INDIAN INSTITUTE OF TECHNOLOGY, BOMBAY

Department of Mechanical Engineering

Course : ME-637 Manufacturing Automation L-T-P-C : 3-0-0-6

Instructor : K. P. Karunakaran II Semester 2017-18
Date : April 10, 2018 (Tuesday) 9:30 PM Duration: 90 min.
Instructions: Roll No
 Answer all the questions; answer as briefly as
possible. Marks /90

TEST - 3

Part A
(1 mark each)

1. Which is the moving part in the reciprocating-tube hopper (hopper or tube)? Why?
Hopper. This is because the tube cannot move as it is connected to the feed track with is
stationary.

2. What is the maximum number of parts the rotary disc feeder of the indexing type may
convey during any indexing (one or many)?
Many

3. Name the feeder that damages the parts the least.

Stationary hook hopper feeder

4. For “emergency switch”, will you recommend NO or NC contact? Why?

Had it been implemented using NO, any accidental cutting of its cable, say by a rat, will
go undetected. Such a NO-based emergency switch will fail to respond to the emergency.
Therefore, NC is used as emergency switch.

5. Write down the two principal steps of Assembly Automation.

(1) The handling and presentation of the part to the insertion device and (2) The insertion
of the part.
6. Name at least two popular PLC brands.
Allen Bradley, Siemens, Schneider Electric, GE-Fanuc, ABB, Mitsubishi

7. Distinguish between a limit switch and a proximity switch.

Limit switch is a mechanical device that requires physical contact for its actuation whereas
proximity switch is mostly an inductive device which gets activated by the approach of a
metallic object.

8. What do you understand by potential-free contact?

When the contacts of a relay are used only for shorting or opening two terminals that do
not have any voltage or potential, such contacts are known as “potential-free contacts”. It
is always safer to use only potential-free contacts. Even of there is a situation demanding
“potential contacts”, it is possible to achieve the same functionality with the help of

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 “potential-free contacts”.

9. Why is the analog input range of 4-20mA preferred to 0-20mA?

To enable the detection of malfunctioning of the cable.

10. Which one of the following sensors is the most appropriate for counting of boxes on moving
conveyor?
[a] Proximity Switch [b] Limit Switch [c] Photo Switch [d] Pulse Encoder
[c] Photo Switch

11. Which one of the following sensors is the most appropriate for end position or over travel
detection in a machine tool axis?
[a] Proximity Switch [b] Limit Switch [c] Photo Switch [d] Any of them
Any of the above three sensors. (d)

12. What do you understand by “scan time of PLC”?

The PLC eternally reads the all inputs, performs the necessary computation and accordingly
changes the states of the outputs. The time taken do this is called “scan time of the PLC”.

13. Which of the following PLC architecture will you use for IIT Campus water supply
management and why?
[a] Single CPU with I/O modules [b] Single CPU with remote I/O modules
[c] Distributed PLC system with multiple CPUs.
Both [b] and [c] will be applicable

14. What are the four tasks performed in a PLC scan?

i. Input scan: scans the states of the inputs
ii. Program scan: Processes the corresponding program logic
iii. Output scan: Energizes/ de-energizes the outputs
iv. Housekeeping: This includes communications, diagnostics

Part B
(Weightage is given against each)

1. Distinguish between micro-processor and micro-controller. [2]

Feature micro-processor Micro-controller
Sensors Only computing and no They can be connected to
sensors are connected. sensors and hence can be used
for online process control.

2. Distinguish between micro-controller and PLC. [2]

Feature PLC Micro-controller
Programming Ladder logic. C-like language.
Ease of use Easy to understand for non- Complex to program as it
electronic experts as it requires requires a fair amount of

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 no sophisticated programming electronic knowledge.
skills.
Size Large. Very compact.
Applications Mostly for the control of Mostly for the control of
industrial equipment. Eg.: domestic appliances and small
CNC machines, robots, but sophisticated equipment.
furnaces etc. These are known as embedded
systems. Eg.: washing
machines, cameras, Micro-
Aerial vehicles (MAVs) etc.

3. During every PLC scan, a minimum of 2 pulses and a maximum of 3 pulses are
accumulated. For how many scans should the pulses be accumulated so that the counting
error is below its 1% with certainty? [2]
In one scan, 2 pulses are accumulated. Sometimes, 3rd pulse also can come. Error in
counting will always be 1 pulse. If 3 pulses are counted in each scan, we need 34 scans,
i.e. 102 pulses with 1 pulse as measuring error and error = (1 x100)/102 <1%. However, if
only 2 pulses are accumulated per scan, we need 51 scans to accumulate 102 pulses for
error to be less than 1%. Hence, 51 scans (Higher of 34 & 51) are needed to have error
less than 1% with certainty.

4. List the various motions and salient features of tumbling barrel hopper feeder. [3]
- The barrel is mounted on rollers in inclined position. As the rollers rotate, the parts are
tumbled.
- The feed track is vibrated which gives the parts falling on it the velocity to move.

5. Draw pump motor starter logic in the form of ladder diagram. [‘Start’ push button will be
pressed for 0.5s and released. Motor should continue to run. Motor can be stopped by
pressing ‘Stop’ push button. For motor to run, lubrication system must be running. NO
contact from lubrication system is available. [3]

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6. What is an escapement? Explain its most significant function in an assembly machine. What
are its other functions? [3]
Escapement ensures supply of the required number of parts at the required time. It may
also be called “metering device”.

Its functions are:

• To synchronize demand and supply of parts – to receive a request for part and respond
• To meter and send. At a time one or more parts may have to be sent to one or more
machines.
• Sometimes, escapement may also change the orientation as required before feeding.

Other functions:
• Generally the workstation should have some mechanism of communicating the need
for the part to the escapement.
• It may be required for some escapements to feed to more than one workstations.
• Some escapement may also help in changing the orientation before feeding.

7. Distinguish between “center board hopper feeder” and “half center board hopper feeder” in
terms of (a) construction, (b) feed rate and (c) capacity. Which one has higher feed rate and
why? [4]
Feature Centre board hopper feeder Half centre board hopper feeder
(a) construction Parts lie on both sides of the Parts lie only on one side of the
board (not required to draw the hopper as the other side is
figure!) closed (not required to draw the
figure!)

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 (b) feed rate Low as the parts picked from
one side have the possibility of
falling onto the other side.
(c) capacity High as both sides can hold
parts.
High as the parts are prevented
from falling onto the other side.
Half as one half is closed.

8. Draw an escapement which receives certain cylindrical parts from a single feed track and
distributes to two workstations alternately. [4]

9. Draw an escapement for supplying 3 rivets at a time to the workstation. [4]

10. What are the four assembly methods used for obtaining tight fits between the components
made to wide tolerances? [4]
Assembly Process Example
Selective Assembly – also For any part, choose the mating part whose dimension
known “matched parts is close to it as required. This involves measuring each
assembly”. “Group component and finding its match. This can be
interchangeable assembly” is assembled and reassembled without any difficulty.
a subset of this. However, when one of them fails, the pair shall be
replaced.

Adjusted Parts Assembly
Bearings,
Box of slip gauges
The required fit is achieved by adjusting a screw or any
such adjustment till the desired tolerance is achieved.
This can be assembled and reassembled without any
difficulty. When one of them fails, the failed part alone
needs replacement.

Spokes assembly in cycle wheel,

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Fitted Parts Assembly
Compensated Assembly
11. A and B are two digital inputs. Show ‘AND’, ‘OR’, ‘XOR’ and ‘INVERSE’ logics in ladder
diagram.
AND
XOR
12. List down the guidelines for designing parts for handling and assembly. Draw figures
wherever required.
Guidelines for design for handling
Assembly of gears in watches,
Watch time setting,
Leveling of machine tools,
Alignment of machine tool bed,
Elimination of backlash using preloading,
Tuning of guitar, carburettor etc.
The required fit is achieved by a subtractive process;
i.e., material is removed from one of the parts till the
required fit is achieved. When disassembled,
reassembly cannot be guaranteed. When one of them
fails, the failed part alone needs replacement.
Cutting the length of a screw to suit the assembly,
Scrapping of machine table,
Implants made to standard sizes
The required fit is achieved by an additive process; i.e.,
material is added between the two parts to achieve the
required fit. This can be assembled and reassembled
without any difficulty (of course, depending on the
bonding material used). When one of them fails, the
failed part alone needs replacement.
Power cable with connectors at both ends,
Washer or shims used during assembly
[4]
OR
INVERSE
[6]
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 1. Design parts that have end-to-end symmetry and rotational symmetry about the axis
of insertion. If this cannot be achieved, try to design parts having the maximum
possible asymmetry.

2. Design parts that, in those instances in which the part cannot be made symmetric, are
obviously asymmetric.

3. Provide features that will prevent jamming of parts that tend to nest or stack when
stored in bulk.

4. Avoid features that will allow entangling of parts when stored in bulk.

5. Avoid parts that stick together or are slippery, delicate, flexible, very small or very
large, or that are hazardous to the handle (i.e., parts that are sharp, splinter easily etc.)

Guidelines for Design for Assembly

1. Design so that there is little or no resistance to insertion and provide chamfers to
guide insertion of two mating parts. Generous clearances should be provided, but care
must be taken to avoid clearances that will result in a tendency for parts to jam or
hang up during insertion.

Incorrect geometry can allow part to jam during insertion.

Provision of air-relief passages to improve insertion into blind holes.

Design for ease of insertion: assembly of long stepped bushing into counter-bored hole.

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 Provision of chamfers to allow easy insertion.
2. Standardize by using common parts, processes and methods across all models and
even across product lines to permit the use of higher volume processes that normally
result in lower product costs.

Standardize parts.
3. Use of pyramid assembly – provide for progressive assembly about one axis of
reference. In general, it is best to assemble from above.

Single-axis pyramid assembly.

4. Avoid, wherever possible, the necessity for holding parts down to maintain their
orientation during manipulation of the subassembly or during the placement of
another part. If holding down is required, then try to design so that the part is secured
as soon as possible after its insertion.

Provision of self-locating features to avoid holding down and alignment.

5. Design so that a part is located before its release. A potential source of problems in
part placement occurs when, because of design constraints, a part has to be released
before its positive location in the assembly. Under these circumstances, reliance is
placed on the trajectory of the part being sufficiently repeatable to consistently locate
it.

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 Design to aid insertion.
6. Consider, when common mechanical fasteners are used, the following sequence,
which indicates the relative cost of different fastening processes, listed in the order of
increasing manual assembly cost: (a) snap fitting, (b) plastic bending, (c) riveting and
(d) screw fastening.

Common fastening methods

7. Avoid the need to reposition the partially completed assembly in the fixture.

Insertion from opposite directions requires repositioning of assembly.

13. A tank is used to mix two liquids. Its schematic diagram is given in the figure. Draw the
control circuit (in the form of a ladder diagram) that operates as follows: [7]

i. When the ‘Start’ button is pressed, solenoids A and B energize. This permits the two
liquids to begin filling the tank.
ii. When the tank is filled, the float switch trips. This de-energizes solenoids A and B and
starts the motor used to mix the liquids together.
iii. The motor is permitted to run for one minute. After one minute has elapsed, the motor
turns off and solenoid C energizes to drain the tank.
iv. When the tank is empty, the float switch de-energizes solenoid C.
v. A ‘Stop’ button can be used to stop the process at any point.
vi. If the motor becomes overloaded, the action of the entire circuit will stop.
vii. Once the circuit has been energized it will continue to operate until it is manually
stopped.

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14. In a reciprocating-tube hopper, narrow hopper angle leads to jamming of the parts and
wider hopper may not allow parts to readily reach the tube. Prove, from the fundamental
principles and through a free body diagram of a cylindrical piece as the part, that the optimal
semi-hopper angle is 60°. [12]
More detailed descriptions along with necessary figures of the following steps/expressions
are to be given:

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 F1 W F2 cos ∅N2 sin ∅
N1 N2 cos ∅F2 sin ∅
F1 (1 cos ∅ ) D/2 W(D/2) cos ∅N1 (D/2) sin ∅
Where ∅is the hopper wall angle, and D is the diameter of the part.
Eliminating W from Equation 4.1 and Equation 4.3 gives, after rearrangement,
N1 sin ∅F1 (1 cos ∅) cos ∅(N2 sin ∅– F2 cos ∅– F1) ----------- (4)
The maximum value of F2 is given by µsN2 (where µs is the coefficient of static friction)
and, thus, writing F2 µsN2 in Equation 2 and Equation 4 and eliminating N2 give
F1 µ
= cos∅ + sµ --------------- (5)
N1 s sin∅

For the tube to slide, F1/N1 µs, and, therefore, from Equation 5

1/(cos ∅ + µs sin∅) > 1------------ (6)

The expression indicates that the value of ∅should be as large as possible to prevent
jamming when µs is large. However, when µs cot ∅, the parts cannot slide down the
hopper wall. The best compromise is probably given by writing the following two
limiting conditions:
µs cot ∅
cos ∅µs sin ∅1 ------------ (8)
Combination of Equation 7 and 8 gives ∅ 60°.

15. A stationary hook hopper feeder is shown in the figure.

(a) What is its application and why? [2]
(b) In order for the part to glide smoothly at a constant velocity along the hook, obtain its
profile. Describe the various notations used in the derivation. [10]
(c) For a hopper of 250mm inner diameter, Create a table of polar coordinates of the profile
for a speed of 20rpm, part sliding velocity of 250mm/min, 𝜇𝑝 = 𝜇𝑟 = 0.6 and plot it
neatly. Assume any other data required. [4]

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Ans: a. Gentle feeding action, which makes it suitable for feeding delicate parts at low speed
b. The velocity of the part relative to the hook is designated v12,
The velocity of a point on the moving surface of the base relative to the hook is
designated v32.
The direction of the velocity v13 of the part relative to the base is then obtained from
the velocity diagram,
The frictional force between the part and the moving surface is in the direction
opposite to the relative velocity v13 and is the force that causes the part to move along the
hook.
The direction of this force is specified by ψ in Figure. By the law of sines,

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 b.

Where θ is the angle between the velocity vector v32 and the tangent to the hook at the
point under consideration.
Neglecting the inertia force, the external forces acting on the part in the horizontal plane
are shown in Figure 4.24c. When these forces are resolved parallel and normal to the hook
tangent, the conditions for equilibrium are

μrNr = μp W cos (θ + ψ)
Nr = μp W sin (θ + ψ)

Where
μr is the coefficient of dynamic friction between the part and the hook,
μp the coefficient of sliding friction between the part and the moving surface,
Nr the normal reaction between the part and the hook,
W the weight of the part

μr = cot (θ + ψ)

r is the distance from the point under consideration to the center of the hopper and n the
rotational frequency of the hopper base.

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K is a constant given by v12/2πn.

Centre board hopper feeder Stationary hook hopper feeder

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