Chapter 3 - Element of CIM

Rules in Class
 Attend at least 80% of class hours

 Complete all home-works and assignments (If any)
Dr. Van-Phong Vu-Department of Automatic Control

Assessment
 Assignment (50%)
 After each chapter will have one assignment/homework.
 Final Project (50%)
 Student have to complete a small project and present in the class.

Textbook and References
 [1] Hệ thống sản xuất tích hợp, Đặng Thiện Ngôn, Lê Chí Cương.
 [2] Automation Production System, and Computer Integrated
Manufacturing, Mikell P. Groover, 2015
 Sofware:
 Factory_IO

Contents of This course
 Chapter 1: Introduction
 Chapter 2: Life Cycle of Product
 Chapter 3: Elements of CIM
 Chapter 4: Group Technology Layout
 Chapter 5: Computer Aided Process Planning
 Chapter 6: Product Data Management
 Chapter 7: Quality Management and Fault Diagnosis
 Chapter 8: Just-in-Time Manufacturing, Lean Manufacturing, and
Agile Manufacturing.
Chapter 3: Elements of CIM

Contents of Chapter 3
 3.1 Introduction of Automation

 3.2 Industrial Control System
 3.3 Hardware and Devices
 3.4 CNC
 3.5 Robots
 3.6 PLC

3.1 Introduction to Automation

 Automation: process or procedure is accomplished without human
assistance.
 BASIC ELEMENTS OF AN AUTOMATED SYSTEM

Power for Process
Power Power for handling
Power for Automation


 Power for Handling time:
 Loading and unloading the work unit
 Material transport between operations.
 Power for Automation:
 Controller unit.
 Power to actuate the control signals.
 Data acquisition and information processing

 Program of Instructions: The actions performed by an automated
process are defined by a program of instructions.
 Work Cycle Programs
 Decision Making in the Programmed Work Cycle
 Control System:

 Level of Automation:

3.2 Industrial Control System

 Control System:
 Regulatory Control

 Control System:
 Feedforward control, combined with feedback control.


 Control System:
 Steady-State Optimization

 Control System:
 Adaptive Control

 Control System:
 Supervisory Control and Data Acquisition (SCADA)

 Control System:
 Distributed Control Systems.

3.3 Hardware and Devices

 Sensor: a device that converts a physical variable of one form into another
form that is more useful for the given application

 Sensor: a device that converts a physical variable of one form into another
form that is more useful for the given application

 ACTUATORS: a hardware device that converts a controller command
signal into a change in a physical parameter
 Classified into one of three categories:
 Electric
 Hydraulic
 Pneumatic.

 Electric Motors
 DC Motors:
 DC motor
 DC servomotors
 Brushless DC motor

 AC Motors:
 Two important disadvantages of DC motors:
 Commutator and brushes  maintenance problems with these motors
 the most common electrical power source in industry is alternating
current, not direct current
  Develop AC motors.
 AC motors: Synchronous motors+Induction motors
 Stepper Motors

 Rotary-to-Linear Motion
 Conversion:

 Linear Motors.

3.4 Computer Numerical Control
(CNC)

3.4 CNC


3.4 CNC
 Numerical control (NC):
 Form of programmable automation-
 Mechanical actions of a machine tool or other equipment are
controlled by a program containing coded alphanumeric data
 Application of NC:
 machine tool applications: drilling, milling, turning, and other
metal working
 other applications: assembly, rapid prototyping, and inspection

3.4 CNC
 Basic components:
part program is the set of
detailed step-by-step
commands that direct the
actions of the processing
equipment
machine control unit (MCU) is a

microcomputer storing the program of
instructions and executes it by converting
each command into mechanical actionsn of
the processing equipment, one command at
a time

3.4 CNC
 NC Coordinate Systems
 Program the NC processing equipment must define a standard axis
system
 Two axis systems used in NC:
 Flat work parts
 rotational parts.
 Coordinate systems are based on the Cartesian coordinates

3.4 CNC
 NC Coordinate Systems  Three linear axes (x, y, z)
 x- and y-axes are used to
move and position the
worktable
 z-axis is used to control
the vertical position of the
cutting tool
• Three rotational axes (a, b,

c)
• a-, b-, and c-rotational axes
specify angular positions
about the x-, y-, and z-axes

3.4 CNC
 Motion Control Systems
Motion Control
Point-to-Point Continuous path

3.4 CNC
 Absolute Positioning
 the work head locations are always defined with respect to the origin
of the axis system
 Incremental Positioning
 The next work head position is
defined relative to the
present location

3.4 CNC
 The CNC Machine Control Unit

3.4 CNC
 Controls for Machine Tool Axes and Spindle Speed:
 control the position and velocity (feed rate) of each machine axis
 the rotational speed of the machine tool spindle
 Sequence Controls for Other Machine Tool Functions:
 Coolant
 Fixture clamping
 Tool changer
 interlocks
 emergency warnings

3.4 CNC
 CNC Software: interpret the NC part programs and generate
the corresponding control signals
 to drive the machine tool axes
CNC Software
operating system software
operate the communication
machine interface software link between the CPU
and the machine tool
application software
the NC part programs that are written

for machining (or other) applications
3.4 CNC
 Distributed Numerical Control

3.4 CNC
 3.4.1 Machine Tool Applications
 Machining Operations and NC Machine Tools.
 Machining: manufacturing process in which the geometry of the work
is produced by removing excess material
 Create a wide variety of shapes and surface finishes
 Relatively high production rates to yield
 Highly accurate parts
 Relatively low cost.

3.4 CNC
 Four common types of machining operations:
(a) turning

(b) drilling
3.4 CNC
 Four common types of machining operations:
(c) peripheral milling

(d) surface grinding.

3.4 CNC

3.4 CNC
 NC for Other Metalworking Processes
 Punch presses for sheet metal hole punching (đục)
 Presses for sheet metal bending
 Welding machines
 Thermal cutting machines, such as oxy-fuel cutting, laser
cutting, and plasma arc cutting
 Tube bending and wire bending machines.
 Wire EDM: Electric discharge wire cutting operates in a
manner.
3.4 CNC
 Advantages of NC.
 Nonproductive time is reduced
 Greater accuracy and repeatability.
 Inspection requirements are reduced.
 More complex part geometries are possible.
 Shorter manufacturing lead times
 Reduced parts inventory.
 Less floor space.
 Operator skill requirements are reduced.

3.4 CNC
 Disadvantages of NC.
 Higher investment cost.
 Higher maintenance effort.
 Part programming.

3.4 CNC
 3.4.3 ANALYSIS OF POSITIONING SYSTEMS

3.4 CNC
Open loop positioning system

3.4 CNC
Close loop positioning system

3.4 CNC
 Open-loop positioning system:
 uses a stepper motor to rotate the leadscrew or ball screw

3.4 CNC
 possible step angles
 alpha = step angle, °;

 ns = the number of step angles for the motor, which must be an
integer
 The angle of the motor shaft rotates is given by
 Am = angle of motor shaft rotation, °; np = number of pulses

received by the motor; and alpha = step angle, °/pulse
3.4 CNC
 The angle of the screw rotation
 As = angle of screw rotation, °; and rg = gear ratio


 Nm = rotational speed of the motor, rev/min ( revolutions per minute); and

Ns = rotational speed of the screw, rev/min.

3.4 CNC
 Linear movement of the worktable
 X: x_position
 p: pitch of screw
 As/360: number of screw revolution
 Pulses required to achieve a specified x-position increment

3.4 CNC
 Ns = screw rotational speed, rev/min; fp = pulse train frequency, Hz;

and ns = steps per revolution or pulses per revolution

3.4 CNC

3.4 CNC

3.4 CNC
 Closed-loop positioning system:
 uses servomotors and feedback measurements to ensure that the
worktable is moved to the desired position.
 An optical encoder is a device for measuring rotational speed that
consists of a light source and a photodetector on either side of a disk

3.4 CNC
 Closed-loop positioning system:

3.4 CNC
 closed-loop positioning system:

3.4 CNC

3.4 CNC

3.4 CNC

3.4 CNC
 3.4.3 Precision in Positioning Systems
Precision in positioning System
Control resolution Accuracy repeatability
 Control resolution: the distance separating two adjacent

addressable points in the axis movement
 Addressable points: are locations along the axis to which the
worktable can be specifically directed to go

3.4 CNC
 CR1 = control resolution of electromechanical components , mm (in); p =

leadscrew pitch, mm/rev (in/rev); ns = number of steps per revolution; and rg
= gear ratio between the motor shaft and the screw
3.4 CNC
 CR1 = control resolution of electromechanical components , mm (in); p =

leadscrew pitch, mm/rev (in/rev); ns = number of steps per revolution; and rg
= gear ratio between the motor shaft and the screw
3.4 CNC
 CR2 = control resolution of the computer control system, mm (in);

and L = axis range, mm (in).
 Control Revolution of Positioning system

3.4 CNC
 Accuracy:
 Ac = accuracy, mm (in); CR = control resolution, mm (in); and s =

standard deviation of the error distribution
 Accuracies in machine tools are generally expressed for a certain
range of table travel, for example, {0.01 mm for 250 mm

3.4 CNC
 Repeatability: the ability of the positioning system to return to a
given adressable point that has been previously programmed

3.4 CNC

3.4 CNC

3.4 CNC
 3.4.4 Programming

3.4 CNC
 CAD( Computer Aid Design)/CAM (Computer Aid
Manufacturing): used to create the NC part programming.

3.4 CNC

3.4 CNC
 Manual Programming:
 sequence number (N-word)
 preparatory word (G-word)
 coordinates (X-, Y-, Z-words for linear axes, A-, B-, C-words for
rotational axes)
 feed rate (F-word)
 spindle speed (S-word)
 tool selection (T-word)
 miscellaneous command (M-word)

3.4 CNC
 3.4.4 Milling

3.4 CNC
 3.4.4 Drilling

3.5 Robotics

3.5 Robotics
 Advantages of robots
 Robots can be substituted for humans in hazardous or uncomfortable
work environments.
 A robot performs its work cycle with a consistency and repeatability
that cannot be attained by humans.
 Robots can be reprogrammed..
 Robots are controlled by computers and can therefore be connected to
other computer systems to achieve computer integrated
manufacturing.

3.5 Robotics
 3.5.1Classification


3.5 Robotics
 3.5.1Classification


3.5 Robotics
 3.5.1Common Robot Configurations
 Joints and Links

3.5 Robotics
 Joints and Links

3.5 Robotics
 Wrist Configurations:
 The robot’s wrist is used to establish the orientation of the
end effector.
 Robot wrists usually consist of two or three joints that almost
always consist of R and T type rotary joints.

3.5 Robotics
 Wrist

3.5 Robotics
 Work Volume.
 The work volume (also known as work envelope) of the manipu-
lator is defined as the three-dimensional space within which the
robot can manipulate the end of its wrist.

3.6 PLCs

3.6 PLCs
 A programmable logic controller (PLC) can be defined as a
microcomputer-based controller
 Stored instructions in programmable memory to implement
 Logic,
 Sequencing,
 Timing, counting,
 Arithmetic functions
 through digital or analog input/ output (I/O) modules, for
controlling machines and processes

3.6 PLCs
 Components of the PLC

3.6 PLCs
 Processor is the central processing unit (CPU) of the PLC. It executes the
various logic and sequence control functions by operating on the PLC
inputs to determine the appropriate output signals.
 CPU is the memory unit, which contains the programs of logic,
sequencing, and I/O operations
 A power supply of 120 VAC is typically used to drive the PLC (some
PLCs operate on 240 VAC). The power supply converts the 120 VAC into
direct current (DC) voltages of {5 V}.

3.6 PLCs
 The input/output module provides the connections to the industrial
equipment or process that is to be controlled
 Inputs to the controller are signals from limit switches, push-
buttons, sensors, and other on/off devices.
 Outputs from the controller are on/off signals to operate motors,
valves, and other devices required to actuate the process

3.6 PLCs
 PLC Operating Cycle
 (1) input scan,
 (2) program scan,
 (3) output scan
 The time to perform the scan is called the scan time,

3.6 PLCs
 Programming the PLC
 Ladder Logic Diagram
 Function Block Diagrams
 Sequential Function Charts
 Instruction List
 Structured Text.


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Rules in Class

 Attend at least 80% of class hours

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

 3.1 Introduction of Automation

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Power for Process

Power Power for handling

Power for Automation

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

machine control unit (MCU) is a

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

• Three rotational axes (a, b,

Dr. Van-Phong Vu-Department of Automatic Control

Point-to-Point Continuous path

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

the NC part programs that are written

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

(c) peripheral milling

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

Open loop positioning system

Dr. Van-Phong Vu-Department of Automatic Control

Close loop positioning system

Dr. Van-Phong Vu-Department of Automatic Control

Dr. Van-Phong Vu-Department of Automatic Control

 alpha = step angle, °;

 Am = angle of motor shaft rotation, °; np = number of pulses