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Kasegaon Education Society (KES)

Rajarambapu Institute of Technology (RIT)


DEPARTMENT OF MECHANICAL ENGINEERING

FMTH0301/Rev.5.1
Course Plan
Semester: 8 - Semester

Year:

Course Title: Automation and Robotics

Course Code: ME 408

Total Contact Hours: 4

Duration of SEE Hours: 3

SEE Marks: 50

ISE + MSE Marks: (20+30=50)

Lesson Plan Author: Prof. Mukund Kavade

Date: 19-01-2016

Checked By: Prof. Chandan Waghmare

Date: 20-01-2016

Prerequisites:
1. Knowledge of Advanced Production Systems.
2. CNC Machine tools
3. Knowledge of CNC part programming etc.

Course Outcomes (COs):


At the end of the course the student should be able to:
1.

Recognize manufacturing automation and Advanced Automation Functions


Explain process and discrete manufacturing industries and its processes.
3. Explain and evaluate Transfer Lines and Assembly Automation.
4. Recognize and explain need, meaning and classification of robotics, its control systems and end
effectors.
5. Write simple robot programs in VAL II language.
6. Explain robot applications
2.

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Course Articulation Matrix: Mapping of Course Outcomes (CO) with Program


Outcomes
Course Title: Automation and Robotics

Semester: 8 - Semester

Course Code: ME 408

Year:

Course Outcomes (CO) / Program Outcomes


(PO)

1. Recognize manufacturing automation and


Advanced Automation Functions

2. Explain process and discrete manufacturing


industries and its processes.
3. Explain and evaluate Transfer Lines and
Assembly Automation.

4. Recognize and explain need, meaning and


classification of robotics, its control systems and
end effectors.

H
H

5. Write simple robot programs in VAL II


language.
L

6. Explain robot applications

Degree of compliance L: Low M: Medium H: High

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Course Content
Course Code: ME 408

Course Title: Automation and Robotics

L-T-P-SS: 3-1-0-0

Credits: 4

Contact Hrs: 4

CIE Marks: 50

SEE Marks: 50

Total Marks: 100

Teaching Hrs: 4

Exam Duration: 3 hrs

Content

Hrs

Unit - 1
Chapter No. 1. Manufacturing automation

8 hrs

Automated manufacturing systems, fixed /programmable /flexible automation, Need of


automation, Automation principles and strategies. Basic elements of automated
systemspower, program and control, Advanced automation functions: Safety monitoring,
Maintenance and Repair diagnostics, Error detection and recovery, Levels of automation.

Chapter No. 2. Industrial Control Systems

4 hrs

Industrial control systems in process and discrete manufacturing industries, Continuous and
discrete control, Computer process control, forms of computer process control

Chapter No. 3. Transfer Lines

6 hrs

Fundamentals, Configurations, Transfer mechanisms, storage buffers, control, applications;


Analysis of transfer lines with and without storage buffers.

Chapter No. 4. Automated Assembly Lines

6 hrs

Assembly Automation: Types and configurations, Parts delivery at workstations- Various


vibratory and non-vibratory devices for feeding and orientation, Product design for
automated assembly, Quantitative analysis of assembly systems.

Chapter No. 5. Fundamentals of Industrial Robots

6 hrs

Robot anatomy, Robot motions, Robot specifications, Robot drive systems, Robot control
systems, End effectors, Robot sensors

Chapter No. 6. Robot programming

6 hrs

Robot Programming: Lead through method, Robot program as a path in space, Methods of
defining positions in space, Motion interpolation, branching; Textual robot programming
languages-VAL II. Constants variables and other data objects, Motion commands, End
effectors and sensor commands.

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Chapter wise Plan


Course Code and Title: ME 408 / Automation and Robotics
Chapter Number and Title: 1. Manufacturing automation

Planned Hours: 8 hrs

Learning Outcomes:
At the end of the topic the student should be able to:
TLOs

COs

BL

1. Define and classify manufacturing automation

CO1

L2

2. Recognize the need of manufacturing automation.

CO1

L2

3. Explain the automation principles and trategies

CO1

L2

4. Explain advanced automation functions

CO1

L2

5. Discuss automation levels

CO1

L2

Lesson Schedule
Class No. - Portion covered per hour

Date
planned

1. Introduction to syllabus, COs, POs mapped with the course, teaching,


assessment and evaluation techniques.

11/01/16

2. Automated manufacturing systems, fixed /programmable /flexible


automation

12/01/16

3. Need of automation

14/01/16

4. Automation principles and strategies.

18/01/16

5. Basic elements of automated systems: power, program and control

19/01/16

6. Advanced automation functions: Safety monitoring, Maintenance and


Repair diagnostics

21/01/16

7. Error detection and recovery

25/01/16

8. Levels of automation.

28/01/16

Date
Conducted

Review Questions
Sr. No. - Questions

TLOs

BL

1. What are the Course Outcomes (COs) of this course (Automation and
Robotics)

TLO1

L1

2. What is manufacturing automation? What are its types?

TLO1

L2

3. How flexible automation reduces production down time?

TLO1

L2

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

4. Discuss the reasons for manufacturing automation?

TLO2

L2

5. Disvuss the manufacturing principles and strategies

TLO3

L2

6. Explain the advanced automation functions

TLO4

L2

7. What are the levels of manufacturing automation

TLO5

L2

8. What is manufacturing automation? Why companies implement TLO1


automation?

L2

9. What are the basic elements of automation? Discuss program of


instructions in detail.

L2

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TLO1

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Course Code and Title: ME 408 / Automation and Robotics


Chapter Number and Title: 2. Industrial Control Systems

Planned Hours: 4 hrs

Learning Outcomes:
At the end of the topic the student should be able to:
TLOs's

CO's

BL

1. Summarize Industrial Control systems in process and discrete item


manufacturing industries

CO2

L2

2. To define and differentiate Continuous and discrete control

CO2

L4

3. To explain process control and forms.

CO2

L2

Lesson Schedule
Class No. - Portion covered per hour

Date
planned

1. Industrial control systems in process and discrete manufacturing


industries

01/02/16

2. Continuous and discrete control

02/02/16

3. Computer process control

04/02/16

4. forms of computer process controls

08/02/16

PI Code

Date
Conducted

Review Questions
Sr. No. - Questions

TLOs

BL

1. Compare continuous control with discrete control

TLO2

L4

2. Explain with flow chart feed forward control system

TLO3

L2

3. What is adaptive control system?

TLO3

L2

4. Explain with suitable examples event driven changes and time driven
changes in discrete control system.

TLO3

L2

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PI Code

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Course Code and Title: ME 408 / Automation and Robotics


Chapter Number and Title: 3. Transfer Lines

Planned Hours: 6 hrs

Learning Outcomes:
At the end of the topic the student should be able to:
TLOs's

CO's

BL

1. Explain fundamentals and configuration of transfer lines

CO3

L2

2. Describe transfer mechanism with sketches.

CO3

L1

3. Recognize the need of storage buffers and interpreting the benefits of


the same.

CO3

L4

4. Describe the control of the production lines.

CO3

L2

5. Summarize the applications of production lines.

CO3

L2

6. Analyze efficiency of transfer lines with and without storage buffers.

CO3

L4

Lesson Schedule
Class No. - Portion covered per hour

Date
planned

1. Fundamentals and Configurations of transfer lines

09/02/16

2. Workpart transfer mechanism

11/02/16

3. storage buffers, control, applications

15/02/16

4. Control of the automated production lines

16/02/16

5. Analysis of transfer lines without storage buffers.

18/02/16

6. Analysis of transfer lines with storage buffers.

22/02/16

PI Code

Date
Conducted

Review Questions
Sr.No. - Questions

TLOs

BL

1. Explain with sketch varous configurations of transfer lines.

TLO1

L2

2. Explain with sketch linear work transfer mechanism

TLO2

L1

3. What is storage buffer? Why it is used on transfer lines?

TLO3

L4

4. What are the applications of automated production lines?

TLO5

L2

5. A ten station transfer machine has an ideal cycle time of 30 sec. The
frequency of line stops F = 0.075 stops/cycle. When a line stop occurs, the
average downtime is 4.0 min. Raw workpart cost is Rs.0.55/pc, line
operating cost = Rs.42/hr, and the cost of disposable tooling = Rs.0.27/pc.
Determine: i) Average production rate in pc/hr. ii) Line efficiency iii)

TLO6

L4

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PI Code

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Proportion downtime and Average cost of a component produced.


6. A 30 station transfer line has an ideal cycle time Tc = 0.75 min, average
downtime Td = 6.0 min. per line stop occurrence and a station failure
frequency p = 0.01 for all stations. A storage buffer of capacity of 20 parts
is located in between stations 15 and 16 to improve line efficiency. Using
the upper bound approach Determine: i) Line efficiency ii) Production rate
of the line. Assume that the downtime (Td = 6.0 min) is constant bsp; Line
efficiency iii) Proportion downtime and Average cost of a component
produced.

TLO6

L4

7. In the operation of a 15 station transfer line, the ideal cycle time = 0.58 TLO6
min. Breakdowns occurs at a rate of every 20 cycles, and the average
downtime per breakdown is 9.2 min. Transfer line is located in a plant that
works an 8 hrs/day and 5 days/ week. Determine: i) Line efficiency. How
many parts the transfer line will produce in a week. ht:150%;mso-list:l0
level1 lfo1'>ii) Production rate of the line. Assume that the downtime (Td =
6.0 min) is constant bsp; Line efficiency iii) Proportion downtime and
Average cost of a component produced.

L4

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Course Code and Title: ME 408 / Automation and Robotics


Chapter Number and Title: 4. Automated Assembly Lines

Planned Hours: 6 hrs

Learning Outcomes:
At the end of the topic the student should be able to:
TLOs's

CO's

BL

1. Define, classify and explain configuration of assembly automation

CO3

L2

2. Explain various methods used to deliver parts at workstations

CO3

L2

3. Recognize the design of product for automated assembly

CO3

L3

4. To perform quantitative analysis of automated assembly systems.

CO3

L5

Lesson Schedule
Class No. - Portion covered per hour

Date
planned

1. Assembly Automation: Types and configurations

23/02/16

2. Parts delivery at workstations- Various vibratory and non-vibratory


devices for feeding and orientation

25/02/16

3. Product design for automated assembly

08/03/16

4. Quantitative analysis of assembly systems

10/03/16

5. Quantitative analysis of assembly systems 2

14/03/16

6. Quantitative analysis of assembly systems 3

15/03/16

Date
Conducted

Review Questions
Sr. No. - Questions

TLOs

BL

1. Discuss with sketches Automated assembly system configurations.


Write in tabular format possible work transfer methods for these
configurations.

TLO1

L2

2. Discuss the principles of design for automated assembly

TLO3

L3

3. A six station automatic assembly machine has an ideal cycle time of 12 TLO4
sec. Downtime occurs for two reasons. First mechanical and electrical
failures of the workheads occur with the frequency of once per 50 cycles.
Average downtime for these causes is 3 min. Second defective
components also result in downtime. The fraction defect rate of each of the
six components added to the base part at six stations is q = 2%. The
probability that a defective component will cause a station jam is m = 0.5
for all stations. Downtime per occurrence for defective part is 2 min.
determine: i) Yield of assemblies that are free of defective components ii)

L5

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Proportion of assemblies that contain at least one defective component.


Average production rate of good assemblies.
4. 1. Discuss with sketches Automated assembly system configurations. TLO1
Write in tabular format possible work transfer methods for these
configurations.

L2

5. 2. Discuss the principles of design for automated assembly

TLO3

L3

6. 3. A six station automatic assembly machine has an ideal cycle time of TLO4
12 sec. Downtime occurs for two reasons. First mechanical and electrical
failures of the workheads occur with the frequency of once per 50 cycles.
Average downtime for these causes is 3 min. Second defective
components also result in downtime. The fraction defect rate of each of the
six components added to the base part at six stations is q = 2%. The
probability that a defective component will cause a station jam is m = 0.5
for all stations. Downtime per occurrence for defective part is 2 min.
determine: i) Yield of assemblies that are free of defective components ii)
Proportion of assemblies that contain at least one defective component.
Average production rate of good assemblies.

L5

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Course Code and Title: ME 408 / Automation and Robotics


Chapter Number and Title: 5. Fundamentals of Industrial Robots

Planned Hours: 6 hrs

Learning Outcomes:
At the end of the topic the student should be able to:
TLOs's

CO's

BL

1. To recognize the need of robot

CO4

L2

2. To define robot and robotic system

CO4

L2

3. To explain robot anatomy and physical configurations

CO4

L1

4. To explain robot degrees of freedom

CO4

L2

5. To explain robot motions

CO4

L2

6. To explain robot technical features such as axes of motions, speed,


acceleration, work envelope, accuracy, repeatability, precision, payload
and reliability.

CO4

L2

7. To compare robot drive systems viz. electric, hydraulic and pneumatic.

CO4

L4

Lesson Schedule
Class No. - Portion covered per hour

Date
planned

1. Introduction to robotics, Need of using robot

17/03/16

2. Robot anatomy, Robot motions

21/03/16

3. Robot specifications

22/03/16

4. Robot drive systems

28/03/16

5. Robot control systems

29/03/16

6. End effectors, Robot sensors

31/03/16

Date
Conducted

Review Questions
Sr. No. - Questions

TLOs

BL

1. Define robot. What are the basic elements of robotic system

TLO2

L2

2. What is the need of using robot. What are the basic elements of robotic
system

TLO1

L2

3. Explain the basic configurations of the robots and their work volumes f
robotic system

TLO3

L1

4. Discuss the following robot specifications: i) Work volume ii) Speed of TLO6
movement iii) Robot motions iv) Payload capacity

L2

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

Course Code and Title: ME 408 / Automation and Robotics


Chapter Number and Title: 6. Robot programming

Planned Hours: 6 hrs

Learning Outcomes:
At the end of the topic the student should be able to:
TLOs's

CO's

BL

1. To list robot programming methods

CO5

L1

2. To write robot program using lead through methods

CO5

L3

3. To explain robot program as path in a space.

CO5

L4

4. To explain joint interpolation

CO5

L2

5. To explain methods of defining positions in space

CO5

L2

6. To explain and use motion interpolation in robot programming

CO5

L3

7. To explain and use branching in robot programs.

CO5

L3

8. To explain the methodology of writing robot programs using textual


programming language.

CO5

L2

9. To recognize the use of constants, variables, motion commands, end


effector and sensor commands in robot programs.

CO5

L3

To write the robot programs using VAL II programming language.

CO5

L3

10To explain robot applications

CO6

L2

Lesson Schedule
Class No. - Portion covered per hour

Date
planned

1. Robot Programming: Lead through method,

04/04/16

2. Robot program as a path in space

05/04/16

3. Methods of defining positions in space, Motion interpolation

07/04/16

4. Textual robot programming languages-VAL II

11/04/16

5. Constants variables and other data objects, Motion commands,

12/04/16

6. End effectors and sensor commands.

19/04/16

Date
Conducted

Review Questions
Sr.No. - Questions

TLOs

BL

1. Discuss any three monitor commands used in VAL II programming language.

TLO9

L3

2. Discuss lead through programming methods

TLO1

L1

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Kasegaon Education Society (KES)


Rajarambapu Institute of Technology (RIT)
DEPARTMENT OF MECHANICAL ENGINEERING

3. Write a program in VAL II for palletizing application. Pallet capacity is 20 (5 rows


and 4 columns). Incoming conveyor brings the workpiece at fixed position. Robot
picks it up and places into the pallet. When pallet is full it is taken away from the
work cell and empty pallet is brought in and then cycle repeats. Make suitable
assumptions and state them clearly.

TLO9

L3

4. Write a leadthrough robot program using branching to perform a palletizing


operation. Suppose that the operation required the robot to pick up parts from an
input chute, and place them on a pallet with 24 positions as depicted in figure given
below. When a start signal is given, the robot must begin picking up parts and
loading them into the pallet, continuing until all 24 positions on the pallet are filled.
The robot must then generate a signal to indicate that pallet is full, and wait for the
start signal to begin the next cycle. height:8.1pt'> Write a leadthrough robot program
using branching to perform a palletizing operation. Suppose that the operation
required the robot to pick up parts from an input chute, and place them on a pallet
with 24 positions as depicted in figure given below. When a start signal is given, the
robot must begin picking up parts and loading them into the pallet, continuing until
all 24 positions on the pallet are filled. The robot must then generate a signal to
indicate that pallet is full, and wait for the start signal to begin the next cycle.

TLO9

L3

5. What are the main categories of robot applications? List the processing TLO10
applications of robot..

L2

Prof. Mukund V. Kavade

Prof. Dr. S. S. Gawade

Course Faculty

Head of Department (Mech. Engg.)

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