. .'jr.'1.2;"'

i41! ! ia:'<''

unCef stai-,,j

'.,'re

n:
t-.

L,t

i-r

admissicn uetails

at

98243418ss

5. Re-Design the Product

i4anufacturers can start goin'g green rrith their- products by looking at each
one of thern individually end deciding how they can re-design thern,
l4anufacturers are also finding vlays tc buiid their products so at feast sorne
of the parts can be recycled. ilanufacturers should also design as many paris as
possible in ccmrnon betiT een various products.

,,'is:e

Drivers for Green 14anufacturing

There ere rnany Crivers lvhich are expanding the boundaries for green

r-

nranufacturing. Some of the major cjrivers can be grouped into three key areas:

the: I
ccess I
or n3!;
G.=+
-al--l:
s

1. Competitiveness: The natur-ai desire of manufacturing flrms to improve its

processes and capabilities for competltir e advaniage. This ca;i manifest in
Irn-.s cf tecnnciogy, r-li'r pr6,1r-'ci artd prccess cje,'eio;men: as r'.:,1 as

-{I
:f c:-t-

opporru niiies for business.

r rne

2. Corporate Social Responsibility;

The grovvinE pressure on manufacturing

firms to become more responsible to the social and environmental impacr it
creates. Companies rvould like to brand themsel,",es rniith a "green" image.

i in :-t

3. Legislation: l'lanufacturing firms have to co,istantly

str-ive to meet cLrrrent

and upccming stricter environmental regulations from government.

Benefits of Green Manufacturing

:|

er

'tu

rr,'-

re-

i.

ri'aste rrrhen rvaste has already been eliniinated through recycling.

,L>.

rrn f-

,f,ne of the benefils of

-oreen manufacturing vrould be reducina cost because

in the end the company may not have to sheli out money to remove the

anra:
t ca-

'lers

2. Preserves caoital and saves money.

3. in-,pro.es procu.tir,'iiy and increases cost savings.
4. Green nranufacturing company increases their standards a little

ieci*cl:t-icn.

1*
.-

l!

.-

:sil.

14-

iv-.
> r-Tl

<
I

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l-,,
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e cttja)t

r.it^
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-- / /t'.^
/44COU

:- | C_ -A:'

r r^a

\ ^ l->

*,r\ rr
-a

hicl-re,- in

cualiiy, than c'.h:rs.

3. Helps drive anr j influence corporai.e behai'ior both rnternal and e>:ternal to
ensure sustairabilit;..
b. Green rr,anufacturing pronrotes innovative desion.
7 F>crr :,-l:ntin,ty tO ChanqinO
rUleS in enVirOnr-nental ,rectrlaiionc
v:u,u!r!,r.-r
: nd
-',",'y','Y

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r-!
r

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(ts5 )
r
Ar.fi.cial lnfelrigence is a branch
of sciencervhich dears rvrth
soluUons to complex problems in,
more t uman-like fashion.

ff:ri ::r!fti:

IXtr : Jl ;: i:,":" il,

il".,ffi : : :j,;
: ; ; 3; X
i i :,
irrtelligence ailow's computers
"?
to rearn rro, .*pur;;;.,
recognize parrerl's;j.l
amounts of complex data and
make complex decisions based
on-hu,nrn r.no*ieag.{
reasoning skills' Anificial inteltigence
his
bec,r,.l"-rn
i,npo.tant
6erd of stud,., r.. t
w,ide spread of apprications
in fieids ranging from mgdicjne to
agricurture

[H:';,;;

;it.

*
n

ft:.:iAil:;:,fmporranr

and mosr used branches of Al

are,,E,xpei-t _qysreiris ,*

,fl Expert System

'An expert

i
F

or*^

- bssed decision toor that usesboth

:r^:n^tnte|actiye;omputer
focrs;{
to sotve dilficutt decision probtems
based on knov.,tedse

ccqL-,

;::::::#:::tedse
A rypicai

expert system is made up of fii.e componen*

qJ us)Lrrueo
as
described oeto'
be!or,.,. F;
illustratesthemake-upofa$picafexpertsystern

D
L"

rm

Fig. Architecture cf an Experi Si,siem

1. The Inference Errgine

The inference engine is the,,super,.,iso;-,

th;t ii;-e:is
l.:nor,,.ledge containeci in
ihe _)ipert s'stEiii. it sta::s :
kngf iedge Q_ase, in infererlce englne
is reail_1,a

I
I

prciiai

iudgments basecj upor the sl.rnbclic

det3 ccni,?:nec :r, :i=

rL I,:
l- rlr;
.iIir-

2. The Knowledge

Base

The l:norvledge base is the place \,,'here the facts and rules that represent a hrman
e.\pert's "rules-of-thumb" resjcie. l"lost expert si/stems use ruies as the basjs for.fheiioperaticn, hence the reason mani'e.xpert s)'stems are ca]led "rule-based" s),stJ-!rs.
e

p:apl:

3.

'{
{
l11'Jedg=
.4-: I rt

J'here has to be a method for an e.xpert slstem developer to "feed" knog,ledge inro
base. This funcrion is perforrned through rhe

j-ns in

the e>:pert slrstern's knorr'lecige

developei-'s interface. The interface is a r.,'crd processor- lil:e - l,tor that I,:ts
C='.:loper enter nrr rules, ciiange rule s cr Ceiecr rules.

tttrlr' ., ::l

strIs' :l

The Der.eloper Interface

-4. E-rplanation Subs],stem

ii.:

_ I

. naat,
_
venu

-i
7

t'.':planetion -cubsvsten is C:sierre,J tc explair t,:.the user the line cf ,-ees. n;r,:
that the expert system used to reach a conclusion. Explanation subsystem is e>:ceilent
rnechanisms for use in instructicnal situarions and for debugging the s;,stenr during
lrs developmen t.

h../rLLJ
fnrt-

5.
F:

Tire User Interface

This part of an e.rpert system is used to furnish a convenient means of 1t,o

cor'ntunication ben,;een the user and the.s\fstem.

- \ra.y'

B) NeuralNetrvorks

Thjs diagram represents

an

artificiai neural net'.,"'ork. A neurai

n ct.,'. ork is niade of nodes arranqed
i;r rjiif:rent patterns representing
th,: "inteilisence" oi the rlei-\,,,orl:.
The liir.- thickness indicates tirc
slrei; gtii cf the connections.

r l-.
L],:

ir -:: jrr:-:,r-t-:l:i a:i-rlica:i;n L,: itr,;-:l nei-r.,.ci-1.:s is in p3119rn recognitic,n. Hi...t i-;ar.:,
-:, r:L'irc:'s in ihei;'bra:irs, ie:rn hci.,,to read human r..'riting, recognize a b:c
: i,,.r---, .: :i:,i cna r,';' id.:nlif:' li:tii cliiid;-en ir..n a se i of klCs. tieui-;l neti.,.,,.r-i:s
. ,--:.r --J'-::-,< :: ';s: il,: s;;;= p:::,:.il=s :h;t i-,!Uir-,lS i: ih: brzins U-(i tC i-ecCa:,.::.
:r:i ir'' j;i:c;-eii Eeti.- ins. s:.rn:
",.3".:r:J::l n:ii..,ci-i-:s:rE e digltai iepi-es:l:I:i_ r
.r :.:::::,(. fl-.':', a:e n:C= ;i::.:.i;;;"i
i-,ai_:c:ts, ccrrn:cied b,,,r.,.eight_s, r.,,h;c:..: a:e

Prcf.

Sanjag' 9819 744550

4;i
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indicative of the srrengths of the connections. The neurons
are arranged t:
depending on th! cornplexig of tJre application, rhere could
be a fer,v c,f rh:large number of thenr [hundreds or thousandsJ. lterative
prcpagation cf ir;

layerofneuronstothenext[trainingJiswhatenablestheneuraj
experience.

netr.,.orki..

Unlike humans, 'i'hen a neuraf is fully,trained, it can classifl,

and identii-,' :
massive amounls of complex data. lt could do this at
high speeds thi:
duplicated by hunians.

7s/!;i''t'
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,t)

Adriiission Detaiis at

i,
,.J;u Ii,:_'

'the r
in p:.:

1tf ,,

D) Designfor )l{anufacturi
ng & Designfor Assembly
t.i f 11\|

',...r.,/

i Jft't.l

'-*-_

c:.

Qrnl

In the pest, in most manufacturing irdustriesi when a ne*'product was considered, careful thought was given to how the product u'ould funclion, to its
appearance and, sometimes, to jts reljability. IJoweve r, little thought \\ 3s
given to hc*'easily the product could be assembled and how easill'(he various

ht

I n r.'1'-

,'"----1r
<r\
r-l_:_y-u

parrs coulJ be manufactured. This phi,osophy is often referced to as the

"ovcr-rhe-'*'all" approach. or "we d:sign it-you make it." In other words,
there is an imaginary w'all between the design and manufacturing functions;
designs are thrown "over the ilall" to manufacturing, as illustrated in Fig. l.l.
This ::ritude is particularly serious as ir affects assembly.

it:' p:::1
..1

98203478s5
-

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-l

Fig.

l.l

lllusrraling "ovcr thc uall" design (Ironi Rcf.4)

It lias Lreeli csiirnate,j that about 70iir cf the iifc c1,cle cost of a product is dere rrnrneiJ i...
basrc decisions rnade during product design
Ii6J.These design decisicns include the nrarcr i:i
for each part. part geo:netr-l', tolerarices. surface finish. how paris are organiz-ed into suh-

esselnblies, and the assenrbll' rrethcrds io b'e used. Once these decisions are made

iiI l': reduce the menrrfacturinq cosr cf rhe producl is limited. For example,iirhe
dcsigne r decides that

part is to

th:

aLr:l-

p;-c,.Ju:i

b:

mad= of an aiuminunr sand casring trut u,i ich Fross,-i\ic-s fe atures thal can L'e:chieve.ci onl'.'b.; machini;ig (such as tltreade,J
holes ard clt-rs:1r.,1erances), the manufil^turin! engineer h:s no atternatjve except to plan a prccr.ss sequen..
that starts rr'ith sand msting follo*ed br the sequence of machining opeiations neede,J ro
achieve the specified features. In this example,a better decision might be io use a Dlast::
nrlded pari thal can he mide in a single step. [r is importanr for the manufacti;rir,g e n::l11

:3:- to be given thc opptrrluni{r'to:tjiise the design e ngineer as iite p;od-r,-'t

io fa',orabii infiuencc th: nranuf acturabilitl of the producr.

r t olr ing.

ilrof. Sanjay 9B1g f41SS0

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I
I
I
I

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F
-

tF

Terms used to describe sucir attemob to favorabl,r'influence

;he manufactur.:+
a ne\r' product are design
for mdnufacturing (DF\{) and d*ign
zsstmbrl. (i :
course, DFM
linred,
so rei us use rlie term design
?111.-inexr:'icabry
"od
turing and assembll'
f)F*ua; D"rigi for manufa*uring ancr assernbry for
tematic consideration of manufacturahiut-v
and assemblabljtl,in the developme"i=lI

for

;J:.t"fij:sign'

This jncludes: (1) organizaticnal

;t"";;;;"d

{
ir'orrJ--.f

(2) design f.io.;,

organizationar changes in oFiL,A. Effective

impren:entatjon 6{ DF}.[,,A -:
organizasisnr.l rt^.rui;,;i;., farmalll,or
th a t cl os er'in rera crion
jinforr.
d b"ite, J.al"ni.,

il:3:.*i:.s:^:,i::Tfi"l.'
"n

;;;;;;;

"

accomprrsfiecj in severa]

:1":,:::?11"1,:ls,c11be
sisting
of product designers,

f$:::::131';::1,':g

il; il ; ;: il,

""yr,lijfl.crearing proje ct r.-a:*"nurr.r"Jg.*r;;")r7

-

"in?r"r;::1:i;j;?:l;":,
d, ffi;;;u",-o*igo,ia

u1,,.q"'i1 s
engineers to spend some career
:l rime
-9:td:p
in man-ufact-*i'g ,.
are.*f":,:o uy p*?,"t{ a*,igo; and (3) by ass:gl
3::T,?:f,g3"1i:.^T:t:l1ty
m
an ufa ct urin g engir eers I o th e prod
uci gdg, a "
;
;.1
"
time basis to serve as producibility consultans "p*.t-"o,

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