Ch 1 Introduction

Sections: Six Sigma- reduce variations.

1. Production Systems
2. Automation in Production Systems Seven (7) types of wastes
3. Manual Labor in Production Systems 1. Inventory
4. Automation Principles and Strategies 2. Waiting
3. Defect
The Realities of Modern Manufacturing 4. Overproduction
5. Motion
▪ Globalization - Once underdeveloped countries 6. Transportation
(e.g., China, India, Mexico) are becoming major 7. Over-processing
players in manufacturing Five (5) S – antidote to waste.
1. Sort
▪ International outsourcing - Parts and products 2. Set in order
once made in the Philippines are now being made 3. Shine
offshore (overseas) or near-shore 4. Standardize
5. Sustain the cycle
▪ Local outsourcing - Use of suppliers within the
Philippines to provide parts and services The Production System
▪ Contract manufacturing - Companies that
specialize in manufacturing entire products, not just
parts, under contract to other companies

▪ Quality expectations - Customers, both

consumer and corporate, demand products of the
highest quality

▪ Need for operational efficiency -manufacturers

must be efficient in in their operations to overcome
the labor cost advantage of international
competitors
▪ Automation - automated equipment instead of
labor
▪ Material handling technologies - because
manufacturing usually involves a sequence of
activities.
▪ Manufacturing systems - integration and
coordination of multiple automated or manual
workstations
▪ Flexible manufacturing - to compete in the low-
volume/high-mix product categories
▪ Quality programs - to achieve the high quality
expected by today's customers
A collection of people, equipment, and
procedures organized to accomplish the
manufacturing operations of a company.
Two categories:
▪ Facilities – the factory and equipment in the
facility and the way the facility is organized (plant
layout)
▪ Manufacturing support systems – the set of
procedures used by a company to manage
production and to solve technical and logistics
problems in ordering materials, moving work
through the factory, and ensuring that products
meet quality standards.

▪ Lean production - more work with fewer

resources
Production System Facilities (PSF)
Facilities include the factory, production machines
and tooling, material handling equipment,
inspection equipment, and computer systems that
control the manufacturing operations.
▪ Plant layout – the way the equipment is
physically arranged in the factory
▪ Manufacturing systems – logical groupings of
equipment and workers in the factory
▪ Production line
▪ Stand-alone workstation and worker
Manufacturing Systems
Three categories in terms of the human
participation in the processes performed by the
manufacturing system:
Manufacturing Support Systems (MSS)
Involves a cycle of information-processing activities
that consists of four functions:
1. Business functions - sales and marketing,
order entry, cost accounting, customer billing
2. Product design - research and development,
design engineering, prototype shop
3. Manufacturing planning - process planning,
production planning, MRP, capacity planning
4. Manufacturing control - shop floor control,
inventory control, quality control
Information Processing Cycle in
Manufacturing Support Systems

1. Manual work systems - a worker performing

one or more tasks without the aid of powered tools,
but sometimes using hand tools

2. Worker-machine systems - a worker operating

powered equipment

3. Automated systems - a process performed by a

machine without direct participation of a human
 Product Variety and Production Quantity for
Automated Manufacturing Systems Three Automation Types
Three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation

Fixed Automation
A manufacturing system in which the sequence of
processing (or assembly) operations is fixed by the
equipment configuration.
Typical features:
▪ Suited to high production quantities
▪ High initial investment for custom-engineered
equipment
▪ High production rates
▪ Relatively inflexible in accommodating product
variety Computerized Manufacturing Support Systems

Programmable Automation Objectives of automating the manufacturing support

A manufacturing system designed with the
capability to change the sequence of operations to
accommodate different product configurations.
Typical features:
▪ High investment in general purpose
equipment
▪ Lower production rates than fixed
automation
▪ Flexibility to deal with variations and
changes in product configuration
▪ Most suitable for batch production
▪ Physical setup and part program must be
changed between jobs (batches)
Flexible Automation
An extension of programmable automation
in which the system is capable of changing over
from one job to the next with no lost time between
jobs.
Typical features:
▪ High investment for custom-engineered
system
▪ Continuous production of variable mixes of
products
▪ Medium production rates
▪ Flexibility to deal with soft product variety
systems:
▪ To reduce the amount of manual and clerical
effort in product design, manufacturing planning
and control, and the business functions
▪ Integrates computer-aided design (CAD) and
computer-aided manufacturing (CAM) in
CAD/CAM
▪ CIM includes CAD/CAM and the business
functions of the firm CIM Computer International
Manufacturing
Reasons for Automating
1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical
tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating
Manual Labor in Production Systems
Is there a place for manual labor in the modern
production system?
▪ Answer: YES
▪ Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems
Manual Labor in Factory Operations
The long term trend is toward greater use of
automated systems to substitute for manual labor
▪ When is manual labor justified?
▪ Some countries have very low labor rates and
automation cannot be justified
▪ Task is too technologically difficult to automate
▪ Short product life cycle
▪ Customized product requires human flexibility
▪ To cope with ups and downs in demand
▪ To reduce risk of product failure
Labor in Manufacturing Support Systems
Even if all of the manufacturing systems in the
factory are automated, there will still be a need for
the following kinds of work to be performed:
▪ Equipment maintenance
▪ Programming and computer operation
▪ Engineering project work
▪ Plant management
Automation Principles and Strategies
1. The USA Principle
2. Ten Strategies for Automation and Process
Improvement
3. Automation Migration Strategy
Ten Strategies for Automation and
Process Improvement
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10.Computer-integrated manufacturing
Automation Migration Strategy For Introduction
of New Products
1. Phase 1 – Manual production
▪ Single-station manned cells working
independently
▪ Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
▪ Single-station automated cells operating
independently
▪ As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
▪ Multi-station system with serial operations and
automated transfer of work units between stations

U.S.A Principle

1. Understand the existing process

▪ Input/output analysis
▪ Value chain analysis
▪ Charting techniques and mathematical modeling

2. Simplify the process

▪ Reduce unnecessary steps and moves

3. Automate the process

▪ Ten strategies for automation and production
systems
▪ Automation migration strategy
 QUIZ

1. Business practice of hiring a party outside a

company to perform services and create goods that
traditionally were performed in-house by the
company's own employees
and staff.
a. Globalization
b. International Outsourcing
c. Contract Manufacturing
d. Local Outsourcing

2. Capable of producing a variety of parts with

virtually no
time lost for changeovers from one part style to the
next.
a. Fixed automation
b. Programmable automation
c. Flexible automation
d. Automation Migration Strategy

3. Productivity is defined as:

a. Number of items manufactured per day
b. Output per man-hour of labour
c. Cost per day
d. Cost per unit

4. A manufacturing system in which the sequence

of processing (or assembly) operations is fixed by
the equipment configuration.

5. Logical groupings of equipment and workers in

the factory

6. The principal means of communicating with the

customer.

7. Clerical worker entering data into a PC is an

example of what category of manufacturing
systems?
Ch 2 Manufacturing Operations
Sections: Manufacturing Industries
1. Manufacturing Industries and Products
2. Manufacturing Operations
3. Production Facilities
4. Product/Production Relationships

Manufacturing Defined - Technological

Definition
“Application of physical and chemical processes to
alter the geometry, properties, and/or appearance
of a given starting material to make parts or
products.”

Manufacturing also includes the joining of multiple

parts to make assembled products.

▪ Accomplished by a combination of machinery,

tools, power, and manual labor.
▪ Almost always carried out as a sequence of
Operations

Manufacturing Defined - Economic Definition

“Transformation of materials into items of greater
value by means of one or more processing and/or
assembly operations.”

▪ Manufacturing adds value to the material

▪ Examples:
▪ Converting iron ore to steel adds value
▪ Transforming sand into glass adds value
▪ Refining petroleum into plastic adds value
Classification of Industries
1. Primary industries – cultivate and exploit
natural resources
▪ Examples: agriculture, mining
Production operations in the process industries and
the discrete product industries can be divided into
• Continuous production and
• Batch production
Process industries, e.g., chemicals, petroleum,
basic metals, foods and beverages, power
generation
▪ Continuous production
▪ Batch production

2. Secondary industries – convert output of

primary industries into products
▪ Examples: manufacturing, power generation,
construction ▪ Discrete product (and part) industries, e.g., cars,
aircraft, appliances, machinery, and their
3. Tertiary industries – service sector component parts
▪ Examples: banking, education, government, legal ▪ Continuous production
services, retail trade, transportation

▪ Batch production
Manufactured Products Assembly Operations
▪ Joining processes
▪ Welding
▪ Brazing and soldering
▪ Adhesive bonding
▪ Mechanical assembly
▪ Threaded fasteners (e.g., bolts and nuts,
screws)
▪ Rivets
▪ Interference fits (e.g., press fitting, shrink
fits)
Manufacturing Operations ▪ Other
▪ There are certain basic activities that must be
carried out in a factory to convert raw materials into An assembly operation joins two or more
finished products components tocreate a new entity which is called
▪ For discrete products: an assembly, subassembly,etc.
1. Processing and assembly operations
2. Material handling Other Factory Operations
3. Inspection and testing ▪ Material handling and storage
4. Coordination and control ▪ Inspection and testing
▪ Coordination and control
Classification of manufacturing processes:
Material Handling
“A means of moving and storing materials between
processing and/or assembly operations.”
▪ Material transport
▪ Vehicles, e.g., forklift trucks, AGVs,
monorails
▪ Conveyors
▪ Hoists and cranes

Time Spent in Material Handling

Inspection and Testing

Inspection – examination of the product and its
Processing Operations
components to determine whether they conform to
Three Categories of Processing Operations1.
design specifications.
Shaping operations
▪ Inspection for variables - measuring
1. Solidification processes
▪ Inspection of attributes – gaging
2. Particulate processing
3. Deformation processes
Testing – observing the product (or part, material,
4. Material removal processes
subassembly) during actual operation or under
conditions that might occur during operation.
2. Property-enhancing operations (heat
treatments)
Coordination and Control
3. Surface processing operations ▪ Regulation of the individual processing and
▪ Cleaning and surface treatments assembly operations
▪ Coating and thin-film deposition ▪ Process control
▪ Management of plant level activities
▪ Production planning and control
Ch 3 Introduction to Automation
Sections:
1. Basic Elements of an Automated System
2. Advanced Automation Functions
3. Levels of Automation
Automation Defined
“Automation is the technology by which a process
or procedure is accomplished without human
assistance.”
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
Power to Accomplish the Automated Process
Power for the process
▪To drive the process itself
▪To load and unload the work unit (proper
position and orientation
▪Transport between operations
Power for automation
▪Controller unit
▪Power to actuate the control signals
▪Data acquisition and information processing
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
Program of Instructions
“Set of commands that specify the sequence of steps in
the work cycle and the details of each step.”
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
1. The actions performed by an automated process are
defined by a “Program of Instructions”.
2. A new part or parts are completed during each work
cycle.
3. The particular processing steps for the work cycle are
specified in a “Work Cycle Program” (part programs).
4. The program of instructions is repeated each work
cycle without deviation.
Decision-Making in a Programmed Work Cycle
The following are examples of automated work
cycles in which decision making is required:
▪Operator interaction
▪Automated teller machine
▪Different part or product styles processed
by the system
▪Robot welding cycle for two-door
vs. four door car models
▪Variations in the starting work units
▪Additional machining pass for
oversized sand casting
(nonstandard/unidentical parts)
Features of a Work Cycle Program
-Number of steps in the work cycle
-Manual participation in the work cycle (e.g.,loading
and unloading workparts)
-Process parameters - how many must be controlled?
-Operator interaction – is operator required to enter
processing data?
-Variations in part or product styles
-Variations in starting work units – some adjustments in
process parameters may be required to compensate for
differences in starting units
Control System
-The Control element of the automated system executes
the program of instructions.
-The control system causes the process to accomplish
its defined function, to carry out some manufacturing
operation.
Control System – Two Types
1. Open-loop control system – operates without the
feedback loop
▪Simpler and less expensive
▪Risk that the actuator will not have the intended
effect
2. 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
▪Input Parameter (set point) represents the desired
value of the output
▪The process is the operation or function being
controlled (output value)
▪A sensor is used to measure the output variable and
close the loop between input and output.
▪The controller compares the output with the input and
makes the required adjustment in the process to reduce
the difference between them.
▪The adjustment is accomplished using one or more
actuators which are the hardware devices that physically
carry out the control actions.
Advanced Automation Functions
1. Safety monitoring
2. Maintenance and repair diagnostics
3. Error detection and recovery
Safety Monitoring
“Use of sensors to track the system's operation and
identify conditions that are unsafe or potentially
unsafe”
▪Reasons for safety monitoring
▪To protect workers and equipment
▪Possible responses to hazards:
▪Complete stoppage of the system
▪Sounding an alarm
▪Reducing operating speed of process
▪Taking corrective action to recover from the
safety violation
Safety monitoring – Examples
▪Temperature sensors
▪Heat or smoke detectors
▪Pressure sensitive floor pads
▪Vision systems
Maintenance and Repair Diagnostics
-refer to the capabilities of an automated system to
assist in identifying the source of potential or actual
malfunctions and failures of the system.
▪Status monitoring
▪Monitors and records status of key sensors
and parameters during system operation
▪Failure diagnostics
▪Invoked when a malfunction occurs
▪Purpose: analyze recorded values so the
cause of the malfunction can be identified
▪Recommendation of repair procedure
▪Provides recommended procedure for the
repair crew to effect repairs
Errors
 Random Errors
 Systematic errors are those that result from
some assignable cause such as a change in
raw material properties
Error Detection and Recovery
1. Error detection – functions:
▪Use the system’s available sensors to
determine when a deviation or malfunction
has occurred
▪Correctly interpret the sensor signal
▪Classify the error
2. Error recovery – possible strategies:
▪Make adjustments at end of work cycle
▪Make adjustments during current work
cycle
▪Stop the process to invoke corrective
action
▪Stop the process and call for help
Levels of Automation
1. Device level – actuators, sensors, and other
hardware components to form individual control
loops for the next level
2. Machine level – CNC machine tools and similar
production equipment, industrial robots, material
handling equipment
3. Cell or system level – manufacturing cell or
system
4. Plant level – factory or production systems level
5. Enterprise level – corporate information system
Benefits of Automation
• Increased capacity
• Improved Quality
• Reduced Cost
• Skilled Trade Gap
• Reduced Lead Time
The main disadvantages of automation are:
• Unemployment rate increases due to machines
replacing humans and putting those humans out of
their jobs.
• Technical Limitation: Current technology is
unable to automate all the desired tasks.
• Security Threats/Vulnerability: An automated
system may have limited level of intelligence;
hence it is most likely susceptible to commit error.
• Unpredictable development costs: The
research and development cost of automating a
process may exceed the cost saved by the
automation itself.
• High initial cost: The automation of a new
product or plant requires a huge initial investment in
comparison with the unit cost of the product,
although the cost of automation is spread in many
product batches of
things

Chapter 6- Hardware Components for
Automation and Process Control
Sensors
A sensor is a transducer that converts a physical
stimulus from one form into a more useful form to
measure the stimulus
Sensors can be classified into two basic categories:
1. Analog (continuous)
Examples: thermocouple, strain gauges,
potentiometers.
2. Discrete
Binary (on/off)
Examples: Limit switch, photoelectric
switches.
Digital (e.g., pulse counter)
Examples: photoelectric array,
optical encoder.
Common sensors
▪Accelerometer: Analog device used to measure
vibration and shock.
▪Ammeter: Analog device that measures the
strength of electric current
▪Bimetallic switch: Binary switch that uses
bimetallic coil to open and close electrical contact
as a result of temperature change. Consists of two
metal strips of different thermal expansion
coefficients bonded together.
▪Bimetallic thermometer: Analog temperature
measuring device consisting of bimetallic coil that
changes shape in response to temperature change.
▪Dynamometer: Analog device used to measure
force, power, or torque.
▪Float transducer: Float attached to lever arm.
Pivoting movement of lever arm can be used to
measure liquid level in vessel or to activate contact
switch.
▪Fluid flow sensor: Analog measurement of liquid
flow rate.
▪Fluid flow switch: Binary switch activated by
increase in fluid pressure.
▪Linear variable differential transformer: Analog
position sensor consisting of primary coil opposite
two secondary coils separated by a magnetic core.
When primary coil is energized, induced voltage in
secondary coils is function of core position.
▪Limit switch (mechanical): Binary contact sensor in
which lever arm or pushbutton closes or opens an
electrical contact.
▪Manometer: Analog device used to measure
pressure of gas or liquid.
▪Ohmmeter: Analog device that measures electrical
resistance.
▪Optical encoder: Digital device used to measure
position and/or speed, consisting of a slotted disk
separating a light source from a photocell.
▪Piezoelectric transducer: Analog device based on Types of Actuators
piezoelectric effect of certain materials in which an 1. Electrical actuators
electric charge is produced when the material is ▪Electric motors (linear or rotational)
deformed. Can be used to measure force, ▪DC servomotors
pressure, and acceleration. ▪AC motors
▪Potentiometer: Analog position sensor consisting ▪Stepper motors
of resistor and contact slider. Position of slider on ▪Solenoids
resistor determines measured resistance. ▪Relay
2. Hydraulic actuators
▪Use hydraulic fluid as the driving force
3. Pneumatic actuators
▪Use compressed air as the driving force
Electric motors
▪Proximity switch: Binary noncontact sensor is
triggered when nearby object induces changes in
electromagnetic field.
▪Radiation pyrometer: Analog temperature-
measuring device that senses electromagnetic
radiation.
▪Resistance-temperature detector: Analog
temperature measuring device based on increase DC motors
in electrical resistance of a metallic material as ▪DC motors are widely used:
temperature increases. ▪Convenience of using direct current.
▪E.g. motors in automobiles.
▪One special type of DC motors is Servomotors.
▪A feedback back loop is used to control
speed
▪Strain gauge: Widely used analog sensor to
measure force, torque, or pressure.

AC motors
▪Most used in industry.
▪Tachometer: Analog device consisting of DC ▪Advantages:
generator that produces an electrical voltage ▪Higher power supply
proportional to rotational speed. ▪Ease of maintenance
▪Tactile sensor: Measuring device that indicates
physical contact between two objects.
▪Tachometer: Analog device consisting of DC
generator that produces an electrical voltage
proportional to rotational speed.
▪Tactile sensor: Measuring device that indicates Stepper Motors
physical contact between two objects. ▪Provides rotation in the form of discrete
angular displacement (step angles).
▪Each step angle is actuated by a
Sec 6.2: Actuators discrete electrical pulse.
▪Are used in open loop control systems.
Actuators: are hardware devices that convert a
controller command signal into a change in a
physical parameter.
▪An actuator is also a transducer because it
changes one type of physical quantity into
some alternative form (e.g. electric current to Hydraulic and Pneumatic Actuators
rotational speed of electric motor). ▪Powered by pressurized fluid.
▪Oil for hydraulic systems
 ▪Compressed air for pneumatic systems

Other Actuators
▪Solenoids: a movable plunger inside a stationary
wire coil.
▪Used to open and close valves in fluid flow
systems, e.g., chemical processing
equipment.

▪Electromechanical relays: is an on-off electrical

switch.
▪Operated by low current levels. Hence,
safer to use.
ROBOTICS Translational Motion Joints

Industrial Robot Defined Linear joint (type L)

A general-purpose, programmable machine
possessing certain anthropomorphic characteristics
▪Why industrial robots are important:
▪Robots can substitute for humans in
hazardous work environments
▪Consistency and accuracy not
attainable By humans Orthogonal joint (type O)
▪Can be reprogrammed
▪Most robots are controlled by computers
and can therefore be interfaced to other
computer systems

Robot Anatomy
▪Manipulator consists of joints and links
▪Joints provide relative motion
▪Links are rigid members between joints

▪Various joint types: linear and rotary Rotary Motion Joints

▪Each joint provides a “degree-of-freedom”
▪Most robots possess five or six degrees-of- Rotational joint (type R)
Freedom

Twisting joint (type T)

▪Robot manipulator consists of two sections:

▪Body-and-arm – for positioning of objects in the Revolving joint (type V)

robot's work volume

▪Wrist assembly – for orientation of objects

Types of Manipulator Joints

▪Translational motion
▪Linear joint (type L)
▪Orthogonal joint (type O)

▪Rotary motion
▪Rotational joint (type R)
▪Twisting joint (type T)
▪Revolving joint (type V)
6 Degrees of Freedom (6 DoF)
Translation – Moving along the different axes X, Y
and Z
Moving up and down along the Z axis is called
heaving.
Moving forwards and backwards along the X axis is
called surging.
Moving left and right along the Z axis is called
swaying.
Rotation – Turning in order to face a different axis
Moving between X and Z is called pitch.
Moving between X and Y is called yaw.
Moving between Z and Y is called roll.
Robot Body-and-Arm Configurations
▪ Five common body-and-arm configurations for
industrial robots:
1. Polar coordinate body-and-arm assembly
2. Cylindrical body-and-arm assembly
3. Cartesian coordinate body-and-arm
assembly
4. Jointed-arm body-and-arm assembly
5. Selective Compliance Assembly Robot
Arm (SCARA)
▪ Function of body-and-arm assembly is to position
an end effector (e.g., gripper, tool) in space
SCARA Robot
▪ SCARA stands for Selectively Compliant
Assembly Robot Arm
▪ Similar to jointed-arm robot except that vertical
axes are used for shoulder and elbow joints to be
compliant in horizontal direction for vertical
insertion tasks
Joint Drive Systems
▪ Electric
▪ Uses electric motors to actuate individual
joints
▪ Preferred drive system in today's robots
▪ Hydraulic
▪ Uses hydraulic pistons and rotary vane
actuators
▪ Noted for their high power and lift capacity
▪ Pneumatic
▪ Typically limited to smaller robots and
simple material transfer applications
Robot Control Systems
▪ Limited Sequence Control- most elementary
control type. It can be utilized only for simple
motion cycles, such as pick-and-place operations.
▪ Playback with point-to-point control – records
work cycle as a sequence of points, then plays
back the sequence during program execution
▪ Playback with continuous path control – greater
memory capacity and/or interpolation capability
to execute paths (in addition to points)
▪ Intelligent control – exhibits behavior that makes
it seem intelligent, e.g., responds to sensor
inputs, makes decisions, communicates with
humans
End Effectors Industrial Robot Applications
▪ The special tooling for a robot that enables it to
perform a specific task 1. Material handling applications
▪ Two types: ▪ Material transfer – pick-and-place, palletizing
▪ Grippers – to grasp and manipulate ▪ Machine loading and/or unloading
objects (e.g., parts) during work cycle 2. Processing operations
▪ Tools – to perform a process, e.g., spot ▪ Spot welding and continuous arc welding
welding, spray painting ▪ Spray coating
▪ Other – waterjet cutting, laser cutting, grinding
Grippers used in industrial robot applications 3. Assembly and inspection
include
• mechanical grippers Robot Programming
• vacuum grippers
• magnetized devices ▪ Leadthrough programming - work cycle is
• adhesive devices taught to robot by moving the manipulator through
innovations and advances in mechanical gripper the required motion cycle and simultaneously
technology entering the program into controller memory for
• Dual grippers later playback
• interchangeable fingers ▪ Robot programming languages - uses textual
• Sensory feedback programming language to enter commands into
• Multiple fingered grippers robot controller
• Standard gripper products ▪ Simulation and off-line programming –
program is prepared at a remote computer terminal
Tools are used in applications where the robot and downloaded to robot controller for execution
must perform some processing operation on the without need for leadthrough methods
workpart.
Examples: Leadthrough Programming
• spot welding gun Two types:
• arc welding tool 1. Powered leadthrough
• spray painting gun ▪ Common for point-to-point robots
• rotating spindle for drilling, routing. ▪ Uses teach pendant to move joints to
grinding, and so forth desired position and record that position into
• assembly tool (e.g., automatic memory
screwdriver) 2. Manual leadthrough
▪ Convenient for continuous path control
• heating torch
robots
• water jet cutting tool.
▪ Human programmer physical moves
manipulator through motion cycle and
Robot Application Characteristics records cycle into memory
General characteristics of industrial work situations
that promote the use of industrial robots
Teach Pendant for Powered Leadthrough
Programming
1. Hazardous work environment for humans
2. Repetitive work cycle
3. Difficult handling task for humans
4. Multishift operations
5. Infrequent changeovers
6. Part position and orientation are established in
the work cell