JSPM’s

RAJARSHI SHAHU COLLEGE OF ENGINEERING

TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

Subject: [AR3109]- Automation Systems and Applications

Unit 5: Design for High-Speed Automatic Assembly

Assignment 5
Category A

1. Discuss the importance of Limit’s, Fit’s, and Tolerances while designing high CO3 BL2
speed orienting system.
1. ANS: Limits:
o Definition: Limits refer to the permissible variation in the size
(dimension) of a component. They ensure that the part meets
functional requirements while allowing for manufacturing variability.
o Importance:
 Consistency: By defining limits, engineers maintain
consistency throughout the production cycle.
 Quality Control: Limits help control dimension variability,
ensuring that parts adhere to standards.
 Cost-Efficiency: Allowing some variation reduces production
costs compared to exact dimensions.
o Example: If a shaft’s diameter is specified as 25 mm with an upper
limit of 25.030 mm and a lower limit of 25.010 mm, the tolerance is
20 microns (0.020 mm) 1.
2. Fits:
o Definition: Fits describe the relationship between mating parts before
assembly. They can be clearance, transition, or interference fits.
o Types of Fits:
 Clearance Fit: Allows for relative movement between parts
(e.g., sealing rings).
 Transition Fit: Provides a balance between clearance and
interference (e.g., gears and bearing bushes).
 Interference Fit: Creates a tight fit (e.g., machine tool
spindles).
o Basis Systems: Fits can be hole basis or shaft basis 1.
3. Tolerances:
o Definition: Tolerances represent the allowable deviation from the
nominal dimension.
o Importance:
 Functionality: Tolerances ensure proper functioning of
assembled parts.
 Manufacturability: Real-world manufacturing processes
have inherent variations.
 Cost Optimization: Balancing tight tolerances with cost-
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

effective production.

In summary, understanding and applying limits, fits, and tolerances are critical
for achieving reliable, efficient, and cost-effective designs in high-speed
orienting systems. These principles help strike a balance between precision and
practicalit

Discuss the concept of design for manufacturability

Design for Manufacturability (DFM) is a crucial engineering practice that
focuses on designing products in a way that makes them easier and more cost-
effective to manufacture. Let’s explore the key aspects of DFM:
1. Objective:
o DFM aims to optimize a part, product, or component’s design to
reduce manufacturing costs while maintaining form, fit, and function
requirements.
2. Key Considerations:
o Material Type: Choosing suitable materials impacts both
manufacturing ease and cost. Material properties, availability, and
compatibility with production processes matter.
o Material Form: Different forms (sheets, bars, powders) affect
manufacturability. For example, sheet metal fabrication differs from
2. machining solid blocks. CO3 BL2
o Tolerances: Precisely defining tolerances ensures consistent part
quality and assembly fit.
o Design and Shape: Simplified, well-defined shapes are easier to
manufacture than complex geometries.
o Design for Inspection: Consider ease of inspection during production
to catch defects early.
3. Examples:
o Printed Circuit Boards (PCBs):
 DFM guidelines for PCBs address manufacturability issues
related to layout, component placement, and soldering.
 In summary, DFM ensures that designs transition smoothly
into high-volume manufacturing, optimizing yield and cost-
effectiveness.

Elaborate various factors influencing part feeding system

Certainly! The performance and effectiveness of part feeding systems are
influenced by several factors. Let’s explore these factors:
1. Load Sensitivity:
o Load sensitivity refers to how the feed rate of a part feeder is affected
3. by changes in the load, which is the number of parts present in the CO3 BL3
feeder.
o If the system becomes less efficient as the load increases or decreases,
it impacts overall throughput 1.
2. Part Specifications:
o Geometry: The shape and size of the component play a significant
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

role. Irregular shapes or complex geometries may require specialized

feeding mechanisms.
o Weight: The weight of the part affects how it behaves during
feeding. Light parts may need gentle handling, while heavy parts
require robust mechanisms 2.
3. Material Properties:
o The type of material (e.g., metal, plastic, rubber) influences feeding
behavior. Materials with varying friction coefficients or surface
properties may require adjustments.
o Surface finish (smoothness, roughness) affects part movement within
the feeder 2.
4. Environmental Conditions:
o Temperature and Humidity: Extreme conditions can impact material
properties (e.g., thermal expansion) and affect feeding performance.
o Dust and Contaminants: Airborne particles can interfere with part
orientation and movement. Regular cleaning or protective measures
are essential 3.
5. Feeder Design and Mechanism:
o The choice of feeder type (e.g., vibratory bowl feeders, aerodynamic
feeders) affects flexibility and adaptability.
o Mechanical design (e.g., adjustable orienting devices) allows
customization for different workpieces 32.
6. Feeding Rate Requirements:
o The desired feeding speed determines the system’s design. High-speed
applications require precise control and efficient part transfer.
o Balancing speed with accuracy is crucial 2.
7. Component Variety:
o Feeding systems must handle multiple components. The feeder’s
ability to switch between different parts impacts overall system
flexibility.
o Interchangeable tooling or adjustable parameters enhance versatility 2.
8. Space Constraints:
o Available space in the production environment affects the feeder’s
design and installation.

4. Select the electrical motor for developing part feeding system and justify the CO3 BL4
choice.

Certainly! Selecting the right electric motor for a part feeding system is crucial
for efficient and reliable operation. Let’s break down the process and justify the
choice:

1. Determine Motor Parameters:

o Drive Mechanism: First, identify the drive mechanism for your part
feeding system. Consider options like belt drives, shafts, direct
rotation, pulleys, ball screws, or racks and pinions.
o Dimensions: Understand the load dimensions and mass of the parts
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

you’ll be handling. Also, consider the coefficient of friction for each

moving part’s sliding surface.
o Motor Specifications: Determine operating time, speed, positioning
distance, resolution, stopping accuracy, voltage, power supply, and
any specific requirements (e.g., closed loop, open loop, feedback,
programmable features, agent approval, and IP rating) 1.

2. Calculate Key Factors:

o Moment of Inertia: Moment of inertia measures an object’s
resistance to changes in rotation rate. Calculate it based on the mass
and geometry of the parts you’ll be feeding. For example, for a solid
cylinder, the moment of inertia can be derived using the formulas:

 Jx=81mD2=32πρLD4
 Jy=41m(4D2+3L2)

5. Discuss various types of conveyors used in part feeding system CO3 BL2
1. Belt Conveyor:
o A belt conveyor consists of a continuous belt that moves materials
from one point to another.
o It is widely used due to its versatility and ability to handle various
materials, including bulk goods, packages, and heavy loads.
o Belt support, pulley systems, and drive units are essential components
of a belt conveyor1.
2. Chain Conveyor:
o Chain conveyors use chains to move materials along a fixed path.
o They are suitable for heavy-duty applications, such as in automotive
manufacturing or assembly lines.
o Chain conveyors are reliable and can handle both large and small
items.
3. Ball Transfer Conveyor:
o Ball transfer conveyors consist of ball casters that allow multi-
directional transport of products.
o They are commonly used in packaging and assembly lines where
products need to move in different directions2.
4. Overhead Conveyor:
o Overhead conveyors are suspended from the ceiling or overhead
structure.
o They find applications in industries like automotive manufacturing,
aerospace, and garment production.
o These conveyors are efficient for moving products through assembly
processes1.
5. Pneumatic Conveyors:
o Pneumatic conveyors use air pressure or vacuum to transport materials
through a pipeline.
o They eliminate the need for mechanical components like belts or
chains.
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

o Pneumatic conveyors are suitable for handling powders, granules, and

other lightweight materials3.
6. Vibrating Conveyor:
o Vibrating conveyors use vibrations to move parts along a trough or
tube.
o They are commonly used in food processing, mining, and recycling
industries.
o Vibrating conveyors are effective for transporting bulk materials 1.

Subject Teacher
Mr. P.V. Thote

Subject: [AR3109]- Automation Systems and Applications

Unit 5: Design for High-Speed Automatic Assembly

Assignment 5
Category B & C

1. Suggest different part feeding mechanism for various assembly lines CO3 BL3
1. Automated Flex Feeder:
o The SDC Flex Feeder is an ideal automated feeding system for many
applications. It’s easy to use, reliable, and adaptable.
o Components of the SDC Flex Feeding system include:
 Parts Feeding Hopper: An operator manually loads the
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

hopper with thousands of parts.

 Bucket Conveyor: Unloads a couple of parts at a time and
drops them onto the feed conveyor.
 Vision-Guided Robot ‘Pick-and-Place’: Efficiently picks
and places the parts into the machine based on vision system
feedback.
o The system is flexible and can handle various part sizes, colors, and
variations1.
2. Line Stocking (Line Side Stocking):
o In this method, parts are stocked directly at the assembly line or
workstations.
o It ensures quick access to components during assembly.
o Commonly used in Just-in-Time (JIT) production systems2.
3. Boxed-Supply (Kanban):
o Parts are supplied in boxes or containers (Kanban cards).
o When a box is empty, it triggers replenishment.
o Efficient for managing inventory levels and controlling production
flow2.
4. Sequencing:
o Parts are delivered in a specific sequence required for assembly.
o Useful for optimizing production efficiency and minimizing assembly
errors2.
5. Stationary Kitting (Indirect Supply):
o Parts are pre-assembled into kits or trays at a stationary location.
o Kits are then delivered to workstations as needed.
o Simplifies assembly by grouping related components together2.
6. Traveling Kitting (Kit to Assembly Line):
o Similar to stationary kitting, but the kits move along the assembly line.
o Kits are replenished as they travel through different workstations.
o Ensures parts availability without interrupting the assembly proces

Discuss why it is important to consider design for storage

1. Optimal Space Utilization:
o Efficient storage design ensures that available space is used
optimally.
o Properly organized storage areas prevent clutter, congestion, and
wasted space.
o Well-designed storage layouts allow easy access to materials,
reducing search time and improving productivity.
2. CO3 BL2
2. Inventory Management:
o Effective storage design directly impacts inventory management.
o Properly labeled and organized storage locations help track
inventory levels accurately.
o It enables timely restocking and minimizes stockouts or
overstock situations.
3. Material Flow and Accessibility:
o Storage design affects the flow of materials within a facility.
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

o Consider proximity to production lines, workstations, and

shipping areas.
o Well-planned storage ensures quick access to materials,
reducing handling time.
4. Safety and Ergonomics:
o Safe storage design prevents accidents and injuries.
o Heavy items should be stored at waist height to avoid strain
during lifting.
o Clear pathways and proper lighting enhance safety.
5. Protection of Materials:
o Proper storage protects materials from damage, contamination,
and deterioration.
o Factors like temperature, humidity, and exposure to sunlight
impact material quality.
o Design storage areas to safeguard materials accordingly.
6. Cost Efficiency:
o Efficient storage reduces costs associated with excess inventory,
lost items, and wasted space.
o It minimizes the need for additional storage facilities or
expansion.
7. Compliance and Regulations:
o Some industries have specific regulations regarding storage
(e.g., hazardous materials).
o Compliance with these regulations is crucial to avoid legal
issues.
8. Future Expansion and Adaptability:
o Design storage systems with scalability in mind.
o Consider future growth and adaptability to changing needs.

Discuss Pneumatic Part feeder and its importance

1. What is a Pneumatic Part Feeder?
o A pneumatic feeder is a device commonly used in manufacturing and
production processes to feed parts or materials into various stages of
assembly, packaging, or other operations.
o Unlike traditional manual feeding, pneumatic feeders automate the
process by using compressed air to power the mechanism that moves
parts from a storage bin to a conveyor belt or other processing
3. equipment1. CO3 BL2
2. How Pneumatic Feeders Work:
o Pneumatic feeders operate based on the principles of air
pressure and fluid dynamics.
o The key component is a pneumatic piston, which functions either via
hydraulic (liquid) pressure or an air-driven motor.
o The piston propels parts through a tube or conduit, ensuring controlled
and precise movement.
o These feeders are particularly useful for handling small parts,
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

including closures, liners, fitments, corks, and capsules2.

3. Importance of Pneumatic Part Feeders:
o Efficiency: Pneumatic feeders save time and eliminate unnecessary
labor. They ensure a controlled delivery of parts, enhancing overall
line operation efficiency.
o Precision Handling: By using air pressure, pneumatic feeders offer
precise control over part movement. This is especially crucial for
delicate or critical components.
o Reduced Human Error: Automation reduces the risk of human error
during part feeding, leading to better product quality and consistency.
o Optimized Workflows: Pneumatic feeders streamline material flow,
making it easier for operators to access parts when needed.
o Maintenance: These feeders are relatively simple in design, and
maintenance typically involves tasks like changing filters.
o Versatility: While commonly used for cap handling and conveying to
capping machines, they can handle various small parts in different
industries32.

4. Discuss Vibratory Part feeder and its importance CO3 BL2

1. What is a Vibratory Part Feeder?
o A vibratory feeder is an instrument that uses vibration to feed
material through a process or a machine while controlling the rate of
flow.
o These feeders utilize both vibration and gravity to move material
forward.
o The force of gravity influences these parts to shift direction, causing
them to move down or laterally1.
2. Working Principles of Vibratory Feeders:
o Vibratory feeders operate based on the centrifugal force generated by
the rotation of an eccentric block in the vibrator.
o Here’s how they work:
 The vibrator generates mechanical vibrations.
 These vibrations are harnessed and transferred to the feeder’s
conveying track (often in the shape of a bowl).
 The components (parts) move along the track of the bowl
feeder, feeding them into the production line.
o Essentially, the continuous circular or approximate circular motion
achieved by the vibrations ensures efficient material transportation 2.
3. Importance of Vibratory Part Feeders:
o Automation and Efficiency: Vibratory feeders automate the feeding
process, reducing manual labor and improving efficiency.
o Precision Handling: The controlled vibrations allow precise
movement of parts, critical for delicate or complex components.
o Consistent Flow: By maintaining a steady flow of correctly oriented
parts, these feeders enhance production line consistency.
o Material Protection: Properly designed vibratory feeders protect
materials from damage, contamination, and deterioration.
o Versatility: Vibratory feeders can handle a wide range of materials,
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

from small to large quantities, making them suitable for various

industries31.

5. Elaborate different part feeding mechanism CO3 BL2

1. Automated Part Feeding Systems:
o These systems are commonly used in manufacturing and assembly
processes to feed parts into automated machines. They ensure a
consistent supply of parts for efficient production.
o Automated Flex Feeder: One popular type of automated feeding
system is the Flex Feeder, designed by SDC Automation. Here’s how
it works:
 The system consists of three main components:
 Parts Feeding Hopper: Operators manually load the
hopper with thousands of parts.
 Custom Programmed Conveyor System: A bucket
conveyor unloads a couple of parts at a time onto the
feed conveyor.
 Vision-Guided Robot ‘Pick-and-Place’: A robot
uses vision data to pick and place the parts into the
machine.
 The Flex Feeder’s advantages:
 Flexibility: It can handle various part sizes, colors,
and variations.
 Adaptability: The system can be customized for fast
or slow applications.
 Reliability: Provides a continuous flow of parts to the
robot.
 The touchscreen HMI (Human-Machine Interface) simplifies
operation1.
2. Sewing Machine Feed Mechanism:
o Sewing machines also use feeding mechanisms to move fabric through
the stitching process. Here are the key components:
 Throat Plate (Needle Plate): The fabric passes over this
plate, and the needle enters it to create stitches.
 Feed Dog: A set of metal teeth that move the fabric forward
and backward during stitching.
 Pressure Foot: Holds the fabric against the throat plate while
stitching.
o Different types of sewing machine feed mechanisms include:
 Drop Feed: Common in household sewing machines, where
the feed dog moves the fabric.
 Needle Feed: The needle itself helps feed the fabric.
 Differential Bottom Feed Mechanism: Used in industrial
machines for even feeding.
 Puller (Walking Foot): Assists in feeding thick or slippery
fabrics.
 Unison Feed Mechanism: Combines feed dog and needle
 JSPM’s
RAJARSHI SHAHU COLLEGE OF ENGINEERING
TATHAWADE, PUNE-33
(An Autonomous Institute Affiliated to Savitribai Phule Pune
University, Pune)
DEPARTMENT OF AUTOMATION AND ROBOTICS

feed for precisesion

Subject Teacher
Mr. P.V. Thote