Gopalan College of Engineering and Management

(Accredited by NAAC, 2(f) status by UGC & ISO 9001:2015 certified)

Approved by All India Council for Technical Education (AICTE), New Delhi
GCEM Affiliated to Visvesvaraya Technological University (VTU), Belagavi, Karnataka
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Phone No: 080 – 42229748 Email: gcem@gopalancolleges.com Website: www.gopalancolleges.com/gcem

18ME732 – AUTOMATION & ROBOTICS

(SEMESTER – VII / B.E ME)
Faculty : Dr.Natarajan T / Associate Professor / ME / GCEM / Bangalore

IMPORTANT QUESTIONS FOR SEMESTER END EXAM

Module - 2 Automated production lines

Syllabus

Q.No Questions
What is an automated production line (APL)? Explain the general configuration of an automated
1.
production line with a neat sketch.
What is ‘Storage buffers’? Mention the reasons why storage buffers are used on automated production
2.
lines.
3. Explain the four types of configurations of automated assembly systems with neat sketches.
4. What is AIDC? Explain the ‘barcode’ technology used as AIDC.
5. What does ‘RFID’ stand for? Explain the functions of ‘RFID tag/label’ with a neat sketch.
Numerical Problem - Automated production lines – Upper bound & Lower bound approach
6.
(Refer Class Notes)

1
1. What is an automated production line (APL)? Explain the general configuration of an automated
production line with a neat sketch.

Automated production line (APL):

An automated production line (APL) consists of multiple workstations that are automated and
linked together by a work handling system that transfers parts from one station to the next as depicted
in Figure.

General configuration of an automated production line

 Proc = processing operation

 Aut = automated workstation

A raw work part enters one end of the line, and the processing steps are performed sequentially as
the part progresses forward (from left to right in the drawing).

The line may include inspection stations to perform intermediate quality checks. Also, manual
stations may be located along the line to perform certain operations that are difficult or uneconomical
to automate. Each station performs a different operation, so all operations must be performed to
complete each work unit. Multiple parts are processed simultaneously on the line, one part at each
station.

In the simplest form of production line, the number of parts on the line at any moment is equal to
the number of workstations, as in the figure. In more complicated lines, provision is made for temporary
parts storage between stations, in which case there are more parts than stations.

An automated production line operates in cycles, similar to a manual assembly line. Each cycle
consists of processing time plus the time to transfer parts to the next station. The slowest workstation
sets the pace of the line, just as in an assembly line.

This configuration is common for machining big workpieces, such as automotive engine blocks,
engine heads, and transmission cases. Because these parts require a large number of operations, a
production line with many stations is needed. This configuration can accommodate a large number of
stations. It can also be designed with integrated storage buffers along the flow path.

2
2. What is ‘Storage buffers’? Mention the reasons why storage buffers are used on automated
production lines.

Storage buffers:
A storage buffer is a location in the production line where parts can be collected and
temporarily stored before proceeding to downstream workstations. Automated production lines can be
designed with storage buffers.
The storage buffers can be manually operated or automated. When it is automated, a storage
buffer consists of a mechanism to accept parts from the upstream workstation, a place to store the
parts, and a mechanism to supply parts to the downstream station.
A key parameter of a storage buffer is its storage capacity, that is, the number of work parts it
can hold. Storage buffers may be located between every pair of adjacent stations, or between line
stages containing multiple stations.

Reasons why storage buffers are used on automated production lines:

 To reduce the impact of station breakdowns

Storage buffers between stages on a production line permit one stage to continue operation
while the other stage is down for repairs.

 To provide a bank of parts to supply the line

Parts can be collected into a storage unit and automatically fed to a downstream manufacturing
system. This permits untended operation of the system between refills.

 To provide a place to put the output of the line

 To allow for curing time or other process delay

A curing time is required for some processes such as painting or adhesive application. The
storage buffer is designed to provide sufficient time for curing to occur before supplying the
parts to the downstream station.

 To smooth cycle time variations

Although this is generally not an issue in an automated line, it is relevant in manual production
lines, where cycle time variations are an inherent feature of human performance.

3. Explain the four types of configurations of automated assembly systems with neat sketches.

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.

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
(d) single-station assembly machine

3
 The in-line assembly machine, Figure 17.1(a), is a series of automatic workstations located
along an in-line transfer system. It is the assembly version of the machining transfer line. Synchronous
and asynchronous transfer systems are the common means of transporting base parts from station to
station with the in-line configuration.

In the typical application of the dial-type machine, Figure 17.1(b), base parts are loaded onto
fixtures or nests attached to the circular dial. Components are added and/or joined to the base part at
the various workstations located around the periphery of the dial. The dial indexing machine operates
with a synchronous or intermittent motion, in which the cycle consists of the service time plus indexing
time.

As seen in Figure 17.1(c), the 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.
The carousel configuration can be operated with continuous, synchronous, or asynchronous transfer
mechanisms to move the work around the carousel. Carousels with asynchronous transfer of work are
often used in partially automated assembly systems.

In the single-station assembly machine, Figure 17.1(d), assembly operations are performed on a
base part at a single location. The typical operating cycle involves the placement of the base part at a
stationary position in the workstation, the addition of components to the base, and finally the removal
of the completed assembly from the station. An important application of single-station assembly is the
component placement machine, widely used in the electronics industry to populate components onto
printed circuit boards.

4
4. What is AIDC? Explain the ‘barcode’ technology used as AIDC.

Automatic identification and data capture (AIDC) refers to technologies that provide direct
entry of data into a computer or other microprocessor-controlled system without using a keyboard.
Many of these technologies require no human involvement in the data capture and entry process.

Automatic identification systems are being used increasingly to collect data in material handling
and manufacturing applications. In material handling, the applications include shipping and receiving,
storage, sortation, order picking, and kitting of parts for assembly. In manufacturing, the applications
include monitoring the status of order processing, work-in-process, machine utilization, worker
attendance, and other measures of factory operations and performance.

Of course, AIDC has many important applications outside the factory, including retail sales and
inventory control, warehousing and distribution center operations, mail and parcel handling, patient
identification in hospitals, check processing in banks, and security systems.

BAR CODE TECHNOLOGY

Linear (One-Dimensional) Bar Codes:

In linear width-modulated bar code technology, the symbol consists of a sequence of wide and
narrow colored bars separated by wide and narrow spaces (the colored bars are usually black and the
spaces are white for high contrast). The pattern of bars and spaces is coded to represent numeric or
alphanumeric characters.

Bar code readers interpret the code by scanning and decoding the sequence of bars. The reader
consists of the scanner and decoder. The scanner emits a beam of light that is swept past the bar code
(either manually or automatically) and senses light reflections to distinguish between the bars and
spaces. The light reflections are sensed by a photodetector, which converts the spaces into an electrical
signal and the bars into absence of an electrical signal. The width of the bars and spaces is indicated by
the duration of the corresponding signals. The procedure is depicted in above Figure. The decoder
analyses the pulse train to validate and interpret the corresponding data.

5
5. What does ‘RFID’ stand for? Explain the functions of ‘RFID tag/label’ with a neat sketch.

RFID stands for Radio frequency identification technology.

In radio frequency identification, an identification tag or label containing electronically encoded

data is attached to the subject item, which can be a part, product, or container (e.g., carton, tote pan,
pallet). The identification tag consists of an integrated circuit chip and a small antenna, as pictured in
Figure.

These components are usually enclosed in a protective plastic container or are imbedded in an
adhesive-backed label that is attached to item. The tag communicates the encoded data by RF to a
reader or interrogator as the item is brought into the reader’s proximity. The reader can be portable or
stationary. It decodes and confirms the RF signal before transmitting the associated data to a collection
computer.

RF identification tags are available in two general types:

(1) passive
(2) active

Passive tags have no internal power source; they derive their electrical power for transmitting a
signal from radio waves generated by the reader when in close proximity. Passive tags are smaller, less
expensive, longer lasting, and have a shorter radio communication range.
Active tags include their own battery power packs. Active tags generally possess a larger
memory capacity and a longer communication range (typically 10 m and more). Applications of active
tags tend to be associated with higher value items due to the higher cost per tag.

The principal applications of RFID in industry are

 inventory management
 supply chain management
 tracking systems
 warehouse control
 location identification
 work-in process tracking

6
6. Numerical Problem - Automated production lines – Upper bound & Lower bound approach
(Refer Class Notes)