Manpros System Automation-1

Manufacturing System Automation
Herwan Yusmira

MANUFACTURING SYSTEMS AUTOMATION
Contents:
1. Automation fundamental 4. Machining Center
• Manufacturing system. • APC
• Automation. • ATC.
2. Hardware component for automation 5. Industrial Robotics

• Sensors. • Robot anatomy.
• Actuators. • Control systems and robot programming.
• Interface devices. • Application of industrial robot.
• Process controllers.
3. Computer Numerical Control 6. Slider
• The technology of CNC. • Slider anatomy.
• CNC positioning systems.
• CNC part programming. 7. Automatic Guided Vehicle
• Application of CNC. • The AGV.

A manufacturing system can be defined as a collection of integrated equipment and
human resources that performs one or more processing and/or assembly operations on a starting
work material, part, or set of parts. The integrated equipment consists of:
• Production machines,
• Material handling and positioning devices,
• Computer systems.
Manufacturing support
systems
Manufacturing
Support Systems Quality Control

system
Manufacturing
System
Manufacturing processes and assembly operations Finished

materials
products
Figure1. Integrated Manufacturing System:

Automation can be defined as the technology by which a process or procedure is performed
without human assistance. Humans may be present as observers or even participants, but the
process itself operates under its own self-direction.
THREE COMPONENTS OF AN AUTOMATED SYSTEM
1. power,
2. a program of instructions, and
3. a system to carry out the instructions.
The form of power used in most automated systems is electrical with the advantages of:
• it is widely available,
• it can be readily converted to other forms of power such as mechanical, thermal, or hydraulic,
• it can be used at very low power levels for functions such as signal processing,
communication, data storage, and data processing, and
• it can be stored in long-life batteries.

Power
Program of Process Output

Control system
Instructions Process
Figure 2. Elements of an automated system:

1. power, 2. Program of Instructions, 3. Control system

Examples of automation:
• Melting a metal in a casting operation.

• Maintain a certain controlled variable at a specified level, such as
regulating the temperature in a heat treatment furnace.
• Driving the motions of a cutting tool relative to a workpiece, changing
the x-coordinate position of a machine tool worktable, cutter positions,
cutting speeds, feeds, and other details of the operation in a machining
operation.
• Opening or closing a valve in a fluid flow system.
• Turning a motor on or off.
• Safety monitoring requirements.
• Equipment malfunctions.
• All others.

Types of control system
A closed loop system

(1) (5) (6) (2) (3)
Input Output
Controller Actuator Process
variable
parameter
(4)
Feedback
sensor
(a)
An open loop system

Output
Input Controller Actuator Process
parameter variabl
e
(b)
Figure 3. A close and an Open loop system:

Figure 4. A close and an Open loop system:

Types of Automation:
Fixed Automation
In fixed automation, the processing or assembly steps and their sequence are fixed by the
equipment configuration. The program of instructions is determined by the equipment design
and cannot be easily changed. Each step in the sequence usually involves a simple action, such
as feeding a rotating spindle along a linear movement. Although the work cycle consists of
simple operations, integrating and coordinating the actions can result in the need for a rather
sophisticated control system, and computer control is often required.
Typical features of Fixed automation:

• high initial investment for specialized equipment,
• high production rates, and
• little or no flexibility to accommodate product variety.
(Automated systems with these features can be justified for parts and products that are produced in very large quantities. The
high investment cost can be spread over many units, thus making the cost per unit relatively low compared to alternative
production methods).

Programmable Automation
As its name suggests, the equipment in programmable automation is designed with the
capability to change the program of instructions to allow production of different parts or
products. New programs can be prepared for new parts.
The features of programmable automation are:
• high investment in general purpose equipment that can be reprogrammed,

• lower production rates than fixed automation,
• ability to cope with product variety by reprogramming the equipment, and
• suitability for batch production of various part or product styles. Examples of
programmable automation include CNC and industrial robotics.

Flexible Automation
Flexible automation is an extension of programmable automation in which there is

virtually no lost production time for setup changes and/or reprogramming. Any
required changes in the program of instructions and/or setup can be accomplished
quickly; that is, within the time needed to move the next work unit into position at the
machine. A flexible system is therefore capable of producing a mixture of different
parts or products one right after the other instead of in batches.
The features are:

• high investment cost for custom-engineered equipment,
• medium production rates, and
• continuous production of different part or product styles.
(Fixed automation is applicable in situations of hard product variety, programmable automation is applicable to
medium product variety, and flexible automation can be used for soft product variety).

Flexibility and Productivity of Manufacturing Systems
Soft automation Hard automation
Figure 5. Flexibility and productivity of various manufacturing systems. Note the overlap between the systems; it is due to
the various levels of automation and computer control that are possible in each group.

Hardware components for automation
Sensor
A sensor is a device that converts a physical stimulus or variable of interest (e.g., temperature, force,
pressure, or other characteristic of the process) into a more convenient physical form (e.g., electrical
voltage) for the purpose of measuring the variable. The conversion allows the variable to be interpreted as
a quantitative value. Sensors of various types are classified according to type of stimulus; mechanical
(position, velocity, force, torque, and many others), electrical (voltage, current, and resistance), thermal,
radiation, magnetic, and chemical variables.
In addition to type of stimulus, sensors are also classified as analog or discrete.

• An analog sensor measures a continuous analog variable and converts it into a continuous signal
such as electrical voltage. Thermocouples, strain gages, and ammeters are examples of analog sensors.
• A discrete sensor produces a signal that can have only a limited number of values. Within this
category, we have binary sensors and digital sensors.
• A binary sensor can take on only two possible values, such as Off and On, or 0 and 1. Limit
switches operate this way.
• A digital sensor produces a digital output signal, either in the form of parallel status bits,
such as a photoelectric sensor array or a series of pulses that can be counted, such as an
optical encoder. Digital sensors have an advantage that they can be readily interfaced to a
digital computer, whereas the signals from analog sensors must be converted to digital in
order to be read by the computer.
Actuators
An actuator is a device that converts a control signal into a physical action, which usually
refers to a change in a process input parameter. The action is typically mechanical, such
as a change in position of a worktable or rotational speed of a motor. The control signal
is generally a low level signal, and an amplifier may be required to increase the power of
the signal to drive the actuator.
Actuators can be classified according to type of amplifier as

• electrical (i.e. servomotors and stepper motors),
• hydraulic (utilize hydraulic fluid to amplify the control signal and are often
specified when large forces are required in the application),
• pneumatic are driven by compressed air, which is commonly used in factories.
All three actuator types are available as linear or rotational devices.

Interface devices
Interface devices allow the process to be connected to the computer controller and vice versa. Sensor
signals from the manufacturing process are fed into the computer, and command signals are sent to
actuators that operate the process. This enable communication between the process and the controller.
The devices include analog-to-digital converters, digital-to-analog converters, contact input/output
interfaces, and pulse counters and generators.
Continuous analog signals from sensors attached to the process must be transformed into digital values
that can be used by the control computer, a function that is accomplished by an analog-to-digital
converter (ADC). As illustrated in Figure 4, an ADC
• samples the continuous signal at periodic intervals,

• converts the sampled data into one of a finite number of defined amplitude levels, and
• encodes each amplitude level into a sequence of binary digits that can be interpreted by the
control computer.
Important characteristics of an ADC include sampling rate (frequency) and resolution (precision).

Variable
Continuous analog signal
Discrete sampled signal
Time
Figure 6. An analog-to-digital converter (ADC) works by converting a

continuous analog signal into a series of discrete sampled data.

A digital-to-analog converter (DAC) accomplishes the reverse process of
the ADC. It converts the digital output of the control computer into a
continuous signal capable of driving an analog actuator or other analog
device. The DAC performs its function in two steps:
• decoding, in which the sequence of digital output values is

transformed into a corresponding series of analog values at
discrete time intervals, and
• data holding, in which each analog value is changed into a
continuous signal during the duration of the time interval. In the
simplest case, the continuous signal consists of a series of step
functions, as in Figure 7, which are used to drive the analog
actuator.

Ideal output envelope
Variable
Series of
discrete step
functions
Time
Figure 7. A digital-to-analog converter (DAC) works by converting a series of discrete
sampled data into a continuous analog signal.

Process Controller
A widely used process controller is a programmable logic controller (PLC), a
microcomputer-based controller that uses stored instructions in programmable memory
to implement logic, sequencing, timing, counting, and arithmetic control functions,
through digital or analog input/output modules, for controlling various machines and
processes. The major components of a PLC, shown in Figure 9, are:
• input and output modules, which connect the PLC to the industrial
equipment to be controlled;
• CPU which executes the logic and sequencing functions to control the process by
operating on the input signals and determining the proper output signals
specified by the control program;
• PLC memory, which is connected to the processor and contains the logic and
sequencing instructions;
• power supply—115 V AC is typically used to drive the PLC. And
• a programming device (usually detachable) is used to enter the program into
the PLC.

A variety of PLC programming languages have been
developed, ranging from ladder logic diagrams to
structured text. Advantages associated with PLC
include:
• programming a PLC is easier than wiring a

relay control panel;
• PLCs can be reprogrammed, whereas
conventional hard-wired controls must be
rewired and are often scrapped instead because
of the difficulty in rewiring;
• PLC can be interfaced with the plant computer
system more readily than conventional controls;
• PLCs require less floor space than relay
controls, and
• PLCs offer greater reliability and easier
maintenance. Figure 8. PLC system in a rack, left-to-
right: power supply unit (PSU), CPU,
interface module (IM) and communication
processor (CP).
External power source
(4)
Power
PLC
supply
(2)
(5)
Input Inputs from process
Programming (1)
Processor
module
device Output Outputs to process
module
(3)
Memory
Figure 9. Major components of a PLC, programmable logic controller.

END

Computer Numerical Control
Herwan Yusmira

The initial development work on numerical The potential for reducing nonproductive time in
control is credited to John Parsons and Frank the machining cycle was also apparent. In 1956,
Stulen at the Parsons Corporation in Michigan the Air Force sponsored the development of NC
in the late 1940s. Parsons was a machining machine tools at several different companies.
contractor for the U.S. Air Force and had These machines were placed in operation at
devised a means of using numerical various aircraft plants between 1958 and 1960.
coordinate data to move the worktable of a The advantages of NC soon became clear, and
milling machine for producing complex parts aerospace companies began placing orders for
for aircraft. On the basis of Parson’s work, the new NC machines.
Air Force awarded a contract to the company The importance of part programming was clear
in1949 to study the feasibility of the new from the start. The Air Force continued to
control concept for machine tools. The encourage the development and application of
project was subcontracted to the NC by sponsoring research at M.I.T. for a part
Massachusetts Institute of Technology to programming language to control NC machines.
develop a prototype machine tool that This research resulted in the development of APT
utilized the new numerical data principle. in 1958 (APT stands for Automatically
The M.I.T. study confirmed that the concept Programmed Tooling). APT is a part programming
was feasible and proceeded to adapt a three- language by which a user could write the
axis vertical milling machine using combined machining instructions in simple English-like
analog-digital controls. The name numerical statements, and the statements were coded to be
control (NC) was given to the system by which
the machine tool motions were accomplished.
The History of CNC
interpreted by the NC system.
The prototype machine was demonstrated in

Technology of Numerical Control
Three component of NC system:
1. part program is the detailed set of commands to be followed by the processing equipment. It is the
program of instructions in the CNC control system. Each command specifies a position or motion
that is to be accomplished by the work head relative to the work-part. A position is defined by its x-
y-z coordinates. In machine tool applications, additional details in the CNC program include spindle
rotation speed, spindle direction, feed rate, tool change instructions, and other commands related to
the operation. Part program is made by programmer.
2. machine control unit (MCU) is a microcomputer that stores and executes the program by converting
each command into actions by the processing equipment, one command at a time. The MCU also
permits the part program to be edited in case the program contains errors, or changes in cutting
conditions.
3. processing equipment accomplishes the sequence of processing steps to transform the starting
work-part into a completed part. It operates under the control of the MCU according to the
instructions in the part program.

Coordinate system and motion in CNC:

A standard coordinate axis system is used to specify positions in numerical control. The system consists
of the three linear axes (x, y, z) of the Cartesian coordinate system, plus three rotational axes (a, b, c),
as shown in Figure 1(a). Most CNC systems do not require all six axes. Some machine tools have five-
axis to shape complex work-part geometries. These systems typically include three linear axes plus two
rotational axes.
The coordinates for a rotational CNC system are illustrated in Figure 1(b). These systems are associated
with CNC turning operations. Although the work rotates, this is not one of the controlled axes in a
conventional CNC turning system. The cutting path of the tool relative to the rotating workpiece is
defined in the x-z plane.
Figure 1. coordinate machine.

Motion control in CNC:
Motion control systems based on CNC can be divided into two types:
• Point-to-point also called positioning systems, move the work-piece to a programmed location with no
regard for the path taken to get to that location. Once the move is completed, some processing action is
accomplished by the work-head at the location, such as drilling or punching a hole. Thus, the program
consists of a series of point locations at which operations are performed.
• Continuous path (contouring) provides continuous simultaneous control of more than one axis. This
permits the tool to perform a process while the axes are moving, enabling the system to generate angular
surfaces, two-dimensional curves, or three-dimensional contours in the workpiece.
An important aspect of continuous path motion is interpolation, which is concerned with

calculating the intermediate points along a path. Two common forms of interpolation are:
• Linear interpolation is straight line paths, in which the part programmer specifies the
coordinates of the beginning point and end point of the straight line as well as the feed rate to be
used. The interpolator then computes the travel speeds of the two or three axes that will
accomplish the specified trajectory.
• Circular interpolation is a circular arc by specifying the coordinates of its beginning and end
points together with either the center or radius of the arc. The interpolator computes a series of
small straight line segments that will approximate the arc within a defined tolerance.

Motion control in CNC:

Another aspect of motion control is concerned with whether the positions in the coordinate system are
defined absolutely or incrementally. In absolute positioning, the workhead locations are always
defined with respect to the origin of the axis system. In incremental positioning, the next workhead
position is defined relative to the present location. The difference is illustrated in Figure 2.
Figure 2. Absolute vs. incremental positioning. The workhead is at point (2,3) and is to be moved to point (6,8). In absolute
positioning, the move is specified by x 6, 8; while in incremental positioning, the move is specified by x 4, y 5.

Figure 3. Positions of drilled holes in a workpiece. Three methods of measurements are shown:
(a) Absolute dimensioning, referenced from one point at the lower left of the part;
(b) incremental dimensioning, made sequentially form one hole to another; and
(c) mixed dimensioning, a combination of both methods.

oint-to-Point and Contour Machining
Figure 4. (a) Schematic illustration of drilling, boring, and milling with various paths. (b) Machining a sculptured
surface on a 5-axis numerical control machine.

CNC Program Sequences.
The goal of every G-code program is to produce parts in the safest and most efficient way possible. To achieve
this the G-code blocks should be arranged in a very specific order like this:
1. Start the CNC program

2. Load the required tool
3. Turn the spindle on
4. Turn the coolant on
5. Move to position above a part
6. Start the machining process
7. Turn the coolant of
8. Turn the spindle of
9. Move away from the part to a safe location
10. End the CNC program

Sample of CNC Program
Figure 5. Sample of CNC program.

The complete list of address codes includes:

There are also several special character codes that can be added into a G-code program. These are
typically used to start a program, comment out text, or ignore characters and include:

• % Begins or ends a CNC program
• () Defines a comment written by a CNC operator, occasionally these must be in all caps
• / Ignores all characters that come after the slash
• ; Determines when a block of code ends, not shown in a text editor
Programming
Exercises
CAD/CAM
Flow Chart
Figure 6. Information flow chart in CAD/CAM application.

Machining Center
Figure 7. The versatility of CNC milling machine

has been further enhanced by developing what
is called Machining Centre. Left figure visualizes
one of such Machining Centre.
Self-Guided Vehicle
Figure 8. A self-guided vehicle (Caterpillar Model

SGC-M) carrying a machining pallet. The vehicle is
aligned next to a stand on the floor. Instead of following a
wire or stripe path on the factory floor, this vehicle
calculates its own path and automatically corrects for any
deviations.

Industrial Robots
Figure 9. Four types of industrial robots:

(a) cartesian (rectilinear),
(b) cylindrical,
(c) spherical (polar),
(d) articulated (revolute, jointed, or anthropomorphic).
Work Envelopes
Figure 10. Work envelopes for three

types of robots. The choice
depends on the particular application.

Six-Axis S-10 GMF Robot
Figure 11. (a) Schematic illustration

of a six-axis S-10 GMF robot. The payload
at the wrist is 10 kg and repeatability is ±0.2
mm. The robot has mechanical brakes on all
its axes, which are coupled directly.
(b) The work envelope of the robot, as
viewed from the side.

Flexible
Manufacturing
System
Figure 12. A general view of a flexible

manufacturing system, showing several
machine tools and an automated guided
vehicle.

Others

Computer Introduction
Herwan Yusmira

Computer Introduction
Contents
1. Serial and Parallel communication

2. Bit
• Definition and usages.
3. Bytes
4. Data-bit
• Definition
• Number of bit
• Usages.
5. Baud-rate
6. Parity
• Definition and usages
7. ASCII Code.
• Definition and usages

Serial and Parallel connection
In data transmission, serial communication is the process of sending

data one bit at a time, sequentially, over a communication channel or
computer bus. This is in contrast to parallel communication, where
several bits are sent as a whole, on a link with several parallel channels.
Serial communication is used for most computer networks, where the

cost of cable and synchronization difficulties make parallel
communication impractical. Serial computer buses are becoming more
common even at shorter distances, as improved signal integrity and
transmission speeds in newer serial technologies have begun to
outweigh the parallel bus's advantage of simplicity and to outstrip its
disadvantages (clock skew, interconnect density).
Two Connection Type
Figure 1. Parallel and Serial

interface.

Definitions
Bit (Binary digit) is a basic unit of information in computing and digital communications.
In theory, one bit is typically defined as 0 or 1. As a binary digit, the bit represents a logical
value of a two-state. These state values are most commonly represented as either 0 or 1, but
other representations such as true/false, yes/no, +/−, or on/of are possible. The symbol
for the binary digit is either simply bit or the lowercase character b.
Byte. A group of eight bits is commonly called one byte. The upper case letter B is the
standard and customary symbol for byte.
Parity or check bit, is a bit added to a string of binary code to ensure that the total number of
1-bits in the string is even or odd. Parity bits are used as the simplest form of error detecting
code. There are two variants of parity bits: even parity bit and odd parity bit.
Baud rate is a speed of communication over a data channel which can be expressed as bits
per second (bps). For example: 9600 bps or 19200 bps. (6=19200, 5=9600, 4=4800, 3=2400,
2=1200, 1=600, 0=300)
Brief History of ASCII code:
The American Standard Code for Information Interchange, ASCII code, was created in 1963 by the ASA
(American Standards Association) Committee, the agency changed its name in 1969 by ANSI (American National
Standards Institute) as it is known since. This code arises from reorder and expand the set of symbols and
characters already used in telegraphy by the Bell company.
At first only capital letters and numbers, and in 1967 was added the lowercase letters and some control
characters (the characters 0 through 127). This set of only 128 characters is a-standard characters all you need to
write in English language.
In 1981, IBM developed an extension of 8-bit ASCII code, called "code page 437" that replaced some obsolete
control characters for graphic characters. A-128 characters were added with new symbols, signs, graphics and
Latin letters, all punctuation signs and characters needed to write texts in other languages, such as Spanish. In
this way the ASCII characters ranging from 128 to 255.
IBM includes support for this code page in the hardware of its model 5150, known as IBM-PC, considered the
first personal computer. The operating system of this model, the "MS-DOS" also used this extended ASCII code.
Almost all computer systems today use the ASCII code to represent characters and texts.

Morse Code
Figure 2. International Morse code used by

the Bell Company.

USASCII
Figure 3. Chart code of USASCII

used by telephone and type writer
companies.

ASCII Code
Figure 4. ASCII code 0

to 127

ASCII Code
Figure 5. ASCII code

128 to 255

ASCII Code
Figure 6. ASCII code

of alphabets

Exercises

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Manufacturing System Automation

Manufacturing System Automation

2. Hardware component for automation 5. Industrial Robotics

Manufacturing System Automation

Support Systems Quality Control

Manufacturing processes and assembly operations Finished

Figure1. Integrated Manufacturing System:

THREE COMPONENTS OF AN AUTOMATED SYSTEM

Manufacturing System Automation

Program of Process Output

Figure 2. Elements of an automated system:

Manufacturing System Automation

• Melting a metal in a casting operation.

Manufacturing System Automation

A closed loop system

An open loop system

Figure 3. A close and an Open loop system:

Manufacturing System Automation

Manufacturing System Automation

Typical features of Fixed automation:

Manufacturing System Automation

The features of programmable automation are:

• high investment in general purpose equipment that can be reprogrammed,

Manufacturing System Automation

Flexible automation is an extension of programmable automation in which there is

The features are:

Manufacturing System Automation

Soft automation Hard automation

Manufacturing System Automation

In addition to type of stimulus, sensors are also classified as analog or discrete.

Actuators can be classified according to type of amplifier as

All three actuator types are available as linear or rotational devices.

Manufacturing System Automation

• samples the continuous signal at periodic intervals,

Manufacturing System Automation

Discrete sampled signal

Figure 6. An analog-to-digital converter (ADC) works by converting a

Manufacturing System Automation

• decoding, in which the sequence of digital output values is

Manufacturing System Automation

Manufacturing System Automation

Manufacturing System Automation

• programming a PLC is easier than wiring a

Figure 9. Major components of a PLC, programmable logic controller.

Manufacturing System Automation

Manufacturing System Automation

Manufacturing System Automation

The prototype machine was demonstrated in

Manufacturing System Automation

Coordinate system and motion in CNC:

Figure 1. coordinate machine.

Manufacturing System Automation

An important aspect of continuous path motion is interpolation, which is concerned with

Manufacturing System Automation

Motion control in CNC:

Manufacturing System Automation

Manufacturing System Automation

Manufacturing System Automation

1. Start the CNC program

Manufacturing System Automation

Figure 5. Sample of CNC program.

Manufacturing System Automation

Figure 6. Information flow chart in CAD/CAM application.