AUTOMATION AND ROBOTICS

Machining
Machining is not just one process; it is a group of processes. The common feature is the use of
a cutting tool to form a chip that is removed from the workpart, called swarf. To perform the
operation, relative motion is required between the tool and work. This relative motion is
achieved in most machining operations by means of a primary motion, called "cutting speed"
and a secondary motion called "feed'".
There are many kinds of machining operations, each of which is capable of generating
a certain part geometry and surface texture.
In turning, a cutting tool with a single cutting edge is used to remove material from a rotating
workpiece to generate a cylindrical shape. The speed motion in turning is provided by the
rotating workpart, and the feed motion is achieved by the cutting tool moving slowly in a
direction parallel to the axis of rotation of the workpiece.
In milling, a rotating tool with multiple cutting edges is moved slowly relative to the material
to generate a plane or straight surface. The direction of the feed motion is perpendicular to
the tool's axis of rotation. The speed motion is provided by the rotating milling cutter.
Other conventional machining operations include drilling, sawing and grinding.

CNC machines
Computer control programmers and operators use computer numerically controlled (CNC)
machines to cut and shape precision products, such as automobile, aviation, and machine
parts. CNC machines operate by reading the code included in a computer-controlled module,
which drives the machine tool and performs the functions of forming and shaping a part
formerly done by machine operators. CNC machines include machining tools such as lathes,
multi-axis milling machines, laser cutting machines, and wire electrical discharge machines.
CNC machines cut away material from a solid block of metal or plastic—known as a
workpiece—to form a finished part. Computer control programmers and operators normally
produce large quantities of one part, although they may produce small batches or one-of-a-
kind items. They use their knowledge of the working properties of metals and their skills with
CNC programming to design and carry out the operations needed to make machined
products that meet precise specifications.

Computer-aided manufacturing (CAM)

Computer-aided manufacturing is the use of computer software to control machine tools and
related machinery in the manufacturing of workpieces. CAM may also refer to the use of a
computer to assist in all operations of a manufacturing plant, including planning,
management, transportation and storage. Its primary purpose is to create a faster production
process and components and tooling with more precise dimensions and material consistency,
which in some cases, uses only the required amount of raw material (thus minimizing waste),
while simultaneously reducing energy consumption. CAM is a subsequent computer-aided
process after computer-aided design (CAD) and sometimes computer-aided engineering
(CAE), as the model generated in CAD and verified in CAE can be input into CAM software,
which then controls the machine tool.
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Heat treatment
Heat treatment is a method used to alter the physical, and sometimes chemical, properties of
a material. The most common application is metallurgical. Heat treatments are also used in
the manufacture of many other materials, such as glass. Heat treatment involves the use of
heating or chilling, normally to extreme temperatures, to achieve a desired result such as
hardening or softening of a material. Heat treatment techniques include annealing, case
hardening, precipitation strengthening, tempering and quenching. It is noteworthy that while
the term heat treatment applies only to processes where the heating and cooling are done for
the specific purpose of altering properties intentionally, heating and cooling often occur
incidentally during other manufacturing processes such as hot forming or welding.

Lubrication
A lubricant is a substance (often a liquid) introduced between two moving surfaces to reduce
the friction between them, improving efficiency and reducing wear. They may also have the
function of dissolving or transporting foreign particles and of distributing heat. Lubricants
are generally composed of a majority of base oil and a minority of additives to impart
desirable characteristics. Additives deliver reduced friction and wear, increased viscosity,
resistance to corrosion and oxidation, aging or contamination, etc. Another approach to
reducing friction and wear is to use bearings such as ball bearings, roller bearings or air
bearings, which in turn require internal lubrication themselves.

Warehouse
A warehouse is a commercial building for storage of goods. Warehouses are used by
manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc. Some
warehouses are completely automated, with no workers working inside. The pallets and
products are moved with a system of automated conveyors and automated storage and
retrieval machines coordinated by programmable logic controllers and computers running
logistics automation software. These systems are often installed in refrigerated warehouses
where temperatures are kept very cold to keep the product from spoiling, and also where land
is expensive, as automated storage systems can use vertical space efficiently. These high-bay
storage areas are often more than 10 meters high, with some over 20 meters high.
The direction and tracking of materials in the warehouse is coordinated by the WMS, or
Warehouse Management System, a database driven computer program. The WMS is used by
logistics personnel to improve the efficiency of the warehouse by directing putaways and to
maintain accurate inventory by recording warehouse transactions.
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Maintenance
Maintenance, repair and operations or maintenance, repair and overhaul (MRO) is fixing any
sort of mechanical or electrical device if it should become out of order or broken (known as
repair or unscheduled maintenance) as well as performing the routine actions which keep the
device in working order (known as scheduled maintenance) or prevent trouble from arising
(preventive maintenance).
1.Breakdown maintenance.
Repairs or replacements performed after a machine has failed to return to its functional state
following a malfunction or shutdown.
2. Preventive maintenance.
It is a daily maintenance (cleaning, inspection, oiling and re-tightening ), designed to retain
the healthy condition of equipment and prevent failure through the prevention of
deterioration, periodic inspection or equipment condition diagnosis
2a. Periodic maintenance (Time-based maintenance - TBM)
It consists of periodically inspecting, servicing and cleaning equipment and replacing parts to
prevent sudden failure and process problems.
2b. Predictive maintenance
This is a method in which the service life of important parts is predicted based on inspection
or diagnosis, in order to use the parts to the limit of their service life.
3. Corrective maintenance
It improves equipment and its components so that preventive maintenance can be carried out
reliably. Equipment with design weaknesses must be redesigned to improve reliability or
maintainability.

Pneumatics Vs Hydraulics
Pneumatics offers a very clean system suitable for processes which require no risk of
contamination. Hydraulics is generally not used in these environments due to the risk
of hydraulic oil leaks from faulty valves, seals or burst hoses. Pneumatics offers rapid
movement of cylinders and has the great advantage of availability in very small sizes.
Air can flow through pipes very quickly and easily with little resistance, while
hydraulic oil is a viscous substance and requires more energy to move. Hydraulics can
smoothly lift and move loads because the hydraulic oil is not compressible. In terms
of energy costs pneumatics is more costly than hydraulics. This is mainly due to the
amount of energy lost through heat production while compressing air.

Serial and parallel robot manipulators

A serial robot is a set of bodies (called links) connected in series through actuated joints,
which are typically either revolute (i.e. rotating) or prismatic (i.e. translating). One extremity
of this serial chain of links is called the base and the other the end-effector. Serial robots are
also called robot arms. Most industrial robots are serial.
In a parallel robot, the end-effector is connected to the base through several chains of
interconnected links. In other words, a parallel robot has at least two "legs" (or "arms"). Most
of its joints are not actuated, and many of these passive joints have several degrees-of-
freedom (DOFs) (e.g. spherical, universal, and planar joints).
Two of the most popular parallel robots are the telescoping-leg hexapod used in most motion
simulators (often called "motion platforms") and the so-called Delta robot, generally used for
rapid pick-and-place. While there are fewer parallel robots than serial robots in use, the
variety of parallel robots is larger.
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Computer-integrated manufacturing (CIM)

Computer-integrated manufacturing is the manufacturing approach of using computers to
control the entire production process. This integration allows individual processes to
exchange information with each other and initiate actions. Through the integration of
computers, manufacturing can be faster and less error-prone, although the main advantage is
the ability to create automated manufacturing processes. Typically CIM relies on closed-loop
control processes, based on real-time input from sensors. It is also known as flexible design
and manufacturing.

Microcontroller
A microcontroller can be considered a self-contained system with a processor, memory and
peripherals and can be used as an embedded system. The majority of microcontrollers in use
today are embedded in other machinery, such as automobiles, telephones, appliances, and
peripherals for computer systems. While some embedded systems are very sophisticated,
many have minimal requirements for memory and program length, with no operating system,
and low software complexity. Typical input and output devices include
switches, relays, solenoids, LEDs, small or custom LCD displays, radio frequency devices, and
sensors for data such as temperature, humidity, light level etc. Embedded systems usually
have no keyboard, screen, disks, printers, or other recognizable I/O devices of a personal
computer, and may lack human interaction devices of any kind.
Micro controllers must provide real time (predictable, though not necessarily fast) response
to events in the embedded system they are controlling. When certain events occur,
an interrupt system can signal the processor to suspend processing the current instruction
sequence and to begin an interrupt service routine (ISR, or "interrupt handler"). The ISR will
perform any processing required based on the source of the interrupt, before returning to the
original instruction sequence. Possible interrupt sources are device dependent, and often
include events such as an internal timer overflow, completing an analog to digital conversion,
a logic level change on an input such as from a button being pressed, and data received on a
communication link. Where power consumption is important as in battery operated devices,
interrupts may also wake a microcontroller from a low power sleep state where the processor
is halted until required to do something by a peripheral event.

Automated guided vehicle

An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that
follows markers or wires in the floor, or uses vision, magnets, or lasers for navigation. They
are most often used in industrial applications to move materials around a manufacturing
facility or warehouse.
The AGV can tow objects behind them in trailers to which they can autonomously attach. The
trailers can be used to move raw materials or finished products. The AGV can also store
objects on a bed. The objects can be placed on a set of motorized rollers (conveyor) and then
pushed off by reversing them.
Over the years the technology has become more sophisticated and today automated vehicles
are mainly laser navigated e.g. LGV (Laser Guided Vehicle). The navigation is done by
mounting reflective tape on walls, poles or fixed machines. The AGV carries
a laser transmitter and receiver on a rotating turret. The laser is transmitted and received by
the same sensor. The angle and (sometimes) distance to any reflectors that are in line of sight
and in range are automatically calculated. This information is compared to the map of the
reflector layout stored in the AGV's memory. This allows the navigation system to triangulate
the current position of the AGV. The current position is compared to the path programmed in
to the reflector layout map. The steering is adjusted accordingly to keep the AGV on track. It
can then navigate to a desired target using the constantly updating position.