COMPUTER AIDED MANUFACTURING

UNIT III- AUTOMATION AND AUTOMATED ASSEMBLY SYSTEMS 1

Topics covered:

 Automated manufacturing system: Historical development and future trends.

 Automation: Need, basic elements, levels and advanced automation functions.
 Automated assembly: Fundamental, system configuration, part delivery at Workstation and its
applications.
 Design for automated assembly.
 Quantitative analysis of assembly systems.
 Line balancing algorithm: Largest candidate rule, simple problems.
 Line balancing algorithm: Kilbridge and Wester method, simple problems.
 Line balancing algorithms, Ranked positional weights method, computerized techniques, and
simple problems.
 Line balancing algorithms, computerized techniques, and simple problems.

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AUTOMATED MANUFACTURING SYSTEM: HISTORICAL DEVELOPMENT AND FUTURE TRENDS.

An Automated Manufacturing System (AMS) is an interconnected system of material processing stations 2
capable of automatically processing a wide variety of part types simultaneously under computer
control. Such a system exhibits flexibility in parts routing, part processing, part handling, and tool
changing.
Without automated manufacturing systems, factory output would be vastly reduced, production would
be very time consuming, working conditions would be less safe and quality control would be extremely
difficult. Employees would need to work twice as hard to achieve in a day what they can now achieve
in an hour with automated industrial systems. In short, manufacturing would be much more difficult
and dangerous.
Automated Manufacturing Systems: A Brief History
In 1913, Henry Ford pioneered the first successful automated manufacturing system by implementing a
mechanized belt in his automobile factory. The belt allowed for parts to be pulled through an
assembly line at a blazing six feet per minute. This innovation may seem laughable by today’s
standards, but this was an incredible innovation in the early 20th century, which successfully reduced
automobile production time sixfold.
After World War II mass production facilities became more advanced in automated manufacturing.
Increased demand for automobiles and other goods produced high quota expectations which demanded
that owners seek ways to maximize factory output. This demand greatly accelerated the development
of automated technologies.
In 1970, another great innovation pushed industrial automation forward with the introduction of the
first integrated circuits. By the 1980s, companies were spending billions worldwide to automate
production in their now fully optimized plants.

Today’s Automated Manufacturing Systems

Automated manufacturing systems have now become the norm for mass producers. Maximum output
and efficiency has become the gold standard for suppliers, and anything less will result in missed
deadlines and lost profit due to slow, inefficient production.
As a critical part of production in the 21st century, automated industrial systems are now necessary to
maintain peak profitability within an enclosed production plant. Since the 1980’s we have seen
continuous innovation in these systems that only further serve to set the bar higher for next level
optimization.
From SCADA Control Systems to custom built control panels to PLC programming, the sheer amount of
implementation opportunities and different configuration options for automated industrial systems are
staggering. It’s now also essential to implement automated manufacturing systems properly to increase
production and cut costs. Industrial technology is now far past the point of using a “one size fits all”
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system setup. It is important for custom solutions to be implemented in order to create maximum
profit. 3

AUTOMATION: NEED, BASIC ELEMENTS, LEVELS AND ADVANCED AUTOMATION FUNCTIONS.

Automation is the technology by which a process or procedure is accomplished without human
assistance. “Automation = Automatic Control”!
Basic elements of an automated system:
1. Power - to accomplish the process and operate the automated system
2. Program of instructions – to direct the process
3. Control system – to actuate the instructions
Elements of an Automated System

1- Electricity - The Principal Power Source

 Widely available at moderate cost
 Can be readily converted to alternative forms, e.g., mechanical, thermal, light, etc.
 Low level power can be used for signal transmission, data processing, and communication
 Can be stored in long-life batteries
Power to Accomplish the Automated Process
Power for the process
 To drive the process itself
 To load and unload the work unit
 Transport between operations
Power for automation
 Controller unit

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 Power to actuate the control signals

 Data acquisition and information processing
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2- Program of Instructions
Set of commands that specify the sequence of steps in the work cycle and the details of each step
Example: CNC part program
During each step, there are one or more activities involving changes in one or more process
parameters
Examples:
 Temperature setting of a furnace
 Axis position in a positioning system
 Motor on or off
3- Control System – Two Types
1. Closed-loop (feedback) control system – a system in which the output variable is compared
with an input parameter, and any difference between the two is used to drive the output into
agreement with the input
2. Open-loop control system – operates without the feedback loop
 Simpler and less expensive
 Risk that the actuator will not have the intended effect
(a) Feedback Control System and (b) Open-Loop Control System

Example:
Positioning System Using Feedback Control: A one-axis position control system consisting of a lead
screw driven by a DC servomotor and using an optical encoder as the feedback sensor

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When to Use an Open-Loop Control System

 Actions performed by the control system are simple
 Actuating function is very reliable
 Any reaction forces opposing the actuation are small enough as to have no effect on the
actuation
If these conditions do not apply, then a closed-loop control system should be used

Examples of Automation
Day to Day life
 ATM
 Vending machines
 Starting of the vehicle
 Car wipers
Industry
 Painting Robots in the automobile mfg industry
 Soldering Machines
 Automatic capping machines

Example: car painting

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Example: cars manufacturing

Example: soldering & brazing machine

Example: bottle filling & capping

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Example: packaging

Examples of Automation Home Automation

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Why Automation is required?

 Increase in comfort.
 More safety.
 Improve the quality and precision.
 To do the job for which human beings will not have the capacity.
 To avoid monotonous work.

Basic Elements of Control System

 Sensors
 Actuators
 Controllers
Need
Automation in the industrial workplace provides the advantages of improving productivity and quality
while reducing errors and waste, increasing safety, and adding flexibility to the manufacturing
process. In the end, industrial automation yields increased safety, reliability, and profitability.

Why is industrial automation so important?

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The industrial world is facing many technological changes which increased the urgent demand for the
premium quality products and services that can only be supplied by a high level of productivity. This 9
requirement needs process engineering systems, automated manufacturing, and industrial automation.

Hence, industrial automation plays a key role in solving the requirements of companies. It is extremely
significant to face the tasks of:

Globalization – Global industrial automation market demands superior, practical services

Productivity – Automation companies want to enhance their productivity by producing a higher level of
Automation. The key factors include costs, time and quality.

On the other hand, industrial automation is all about working smarter, faster, and proficiently. This
makes automation more powerful and that’s why customers are looking for pioneering, end-to-end
technologies with open, modern architecture and new data from new connections. As the industrial
automation industry comprehends the advantages of the Internet of Things (IoT), it is becoming
essential that organizations adopt these technologies.

Types of automation
Three types of automation in production can be distinguished: (1) fixed automation, (2)
programmable automation, and (3) flexible automation.

FIXED AUTOMATION
It is a system in which the sequence of processing (or assembly) operations is fixed by the equipment
configuration. The operations in the sequence are usually simple. It is the integration and coordination
of many such operations into one piece of equipment that makes the system complex. The typical
features of fixed automation are:

 High initial investment for custom–Engineered equipment;

 High production rates; and
 Relatively inflexible in accommodating product changes.

The economic justification for fixed automation is found in products with very high demand rates and
volumes. The high initial cost of the equipment can be spread over a very large number of units, thus
making the unit cost attractive compared to alternative methods of production. Examples of fixed
automation include mechanized assembly and machining transfer lines.

PROGRAMMABLE AUTOMATION

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In this the production equipment is designed with the capability to change the sequence of operations
to accommodate different product configurations. The operation sequence is controlled by a program,
which is a set of instructions coded so that the system can read and interpret them. New programs can
be prepared and entered into the equipment to produce new products. Some of the features that
characterize programmable automation are:

 High investment in general-purpose equipment;

 Low production rates relative to fixed automation;
 Flexibility to deal with changes in product configuration; and
 Most suitable for batch production.

Automated production systems that are programmable are used in low and medium volume production.
The parts or products are typically made in batches. To produce each new batch of a different
product, the system must be reprogrammed with the set of machine instructions that correspond to
the new product. The physical setup of the machine must also be changed over: Tools must be loaded,
fixtures must be attached to the machine table also be changed machine settings must be entered.
This changeover procedure takes time. Consequently, the typical cycle for given product includes a
period during which the setup and reprogramming takes place, followed by a period in which the batch
is produced. Examples of programmed automation include numerically controlled machine tools and
industrial robots.

FLEXIBLE AUTOMATION
It is an extension of programmable automation. A flexible automated system is one that is capable of
producing a variety of products (or parts) with virtually no time lost for changeovers from one product
to the next. There is no production time lost while reprogramming the system and altering the physical
setup (tooling, fixtures, and machine setting). Consequently, the system can produce various
combinations and schedules of products instead of requiring that they be made in separate batches.

The features of flexible automation can be summarized as follows:

1. High investment for a custom-engineered system.

2. Continuous production of variable mixtures of products.
3. Medium production rates.
4. Flexibility to deal with product design variations.

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The essential features that distinguish flexible automation from programmable automation are:
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1. The capacity to change part programs with no lost production time; and
2. The capability to changeover the physical setup, again with no lost production time.

These features allow the automated production system to continue production without the downtime
between batches that is characteristic of programmable automation. Changing the part programs is
generally accomplished by preparing the programs off-line on a computer system and electronically
transmitting the programs to the automated production system. Therefore, the time required to do the
programming for the next job does not interrupt production on the current job. Advances in computer
systems technology are largely responsible for this programming capability in flexible automation.
Changing the physical setup between parts is accomplished by making the changeover off-line and then
moving it into place simultaneously as the next part comes into position for processing. The use of
pallet fixtures that hold the parts and transfer into position at the workplace is one way of
implementing this approach. For these approaches to be successful; the variety of parts that can be
made on a flexible automated production system is usually more limited than a system controlled by
programmable automation.

The relative positions of the three types of automation for different production volumes and product
varieties are depicted in the following figure.

Automation in Production system - Types of production automation

Know About Advanced Automation Functions

In addition to the general automation functions there are some advanced automation functions which
are used for different processes. Generally they are used for maintaining and safety and performance
of the system. Some of the advanced automation functions are: Monitoring safely, maintenance and
repair and detecting the errors and recovering them.

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Monitoring safely: One of the main reasons of using Automation is to remove the workers form doing
hazardous operations which can lead to the loss of the life. However the workers are needed to
operate the machines instead of doing that hazardous work. The automated machines are designed
safely in order they should not be self destructive. Thus there are reasons to monitor the system
safely. They are: 1.To protects the workers 2.To protect the system which is associated with it. Safety
monitoring of a system involves safety tracking of the system using the sensors. If there is a hazard
then the safety monitoring system responds in either of the ways:

1. By giving an alarm sound (or)

2. By reducing the speed of the system (or)
3. By turning off the automated system.

Maintenance And repair: Modern automation systems are becoming more complex by using the
maintenance and repair components. Actually they are the components which are used for the
maintaining and reducing the failures. There are three modes of operation which are used for
performing this task.

1. Status Monitoring: Initially in this mode the status of the present system is estimated.
It monitors over it by using the sensors or by using the parameters of the system. By using them
the current status of the system is being monitored.
2. Failure notification: This mode comes under procedure when the failure occurs. It
compares the present values and the previous values before and after failures.
3. Recommending for the repair: here after noting the repair, this mode takes the
decision how to repair and what are the parts which are to be repaired.

Detecting the errors and recovering them: the error detection can be done using the sensors. The
different types of errors can be formed in the production system they are: random errors and
systematic errors etc. These can be detected by using the detecting systems and the recovering system
is used for recovering the errors.

AUTOMATED ASSEMBLY: FUNDAMENTAL, SYSTEM CONFIGURATION, PART DELIVERY AT

WORKSTATION AND ITS APPLICATIONS.

Automated assembly
Refers to the use of mechanized and automated devices to perform the various functions in
an assembly line or cell. Automated assembly system performs a sequence of automated operations to
combine multiple components in to a single entity which can be a final product or sub assembly.

FUNDAMENTALS OF AUTOMATED ASSEMBLY SYSTEMS

 An automated assembly system performs a sequence of automated assembly operations to
combine multiple components into a single entity.
 The single entity can be a final product or a subassembly in a larger product. In many cases,
the assembled entity consists of a base part to which other components are attached.
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 The components are joined one at a time (usually), so the assembly is completed progressively.
 A typical automated assembly system consists of the following subsystems;
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o one or more workstations at which the assembly steps are accomplished,
o parts feeding devices that deliver the individual components to the workstations, and
o a work handling system for the assembled entity.
 In assembly systems with one workstation, the work handling system moves the base part into
and out of the station. In systems with multiple stations, the handling system transfers the
partially assembled base part between stations.
 Control functions required in automated assembly machines are the same as in the automated
processing lines (I) sequence control, (2) safety monitoring, and (3) quality control.
System Configurations
Automated assembly systems can be classified according to physical configuration. The principal
configurations, illustrated in Figure, are: (a) in-line assembly machine, (b) dial type assembly machine,
(c) carousel assembly system, and (d) single station assembly machine.

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In-Line Assembly – A series of automatic workstations located along an in-line transfer system—the
assembly version of the machining transfer line. Synchronous and asynchronous transfer systems may 14
be used to transport parts from workstation to workstation.

Dial Type - Base parts loaded onto fixtures or nests around the periphery of the circular dial, and—as
the dial table turns— components are assemblied sequentially onto the base part. Synchronous transfer
system in operation, as all nests move at the same time, sometimes through continuous motion, but
more often intermittently.

Carousel Assembly System - Represents a hybrid between the circular work flow of the dial type
assembly machine, and the straight work flow of the in-line system. Carousels can be operated with
continuous, synchronous, or asynchronous transfer mechanisms

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Single-station Assembly - Consists of one workstation where components are assembled, successively,
onto a base part that has entered the system. Once all the components have been assembled onto the
base part, the base part leaves the system. Inherently slower than the other three system
configurations, as only one base part is processed at a time.

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Parts Delivery at Workstations

Parts delivery to workstations depends upon specific pieces of delivery equipment, particularly 16
associated with automatic assembly. These pieces of equipment are connected together to create the
parts delivery system. The following hardware for parts delivery consists of:
 Hopper—a container into which components are loaded at the workstation, and which passes
components to the parts feeder
 Parts feeder—a mechanism used for removing components from the hopper, and passing them
to the feed track; the parts feeder is often connected to the hopper to form one unit
 Selector and/or orientor—devices found on the feed track that establish the proper orientation
of the components for the assembly work head: a selector is a filter device that only-correctly
oriented parts to pass; while an orientor re-orients parts that are not properly oriented initially
on the feed track
 Feed track—the pathway along which the components pass from the hopper and parts feeder to
the assembly work head, whilst maintaining proper orientation of the parts via
selectors/orientors along the way; it generally operates by gravity, though powered feed tracks
(operated by vibratory action or air pressure) may also be encountered
 Escapement and placement devices—devices used to remove components from the feed track
(escapement), and to place them at the workstation for the assembly operation (placement);
there are a number of different device designs to accomplish this
Parts delivery at workstations is dependent on the following hardware components: the hopper; the
parts feeder; selector and/or orientor devices; the feed track; and escapement and placement
devices.

The hopper and parts feeder device are often combined, as shown schematically and pictorially in
Figure.

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The hopper and parts feeder device are often combined as one entity.

Selector and orientor devices are small simple devices built onto the feed track to force the removal
of unacceptable components, or the re-orientation of misaligned ones.

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Escapement and placement devices

Meanwhile, depending upon the assembly system type, various escapement and placement devices 18
may be favored.
Horizontal placement device
Device used on dial-type assembly machines: parts move via horizontal delivery into vacant nests on
the dial, as they appear, from the feed track; meanwhile the circular motion of the dial table means
that the nests are revolved away from the feed track, permitting the next component in the feed track
to move into the next vacant nest, and so forth.

Vertical placement device

Device used on dial-type assembly machines: here, the parts feeder is arranged vertically above the
dial table, so that when the table turns, to reveal an empty nest, the component can fall by gravity
from the feed track into the empty nest. Successive parts fall by gravity to take up their position at
the mouth of the feed track in turn.

Escapement device
This device is actuated by the top of the carrier contacting the lower surface of the rivet-shaped part,
causing its upper surface to press against the spring blade, which releases the part so that it falls into

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the work carrier nest. The work carriers are moved horizontally to cause the release of the part, and—
after the first part has escaped—the work carrier and released part move off, to be replaced by the 19
next work carrier, and so forth.

Pick-and-place mechanism (1)

This mechanism uses a pick-and-place unit with a horizontal arm that may be extended and retracted
as necessary, so that parts may be removed from the feed track, and placed into work carriers.

Pick-and-place mechanism (2)

This mechanism uses a pick-and-place unit with a revolving arm, so that parts may be removed from
the feed track, and placed into work carriers.

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Escapement and placement devices include mechanisms with various designs to suit the needs of the
workstation in question; they include: horizontal and vertical placement devices; work-carrier 20
actuated escapement devices; and pick-and place mechanisms.
Quantitative Analysis of Assembly Systems
1. Parts delivery system at workstations
2. Multi-station automated assembly systems
3. Single-station automated assembly systems
4. Partial automation
DESIGN FOR AUTOMATED ASSEMBLY.
 One of the obstacles to automated assembly is that many of the traditional assembly methods
evolved when humans were the only available means of assembling a product.
 Many of the mechanical fasteners commonly used in industry today require the special
anatomical and sensory capabilities of human beings.
 Consider, for example, the use of a bolt, lock washer. And nut to fasten two sheet metal parts
on a partially assembled cabinet. This kind of operation is commonly accomplished manually at
either a single assembly station or on an assembly line.
 The cabinet is positioned at the workstation with the two sheet metal parts to be fastened at
an awkward location for the operator to reach. The operator picks up the bolt, locks washer-,
and nut, somehow manipulating them into position on opposite sides of the two parts, and
places the lock washer and then the nut onto the bolt.
 As luck would have it, the threads of the nut initially bind on the bolt threads, and so the
operator must unscrew slightly and restart the process, using a well-developed sense of touch
to en-sure that the threads are matching.
 Once the bolt and nut have been tightened with fingers, the operator reaches for the
appropriate screwdriver (there are various bolt sizes with different heads) to tighten the
fastener

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The following are some recommendations and principles that can be applied in product design to
facilitate automated assembly
 Reduce the amount of assembly required
 Use of modular design.
 Reduce the number of 'fasteners required
 Reduce the need for multiple components to be handled at once
 Limit the required directions of access
 High quality required in components
 Hopperability

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QUANTITATIVE ANALYSIS OF ASSEMBLY SYSTEMS.

Certain performance aspects of automated assembly systems can be studied using mathematical 23
models. In this section, we develop models to analyze the following issues in automated assembly: (1)
parts delivery system at workstations, (2) multi-station automated assembly systems,(3) single station
automated assembly systems, and (4) partial automation.

Note: The Assembly process [LCR, K&W, RPW and computational methods are explained separate
document]

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