ASSIGNMENT: 02

THEORY OF AUTOMATION

Name :- Abhinay Singh

B.tech(mechatronics)
8th Semester
SAP ID :- 500047462
Roll No. :- 03
Que.1 What is the objective of Adaptive Control with Constraints? Draw the block diagram of a
typical computerized Adaptive Control with Constraints system for drilling operation and explain in
detail.

Ans.

Adaptive control possesses attributes of both feedback control and optimal control. Like a feedback
system measurements are taken on certain process variables. Like an optimal system, an overall
measure of performance is used. In adaptive control, this measure is called the index of performance
(IP).

In practice the AC system of machine tools can be classified into two types:

１. AC with optimization (ACO)

２. AC with constrains (ACC)

ACO refers to systems in which the performance is optimized according to a prescribed IP, sometimes
called the figure of merit. The IP is usually an economic function such as maximum production rate or
minimum machining cost.

ACC are systems in which machining conditions such as spindle speed or feed rate are maximized within
the prescribed limits of machines and tool constrains such as maximum torque, force or horse power. It
has been shown in cases where part configuration is not simple; the NC has many economic advantages
over conventional machining process. Similarly the use of AC systems is mostly justified when extremely
hard materials such as titanium and stainless steel have to be machined. A further saving of time is
achieved in the programming stage. In selecting feeds and speeds, the programmer must accommodate
the worst cutting conditions. In AC system the correct feed and speed are automatically found and it is
not necessary to spend efforts on calculations of optimum feeds and speeds. By increasing tool life
simultaneously with time saving, the adaptive control system contribute to lower operating costs, which
justifies the extra price of adding AC to a conventional NC machine.
Que. 2 Explain the various problems encountered in interfacing handling and storage systems with
manufacturing units. (b) What are the special features of AS/RS components? Discuss briefly.
Ans.-

Inaccurate Quantities

Inaccuracy remains one of the biggest problems facing all warehouses. Inaccuracy takes shape in many
forms, such as inaccurate quantities, inaccurate storage locations, inaccurate pricing and inaccurate
identification. At some point in time, most companies experience an inaccurate quantity of one or more
products in their warehouse. This happens very often with retail companies, especially big-box retailers
that have millions of product stock-keeping units, or SKUs. Often, an inaccurate quantity of products
stems from one of the other areas of inaccuracy. An item placed in the wrong location of a warehouse
can get overlooked when searching for inventory. This leads to an inaccurate count of the inventoried
item.

Capacity

For warehouses large and small, capacity issues often equate to inventory issues. Often when a
warehouse becomes crowded with pallets and cases of inventory, basic rules for managing the
warehouse get overlooked. In an attempt to store more inventory, products often get damaged, lost and
not accounted for in the inventory management system. Storage problems can also create obsolete
inventory issues. A company may have one carton of a product left but is unable to find it because of
storage problems. The product then becomes obsolete and gets written off the company’s balance
sheet.

Damage

Inventory typically gets handled multiple times in a warehouse. Each time it gets touched or moved it
becomes susceptible to damage. Many companies try to recoup some of the financial lose of damaged
inventory by selling it at substantial discounts to the public--think about those furniture liquidation
centers that sell scratch and dent merchandise. Damaged inventory happens in numerous ways. If a
company experiences an abundance of damaged inventory it should consider additional employee
training along with conducting a root-cause analysis to determine the origin of the problem.

Product Identification

Warehousing inventory issues occur when inventory arrives with incorrect labels, barcodes, product
SKUs or packaging. For example, an orange plastic cup has an SKU of ABC123 while a blue plastic cup has
an SKU of DEF456. Both cups are packaged 100 units per carton. The outside of each carton includes the
product’s SKU and description plus a barcode for scanning the product into the inventory software.
Upon arrival, the warehouse scans the barcode on the cartons marked orange plastic cups, but the
manufacturer inadvertently placed the blue plastic cup’s barcode on the cartons. The warehouse
personnel accept the barcode scan without verifying the box contents. This act creates an immediate
inventory discrepancy.
Training

Unfortunately, a large number of warehouse inventory issues results from improper or a complete lack
of employee training. Typically, issues involving inventory accuracy, damage and product identification
can get traced back to human error. Improperly trained warehouse personnel create inventory issues
that better-trained personnel regularly avoid. For example, an under-qualified forklift driver is more
likely to damage products during inventory put away and retrieval than an experienced forklift driver.
Proper training increases a warehouse’s efficiency and productivity and decreases inventory
management issues.

B, In general, an AS/RS performs a basic set of operations without human intervention, regardless

of the specific type of system that is employed.

1. Automatic removal of an item from a storage location

2. Transportation of this item to a specific processing or interface point

3. Automatic storage of an item in a predetermined location, having received an item from a

processing or interface point

Importance of AS/RS

 An AS/RS is highly space efficient. Space now occupied by raw stock, work in process, or

finished parts and assemblies can be released for valuable manufacturing space.

 Increased storage capacity to meet long-range plans.

 Improved inventory management and control.
 Quick response time to locate, store, and retrieve items.
 Reduced shortages of inventory items due to real-time information and control.
 Reduced labor costs due to automation.
 Improved stock rotation.
 Improved security and reduced pilferage because of closed storage area.
 Flexibility in design to accommodate a wide variety of loads.
 Flexibility in interfacing with other systems such as AGVS, FMS, and inspection systems such

as coordinate measuring machines.

 Reduced scrap and rework due to automatic handling of parts.

 Reduced operating expenses for light, power, and heat.
 Helps implement just-in-time (JIT) concepts by getting the right parts, tools, pallets and

fixtures to the right place at the right time because of automatic control of storage and retrieval

functions and accurate inventory management.

Que. 03 Describe various hydraulic and pneumatic systems used for Automated Material Handling.

Ans.- The list of various hydraulic and pneumatic equipments that are used in the automated material
handling industry are as follows:

Hydraulic pump: It is defined as the device that converts the mechanical energy into the hydraulic
energy. The pumps are of various types, positive displacement pumps, reciprocating pumps. These can
be further classified.

Pneumatic pumps: It is defined as the pump which converts the mechanical energy of air into the fluid
energy or pressure. These can also be classified and one can be selected as per the applications.

Valves: These can be classified as hydraulic and pneumatic. The difference lies in the medium of
working, the hydraulic ones work on pressurised liquids while the pneumatic ones work on the
pressurised air. Valves are the devices that are used to control the flow of the fluid in a particular
direction as per the requirement of the process.

Actuators: These are defined as the devices that convert the hydraulic energy of the fluids into the
mechanical energy. The mechanical energy can be observed either by reciprocating motions or rotary
motion.

For reciprocating actuations we have the cylinders and for rotary applications we have the motors.
These can further be classified to hydraulic or pneumatic as per the need of the process and the nature
of the fluid being used.

Power packs: The set of equipments that is used to control the motion of the pumps and motors as per
the requirement is referred to as the power pack of the hydraulic systems

Que.-(4) Explain use of computer applications, sensors, GPS/GIS, and RFID in material handling
system.

Ans.- The above mentioned equipments play a vital role in the material handling systems.

Computer applications: These play a vital role in management of the material in the location or the
warehouse. There are various computer applications that are used in order to display the present
amount of material present or the present location where the material is present. Another application
that can be observed is data logging. This can be easily accomplished by use of HMI or in some cases PLC
and SCADA.

Sensors: These are very crucial to the application of the material handling system. These can be used in
two ways. One of them being the in AGVs, where the sensors are used to identify the path and follow it
or identify the beacon in the case of self-guided vehicles. The another way in which the sensors can be
used is in identification of the material, in case of AS/RS systems for identification of delivery lane and
pickup lane or also the extent up to which the equipments can work.

PS/GIS: The positioning systems or the geographic information systems play a important role in the
material handling process in case of AGV. Specially in the case of self guided AGV these are useful since
these can be used to track the location of the vehicle in case of breakdown and also in case of
monitoring. These are equally useful in other material handling systems.

RFID: This is one kind of sensor that is used for the communication from one point to another. This can
be used in order to communicate regarding the receiving of certain products if they are tagged. Also
these can be used to communicate the completion of operation to carry out the next step.

Que.-(5) Explain the concept of simulation during automation of industry? Differentiate between the
discrete control system and continuous control system with industrial applications.

Ans.- .- A simulation is an approximate imitation of the operation of a process or system; the act of
simulating first requires a model is developed. This model is a well-defined description of
the simulatedsubject, and represents its key characteristics, such as its behaviour, functions and abstract or
physical properties.

Continuous Control Systems-

In continuous control, the usual objective is to maintain the value of an output variable et a desired level,
similar to the operation of a feedback control system as defined . However, most continuous processes in
the practical world consist of many separate feedback loops, all of which have to be controlled and
coordinated to maintain the output variable at the desired value. Examples of continuous processes are the
following:
Control of the uuiput of a chemical reaction that depends on temperature, pressure, lind input flow rates
of several reactants. All of these variables and/or parameters are continuous .
Control of the position of a workpart relative to a cutting tool in a contour milling operation in which
complex curved surfaces are generated. The position of the part is defined by X, j'. and acoordinate
values. As the part moves, the x, y, and z values can he considered as continuous variables and/or
parameters that change over lime to machine the part.

.
Discrete Control Systems-

In discrete control, the parameters and variables of the system are changed at discrete moments in time.
The changes involve variables and parameters that are also discrete, typically binary (ON/OFF). The
changes are defined in advance by means of a program of instructions, for example, a work cycle program
. The changes are executed either because the state of the system has changed or because a certain amount
of time has elapsed. These two cases can be distinguished as (1) eventdriven changes or (2) timedriven
changes .

An eventdriven change is executed by the controller in response to some event that has caused the state of
the system to he altered. The change can be to initiate an operation or terminate an operation, start a
motor or stop it, open a valve or close it, and so forth. Examples of eventdriven changes are'. A robot
loads a workparl into the fixture, and the part is sensed by a limit switch. Sensing the part's presence is the
event that alters the system state. The eventdriven change is that the automatic machining cycle can now
commence. The diminishing level of plastic molding compound in the hopper of an injection molding
machine triggers a lowlevel switch, which in tum triggers a valve to open that starts the flow of new
plastic into the hopper. When the level of plastic reaches the highlevel switch, this triggers the valve to
close, thus stopping the flow of pellets into the hopper. Counting parts moving along a conveyor past an
optical sensor is an eventdriven system. Each part moving past the sensor is an event that drives the
counter.

Que:-(6) Explain ten strategies for industrial automation and its process improvement .

Ans.-

1. Specialization of operations, The first strategy involves the use of special-purpose equipment
designed to perform one operation with the greatest possible efficiency. This is analogous to the
concept of labor specialization, which is employed to improve labor productivity

2. Combined operations. Production occurs as a sequence of operations. Complex parts require dozens,
or even hundreds, of processing steps. The strategy of combined operations involves reducing the
number of distinct production machines or workstations through which the part must be routed. This is
accomplished by performing more than one operation at a given machine, thereby reducing the number
of separate machines needed

3. Simultaneous operations. A logical extension of the combined operations strategy is to

simultaneously perform the operations that are combined at one workstation. In effect, two or more
processing (or assembly) operations are being performed simultaneously on the same work part, thus
reducing total processing time.

4. Integration of operations. Another strategy is to link several workstations together into a single
integrated mechanism, using automated work handling devices to transfer parts between stations. In
effect, this reduces the number of separate machines through which the product must be scheduled.
With more than one workstation, several parts can be processed simultaneously, thereby increasing the
overall output of the system.
5. Increased flexibility. This strategy attempts to achieve maximum utilization of equipment for job shop
and medium-volume situations by using the same equipment for a variety of parts or products, It
involves the use of the flexible automation concepts. Prime objectives are to reduce setup time and
programming time for the production machine. This normally translates into lower manufacturing lead
time and less work-in-process.

6. Improved material handling and storage. A great opportunity for reducing nonproductive lime exists
in the use of automated material handling and storage systems. Typical benefits include reduced work-
in-process and shorter manufacturing lead times.

7. On-line inspection, Inspection for quality of work is traditionally performed after the process is
completed. This means that any poor-quality 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, ClM
involves extensive use of computer applications, computer data bases, and computer networking
throughout the enterprise

Que(7):- Explain the concept and use of Flexible Manufacturing Systems and lean manufacturing
systems with regard to agile manufacturing systems. Discuss with an industrial example.

Ans.- Flexible Manufacturing Systems -

A flexible manufacturing system (FMS) is a method for producing goods that is readily adaptable to
changes in the product being manufactured, both in type and quantity. Machines and
computerized systems are configured to manufacture different parts and handle varying levels
of production. A flexible manufacturing system (FMS) gives manufacturing firms an advantage to quickly
change a manufacturing environment to improve process efficiency and thus lower production cost.
However, up-front costs may be greater for installing specialized equipment that allows for flexibility
and customization.

The Basics of Flexible Manufacturing Systems

The roots of a flexible manufacturing system were laid by Jerome H. Lemelson (1923-97), an American
inventor with a master's degree in Industrial Engineering who filed numerous patents for the idea of an
FMS in the early 1950s. His original conception was a robot-based system that could weld, rivet, convey
and inspect manufactured goods. FMS debuted on factory floors in the late 1960s and proliferated in
the 1970s in the U.S. and Europe. A
flexible manufacturing system can include a configuration of processing workstations interconnected
with computer terminals that process the end-to-end manufacturing of a product, from
loading/unloading functions to machining and assembly to storing to quality testing and data processing.
The system can be programmed to run a batch of one set of products in a particular quantity and then
automatically switch over to another set of products in another quantity.

Pros and Cons of a Flexible Manufacturing System

The main benefit is the enhancement of production efficiency, whereby downtime is reduced because
the need to shut down the production line to set up for a different product is eliminated. One
disadvantage of FMS is its higher up-front cost and the time required to carefully preplan the system
specifications. Another possible drawback is the higher cost associated with the need for specialized
labor to run, monitor and maintain the FMS; however, since the FMS is meant to increase production
automation (i.e., reduce labor input), the result is typically a net benefit in terms of cost. Common FMS
layouts take the form of line, loop, ladder, and open field.

Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing

systems while simultaneously maximizing productivity. ... Lean manufacturing is based on a
number of specific principles, such as Kaizen, or continuous improvement.

Agile manufacturing:-
Agile manufacturing systems can be conceptually thought of as being an integrated whole of complex
interacting sub-systems, organized in such a way as to endeavor towards a common set of goals
(Merchant, 1984). Due to the inherent complexities and agility associated with the modern
manufacturing systems, modeling these complex interacting subsystems using common analytical and
mathematical approaches has proved to be very difficult.

Process Planning, scheduling and manufacturing resource planning (MRP) are considered as three major
items in the planning sub-system. Process planning transforms information of a product into sequences
of operations with a schedule. Scheduling and MRP are carried out as service functions. CI techniques
appear to be the perfect approach in dynamic planning, scheduling and manufacturing resource
planning.
Que(8):- explain the concept of cellular manufacturing and group manufacturing technology which
you have observed in any industry.

Ans.- Group Technology and Cellular Manufacturing (GT/CM) have been widely-researched areas in the
past 15 years and much progress has been made in all branches of GT/CM. Resulting from this research
activity has been a proliferation of techniques for part-machine grouping, engineering data bases, expert
system-based design methods for identifying part families, new analytical and simulation tools for
evaluating performance of cells, new types of cell incorporating robotics and flexible automation, team-
based approaches for organizing the work force and much more; however, the field lacks a careful
compilation of this research and its outcomes. The editors of this book have commissioned leading
researchers and implementers to prepare specific treatments of topics for their special areas of
expertise in this broad-based philosophy of manufacturing. The editors have sought to be global both in
coverage of topic matters and contributors. Group Technology and Cellular Manufacturing addresses
the needs and interests of three groups of individuals in the manufacturing field: academic researchers,
industry practitioners, and students.

Cellular manufacturing technology -

Cellular manufacturing is a process of manufacturing which is a subsection of just-in-
time manufacturing and lean manufacturing encompassing group technology. The goal of cellular
manufacturing is to move as quickly as possible, make a wide variety of similar products, while making
as little waste as possible. Cellular manufacturing is a process of manufacturing which is a subsection
of just-in-time manufacturing and lean manufacturing encompassing group technology. The goal of
cellular manufacturing is to move as quickly as possible, make a wide variety of similar products, while
making as little waste as possible. Cellular manufacturing involves the use of multiple "cells" in
an assembly line fashion. Each of these cells is composed of one or multiple different machines which
accomplish a certain task. The product moves from one cell to the next, each station completing part of
the manufacturing process. Often the cells are arranged in a "U-shape" design because this allows for
the overseer to move less and have the ability to more readily watch over the entire process. One of the
biggest advantages of cellular manufacturing is the amount of flexibility that it has. Since most of the
machines are automatic, simple changes can be made very rapidly. This allows for a variety of scaling for
a product, minor changes to the overall design, and in extreme cases, entirely changing the overall
design. These changes, although tedious, can be accomplished extremely quickly and precisely. A cell is
created by consolidating the processes required to create a specific output, such as a part or a set of
instructions. These cells allow for the reduction of extraneous steps in the process of creating the
specific output, and facilitate quick identification of problems and encourage communication of
employees within the cell in order to resolve issues that arise quickly. Once implemented, cellular
manufacturing has been said to reliably create massive gains in productivity and quality while
simultaneously reducing the amount of inventory, space and lead time required to create a product. It is
for this reason that the one-piece-flow cell has been called "the ultimate in lean production.
group manufacturing technology :-

Group Technology (GT) is a manufacturing philosophy designed to simplify and standardize production
operations by taking advantage of similarity. Manufacturing performance parameters such as cycle time,
quality and costs can be improved by capitalizing on similarities that can be found in such things as
workpiece design, assembly methods, purchasing of materials, or tooling designs.

Que(9):- Explain Robot assisted material handling and State its industrial applications

Ans:- There are six main types of industrial robots: cartesian, SCARA, cylindrical, delta, polar and
vertically articulated. However, there are several additional types of robot configurations. Each of these
types offers a different joint configuration.

The following robotic applications are the most common in the automotive industry:

1. Collaborative Robots
These collaborative robots are built to work together with other robots, on enormous assembly lines.
Robots must collaborate between handling and welding robots to make such assembly lines function
properly.
2. Robotic Painting
Professional painters are difficult to find and the job is a highly toxic one. This makes it perfect for
robots, because the paint job needs to be highly consistent over a large area of paint, and reducing the
amount of wasted material can add up to quite a bit of savings over time.
3. Robotic Welding
Robotic welding has been the top robotic application in the automotive sector for a long time, as every car
needs a high number of welds before it’s complete. Given the high value of the finished product,
productivity from automation is enormous.
4. Robotic Assembly
In many automotive plants, robots are assembling smaller components like pumps and motors at high
speeds. Often, robots are performing tasks like windshield installation and wheel mounting to increase
throughput.
5. Material Removal
High consistency and repeatability make robots perfect for material removal processes like trimming and
cutting. This could be in the form of cutting fabrics, trimming plastic moldings and die castings or even
polishing molds.
6. Part Transfer and Machine Tending
Pouring molten metal, transferring metal stamps, and loading and unloading CNC machines are all best
completed by a robot as they are dangerous. When completed consistently with little downtime they can
also be a source of major productivity.
Que(10):- Expalin the process of work part transfer. Discuss on significance of storage buffers during
work part transfer.

Ans.-

 A raw workpart enters one end of the line and the processing steps are performed sequentially
as the part moves from one station to the next.
 It is possible to incorporate buffer storage zones into the flow line, either at a single location or
between every workstation.
 It is also possible to include inspection stations in the line to automatically perform intermediate
checks on the quality of the workparts.
 Manual stations might also be located along the flow line to perform certain operations which
are difficult
 Symbols used in production systems diagrams

Objectives of the use of Transfer line-

 o reduce labor costs
 To increase production rates
 o reduce work-in-process
 To minimize distances moved between operations
 To achieve specialization of operations
 To achieve integration of operations