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
 UNIT III
INDUTRIAL APPLICATIONS
 UNIT III
ASSIGNMET
 Unit-III

1. a). Discuss the different types of assembly systems.

b). Explain the other ways to improve line balancing in flexible assembly lines.

2. Theory from Automated Assembly

3. Problems from Line Balancing

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT III
SHORT ‘Q’ & TUTORIAL
 UNIT-III

1. What is Line Balancing in Automation?

In flow line production there are many separate & distinct processing & assembly
operations to be performed on the product. Invariably, the sequence of processing
or assembly steps is restricted, at least to some extent, in terms of the order in
which the operations can be carried out. For example, a threaded hole must be
drilled before it can be tapped. In mechanical fastening, the washer must be
placed over the bolt before the nut can be turned & tightened.
2. What is Partial Automation?
Many assembly lines in industry contain a combination of automated & manual
work stations. These cases of partially automated production lines occur for two
main reasons:
a) Automation is introduced gradually on an existing manual line
b) Certain manual operations are too difficult or too costly to automate.

3. What are the reasons for downtime on an Automated Production line?

a) Tool failures at workstations.
b) Tool adjustments at workstations
c) Scheduled tool charges
d) Limit switch or other electrical malfunctions.

4. Write short note on Storage Buffers.

The preceding analysis assumes no buffer storage between stations. When the
automated portion of the line breaks down, the manual stations must also stop for
lack of work parts. Storage buffers located before & after the manual stations
would reduce forced downtime at these stations.
5. What are assumptions for the operation of the Transfer line & rotary
indexing machines?

-The workstations perform operations such as machining & not assembly.

-Processing times at each station are constant though they may not be equal.
-There is synchronous transfer of parts.
-No internal storage of buffers.
6. What is ideal cycle time on the line?
Tc is the processing time for the slowest station of the line plus the
transfer time;

Tc = max (Tsi) + Tr ---------------- (1)

DEPARTMENT OF MECHANICAL ENGINEERING

 7. Write short note on Upper Bound Approach.

The upper bound approach provides an upper limit on the frequency on the line
stops per cycle. In this approach we assume that the part remains on the line for
further processing. It is possible that there will be more than one line stop
associated with a given part during its sequence of processing operations.

8. Write short note on Lower Bound Approach.

The lower bound approach gives an estimate of the lower limit on

the expected frequency of line stops per cycle. Here we assume that a station
breakdown results in destruction of the part, resulting in removal of the part
from the line & preventing its subsequent processing at the remaining
workstations.

9. What is the Limit of Storage Buffer Effectiveness?

Two extreme cases of storage buffer effectiveness can be identified:

No buffer storage capacity at all.
Infinite capacity storage buffers

If we assume in our Analysis that the ideal cycle time is the same
for all stages considered. In the case of no storage capacity, the
production line acts as one stage when station breaks down the entire
line stops.

10. How Automation is introduced gradually on an existing manual line?

- Suppose that demand for the product made on a manually operated line
increases, & it is desired to increase production & reduce labor costs by
automating some or all of the stations.

-The simpler operations are automated first, & the transition toward a
fully automated line is accomplished over a long period of time.
Meanwhile, the line operates as a partially automated system

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT IV
AUTOMATED MATERIAL HANDLING
Objective:

 To perform a sequence of automated or mechanized assembly operations Flexible

manufacturing system (FMS)—a highly automated machine cell that produces part

Outcome:

 Understand the Automated Material handling equipments and types

Automated material handling: Types of equipment, functions, analysis and design of

material handling systems conveyor systems, automated guided vehicle systems.
Automated storage systems: Automated storage and retrieval systems; work in process
storage, interfacing handling and storage with manufacturing.

UNIT-IV
Automated Material Handling and Storage Systems

AUTOMATED MATERIAL HANDLING

INTRODUCTION
Automated material handling (AMH) systems improve efficiency of transportation, storage
and retrieval of materials. Examples are computerized conveyors, and automated storage and
retrieval systems (AS/RS) in which computers direct automatic loaders to pick and place
items. Automated guided vehicle (AGV) systems use embedded floor wires to direct
driverless vehicles to various locations in the plant. Benefits of AMH systems include quicker
material movement, lower inventories and storage space, reduced product damage and higher
labour productivity.

Objectives
After studying this unit, you should be able to understand the
 Importance of AGV in a computer-integrated manufacturing system,
 Role of industrial robots in a computer-integrated manufacturing systems, and
 Alternative for automated material handling system.

INTRODUCTION TO AGVS

A material-handling system can be simply defined as an integrated system involving such

activities as handling, and controlling of materials. Materials include all kinds of raw
material, work-in-progress, sub-assemblies, and finished assemblies. The main motto of an
effective material-handling system is to ensure that the material in the right amount is safely
delivered to the desired destination at the right time and at minimum cost. It is an integral part
of any manufacturing activity. Role of AGVs and Robots have become strategic with respect
to the modern material handling practices followed in the present day industry. The next

DEPARTMENT OF MECHANICAL ENGINEERING

section deals with the automated guided vehicles (AGVs). In Section 3.2, we have introduced
the modern industrial robots and the attributes related with them, which are essential for their
understanding.
Automated Guided Vehicles
Automated guided vehicle systems (AGVs), commonly known as driverless vehicles, are
turning out to be an important part of the automated manufacturing system. With the shift
from mass production to mid-volume and mid-variety, flexible manufacturing systems, are
increasingly in use. They require not only machine flexibility but also material-handling,
storage, and retrieval flexibility. Hence, the importance of AGVs has grown in manifold. It is
a battery-powered driverless vehicle with programming capabilities for destination, path
selection, and positioning. The AGVs belongs to a class of highly flexible, intelligent, and
versatile material-handling systems used to transport materials from various loading locations
to various unloading locations throughout the facility. The capability related to collision
avoidance is nicely inbuilt in AGVS. Therefore, the vehicle comes to a dead stop before any
damage is done to the personnel, materials, or structures. They are becoming an integral part
of flexible manufacturing system installations.
Now-a-days, AGVS are versatile in nature and possess flexible material-handling system.
They use modern microprocessor technology to guide a vehicle along a prescribed path and
makes correction if the vehicle strays from the path. A system controller receives instructions
directly from the host computer, communicates with other vehicles, and issues appropriate
commands to each vehicle. To avoid collision, communication is necessary among the
AGVs. To facilitate the communication, they are connected through a wire in the floor or by
radio.
Components of AGVS
 There are four main components of an automated guided vehicle system. They are as
follows :
 The Vehicle : It is used to move the material within the system without a human
operator.
 The Guide Path : It guides the vehicle to move along the path.
 The Control Unit: It monitors and directs system operations including feedback on
moves, inventory, and vehicles.
 The Computer Interface : It is connected with other computers and systems such as
mainframe host computer, the Automated Storage and Retrieval System (AS/RS), and
the Flexible Manufacturing System.
Different Types of AGVS
 There are different types of automated guided vehicles that are able to cater different
service requirements. The vehicle types include :
 AGVS towing vehicles
 AGVS unit load transporters
 AGVS pallet trucks
 AGVS forklift trucks
 AGVS light-load transporters
 AGVS assembly line vehicles

DEPARTMENT OF MECHANICAL ENGINEERING

The level of sophistication of the AGVS has increased to allow automatic positioning and
pickup and drop-off (P/D) of cargo, and they also perform P/D services between machining
work centers, storage racks, and the AS/RS. They are also capable of two-way travel on the
same path and real-time dispatching under the control of the computer. The different types of
AGVS are discussed in the section to follow.
AGVS Towing Vehicle
AGVS towing vehicles were the earliest variety to be introduced. A towing vehicle is an
automated guided tractor. A wide variety of tractors can be used, such as flatbed trailers,
pallet trucks, custom trailers, and bin trailers. Different types of loading equipment used for
loading and unloading the trailer include an AGV-pulled train, hand pallet truck, cranes,
forklift truck, automatic transfer equipment, manual labor, shuttle transfer, and programmed
automatic loading and unloading device.
AGVS Pallet Trucks
AGVS pallet trucks are designed to lift, maneuver, and transport palletized loads. It is used
for picking up or dropping off loads from and on to floor level, than removing the need for
fixed load stands. No special accessories are needed for loading and unloading the AGVS
pallet except that the loads should be on a pallet. It is basically used in floor-level loading and
unloading operation. Loading and unloading can be done in two ways viz. automatically or
manually. For the transportation of load, the normal course followed by the vehicle is
determined by the storage area destination. Normal operations carried out in pallet trucks are
:

(i) loads are pulled off onto a spur,

(ii) lowering of the pallet forks to the floor,
(iii) pulling out from the pallet, and
(iv) finally automatically returns empty to the loading area.
AGVS Forklift Trucks
An AGVS forklift truck has the capability to pick up and drop off palletized loads both at
floor level and on stands, and the pickup height can be different from the drop-off height.
They are capable of picking up and dropping off a palletized load automatically. It has the
ability to position its forks at any height so that conveyors or load stands with different
heights in the material-handling system can be serviced. AGVS forklift trucks are one of the
most expensive AGVS types. Therefore, they are used in the case of full automation. The
truck is accoutered with sensors at the fork end, so that it can handle high-level stacking on
its own. These systems have the advantage of greater flexibility in integrating with other
subsystems with various loading and unloading heights throughout the material handling
system.
AGVS Light Load Transporters
They are applied in handling small, light parts over a moderate distance and distribute the
parts between storage and number of work stations.
AGVS Assembly-Line Vehicles
AGVS assembly line vehicles are an acclimatization of the light-load transporters for
applications involving serial assembly processes. The guided vehicle carries major sub-
assemblies such as motors, transmissions, or even automobiles. As the vehicle moves from
one station to the next, succeeding assembly operations are performed. After the loading of
part onto the vehicle, the vehicle moves to an assembly area and stops for assembly. As the
assembly process is completed, the operator releases the vehicle that proceeds to the next

DEPARTMENT OF MECHANICAL ENGINEERING

part’s staging area for new parts. After that the vehicle moves forward to the next assembly
station. The process is repeated until the final unloading station is reached.
The main advantage of the AGVS assembly line is its lower expense and ease of installation
compared with “hard” assembly lines. The line can be easily reconfigured by altering the
guide path and by reprogramming. Variable speeds and dwell intervals can be easily
programmed into the system. However, an extensive planning and complex computer control
is needed in the case of overall integration. Some of the guiding factors determining the
functioning of the AGVS are :
(i) Guidance Systems
(ii) Routing
(iii) AGVS Control Systems
(iv) Load Transfers
(v) Interfacing with other subsystems

Next section deals with the guidance systems designed for keeping the vehicle on
predetermined path.
Guidance Systems for AGVS
The main purpose of a guidance system is to keep the vehicle in the predestinated path. The
main advantage of AGVS guidance system is that the guide path can be changed easily at low
cost compared to the high cost of modifying fixed-path equipment such as conveyors, chains,
and tow lines. Many guidance systems are available and their selection will depend on need,
application, and environmental constraints. Some of the familiar guidance systems are wire-
guided guidance system, optical guidance system, inertial guidance system, infrared guidance
system, laser guidance system, and teaching-type guidance system.
Routing of the AGVS
AGVS routing means determining how the vehicle conforms the path and takes a shortest
path between the two points. The commonly used methods are : “frequency selection method
” and the “path switch selection method ”.
AGVS Control Systems
Three types of AGVS control systems are available.
(i) Computer-controlled system
(ii) Remote dispatch control system
(iii) Manual control system

Computer Controlled System

Here, all the exchanges and AGVS vehicle movements are controlled and monitored by the
system controller. A detailed sketch of the computer-controlled system is shown in Figure
3.1. The guide path controller controls the guide path of the AGVS and transfers the
information to the AGVS process controller. Movements of AGVS vehicle are directly
controlled by the AGVS process controller.
Remote Dispatch Control System
Here, a human operator controls the movement of AGVS through a remote control station.
The control system sends destination instructions directly to the vehicle.
Manual Control System
In this type of system, the operator loads the vehicle and enters a destination into the onboard
control panel of the vehicle. The efficiency of the system depends on the skill of the operator.

DEPARTMENT OF MECHANICAL ENGINEERING

Interface with Other Subsystems
The computer-controlled system can link the AGVS materials-handling system with other
subsystems in the organisation. These subsystems include:
(i) Automated storage and retrieval systems.
(ii) Computer numerical control (CNC) machines.
(iii) Shop floor control system.
(iv) Process control equipment.
(v) Flexible manufacturing systems.

They may be linked by a distributed data processing network and the host computer. In the
distributed data processing network, the system control computers communicate with each
other directly without the intermediate or host computer.
In the next section, we will elucidate the main features considered for designing the AGVS
system.
AGVS Design Features
Many design features pertaining to AGVS are common to other material handling systems.
However, there are several special features unique to the AGVS, such as stopping accuracy,
facilities, safety, and maintenance.
A very important attribute of the AGVS system is “Stopping Accuracy” and it varies
considerably with the nature and requirements of the system. A system with automatic load
transfer requires high stopping accuracy. In case of manual load transfer, lower stopping
accuracy is required. In addition to that, unit load transporters are used for systems that
require higher accuracy. In an AGVS, the stopping accuracy is provided by the feedback of
Computer Control Systems. Stopping accuracy depends on the applications, for example, ,
1 inch or more for towing and light-load vehicles, and 3 inch for a manual system.
erfacesinttool r machine inch fo001 .0
Many considerations are undertaken while designing the AGVS, like incorporation of
automatic door-opening devices, elevators etc. Safety features such as emergency contact
bumpers and stop buttons, object detectors, automatic warning signals, and stopping devices
must be built in the AGVS. These features must be of paramount importance in the minds of
the designers so as to avoid the human injuries and damage to other equipment, materials,
and vehicle itself.

System Design of AGVS

The decision process related to the system design is very complex in nature. A number of
issues are to be addressed which includes:
(i) Guide path layout
(ii) Number of vehicles required
(iii) Flow path design
(iv) Selection of guide path type and vehicle type
(v) Type of flow path within the layout
(vi) Location and number of load transfer points and load transfer station storage
space.

DEPARTMENT OF MECHANICAL ENGINEERING

Operational issues such as the routes used by the vehicles during operation are also taken into
consideration. There must be a synergy between the operational and design features for the
successful implementation of AGVS.
Flow Path Design
The flow path design is one of the most important processes in the AGVS design. Some of
the important decisions involved in flow path design are:
(i) Type of guide path layout.
(ii) Flow path within the layout.
(iii) The number and locations of load transfer points.
(iv) Load transfer function station storage space.

Areas of application of the AGVS determine the critical issues like guide path layout, P/D
(Place and Delivery) location points, and load transfer station storage space. However, the
complexity of controls and economic considerations influence the direction of flows.
Vehicle blocking, congestion, and unloaded vehicle travel are the issues to be taken into
consideration and depend on the number of the vehicles and the requests for vehicles from
various pickup and delivery stations. Simulation is used to develop the realistic design under
aforementioned circumstances. The type of information required for developing a simulation
model would include layout of departments, aisles, location of load transfer stations, and
charts containing the material flow intensities between departments.

Automated storage and retrieval systems:

Imagine any plant/manufacturing sector without cluttered aisles, excess inventory, lost or
damaged products, inaccurate records, endless searching, climbing, bending and frustration.
Imagine a highly profitable operation that adds value and decreases expense.
AS/RS are means to high density hands free buffering of materials in distribution and
manufacturing environments. AS/RS is a complete system designed to transport, stage/store,
retrieve, and report on every item in any industrial inventory with up-to-the minute accuracy.

FUNCTIONS OF STORAGE SYSTEM AND DEFINITION OF AS/RS

An automated storage/retrieval system (AS/RS) can be defined as a storage system under
which a defined degree of automation is to be implemented to ensure precision accuracy and
speed in performing storage and retrieval operations. These automated storage and
mechanized systems eliminate human intervention in performing basic sets of operations that
includes :
 Removal of an item from a storage location automatically
 Transferring the above item to a specific processing or interface point
 After receiving an item from a processing or interface point, it is automatically stored
at a predetermined location.
AS/RS COMPONENTS AND TERMINOLOGY
An AS/RS consists of one or more storage aisles that are serviced by a
storage/retrieval (S/R) machine. The stored materials are held by storage racks of
aisles. The S/R machines are used to deliver and retrieve materials in and out of
inventory. There are one or more input/output stations in each AS/RS aisle for
delivering the material into the storage system or moving it out of the system. In

DEPARTMENT OF MECHANICAL ENGINEERING

 AS/RS terminology, the input/output stations are called pickup-and-deposit (P&D)
stations.

Storage Space
It is the three-dimensional space in the storage racks used to store a single load unit of
material.
Storage Racks
This structural entity comprises storage locations, bays and rows.
Bay
It is the height of the storage rack from floor to the ceiling.
Row
It is a series of bays placed side by side.
Aisle
It is the spacing between two rows for the machine operations of AS/RS.
Aisle Unit
It encompasses aisle space and racks adjacent to an aisle.
Storage Structure
It is the rack framework, made of fabricated steel that supports the loads contained in the
AS/RS and is used to store inventory items.
Storage/Retrieval Machine
It is used to move items in and out of inventory. An S/R machine is capable of both
horizontal and vertical movement. A rail system along the floor guides the machine and a
parallel rail at the top of the storage structure is used to maintain its alignment.
Storage Modules
These are the unit load containers used to hold the inventory items. These include pallets,
steel wire baskets and containers, pans and special drawers. These modules are generally
made to a standard base size capable of being stored in the structure and moved by the S/R
machines.
Pickup and Deposit (P/D) Stations

DEPARTMENT OF MECHANICAL ENGINEERING

P/D stations are where inventory are transferred into and out of the AS/RS. They are
generally located at the end of the aisles to facilitate easy access by the S/R machines from
the external material-handling system. The location and number of P/D stations depends upon
the origination point of incoming loads and the destination of output loads.
TYPES OF AS/RS
Several important categories of AS/RS can be distinguished based on certain features and
applications. The following are the principle types :
Unit Load AS/RS
The unit load AS/RS is used to store and retrieve loads that are palletized or stored in
standard-sized containers. The system is computer controlled. The S/R machines are
automated and designed to handle the unit load containers. Usually, a mechanical clamp
mechanism on the S/R machine handles the load. However, there are other mechanisms such
as a vacuum or a magnet-based mechanism for handling sheet metal. The loads are generally
over 500 lb per unit. The unit load system is the generic AS/RS.
Mini Load AS/RS
This system is designed to handle small loads such as individual parts, tools, and supplies that
are contained in bins or drawers in the storage system. Such a system is applicable where the
availability of space is limited. It also finds its use where the volume is too low for a full-
scale unit load system and too high for a manual system. A mini load AS/RS is generally
smaller than a unit load AS/RS and is often enclosed for security of items stored.
Deep-lane AS/RS
This is a high-density unit load storage system that is appropriate for storing large quantities
of stock. The items are stored in multi deep storage with up to 10 items in a single rack, one
load behind the next. Each rack is designed for flow-through, with input and output on the
opposite side. Machine is used on the entry side of the rack for input load and loads are
retrieved from other side by an S/R- type machine. The S/R machines are similar to unit load
S/R machine except that it has specialized functions such as controlling rack-entry vehicles.
Man-on-board AS/RS
This system allows storage of items in less than unit load quantities. Human operator rides on
the carriage of the S/R machine to pick up individual items from a bin or drawer. The system
permits individual items to be picked directly at their storage locations. This provides an
opportunity to increase system throughput. The operator can select the items and place them
in a module. It is then carried by the S/R machine to the end of the aisle or to a conveyor to
reach its destination.
Automated Item Retrieval System
This system is designed for retrieval of individual items or small product cartoons. The items
are stored in lanes rather than bins or drawers. When an item is retrieved from the front by
use of a rear-mounted pusher bar, it is delivered to the pickup station by pushing it from its
lane and dropping onto a conveyor. The supply of items in each lane is periodically
replenished and thus permitting first-in/first-out inventory rotation. After moving itself to the
correct lane, the picking head activates the pusher mechanism to release the required number
of units from storage.

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT IV
POWER POINT PRESENTATION SLIDES
MAINTENANCE AND REPAIR DIAGNOSTICS

 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
 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
 LEVELS OF AUTOMATION

Fig. 2.6
 EXAMPLES OF MANUFACTURING SYSTEMS

 Single-station cells
 Machine clusters

 Manual assembly lines

 Automated transfer lines

 Automated assembly systems

 Machine cells (cellular manufacturing)

 Flexible manufacturing systems

PRODUCTION MACHINES

 In virtually all modern manufacturing systems, most

of the actual processing or assembly work is
accomplished by machines or with the aid of tools
 Classification of production machines:
1. Manually operated machines are controlled or
supervised by a human worker
2. Semi-automated machines perform a portion of the
work cycle under some form of program control, and a
worker tends the machine the rest of the cycle
3. Fully automated machines operate for extended
periods of time with no human attention
 MANUALLY OPERATED MACHINE

Manually operated machines are controlled or supervised by a human

worker. The machine provides the power for the operation and the
worker provides the control. The entire work cycle is operator controlled.
SEMI-AUTOMATED MACHINE

A semi-automated machine performs a portion of the work cycle under

some form of program control, and a worker tends to the machine for the
remainder of the cycle. Typical worker tasks include loading and
unloading parts
FULLY-AUTOMATED MACHINE

Machine operates for extended periods (longer than one work cycle)
without worker attention (periodic tending may be needed).
MATERIAL HANDLING SYSTEM

 In most manufacturing systems that process

or assemble discrete parts and products, the
following material handling functions must be
provided:
1. Loading work units at each station
2. Positioning work units at each station
3. Unloading work units at each station
4. Transporting work units between stations in
multi-station systems
5. Temporary storage of work units
WORK TRANSPORT BETWEEN STATIONS

 Two general categories of work transport in

multi-station manufacturing systems:
1. Fixed routing
 Work units always flow through the same sequence
of workstations
 Most production lines exemplify this category
2. Variable routing
 Work units are moved through a variety of different
station sequences
 Most job shops exemplify this category
(A) FIXED ROUTING AND (B) VARIABLE ROUTING
 AUTOMATION AND MANNING LEVELS

 Level of workstation automation

 Manually operated
 Semi-automated
 Fully automated

 Manning level Mi = proportion of time worker

is in attendance at station i
 Mi = 1 means that one worker must be at the
station continuously
 Mi  1 indicates manual operations
 Mi < 1 usually denotes some form of automation
 AUTOMATION IN THE CLASSIFICATION
SCHEME:
 Type IM: single - station manned cell n=1,w=1
 Type IA: single station automated cell M<1
 Type IIM: multi station manual system with variable
routing
 Type IIA: multi station automated system with variable
routing n>1,w=0,M<1
 Type IIH: Multi station hybrid system with variable routing
 Type IIIM: Multi station manual system with fixed routing
n>1,w>1
 Type IIIA: Multi station automated system with fixed routing
n>1,w=0,M<1
 type IIIH: Multi station hybrid system with fixed routing
n>1
w>1 for some stations, w=0 for some stations,
 THREE CASES OF PRODUCT VARIETY IN
MANUFACTURING SYSTEMS

(a) Single-model case, (b) batch model case, and (c) mixed-model case
CNC MACHINING CENTER WITH AUTOMATIC PALLET
CHANGER - STORES ONE PART
STORAGE CAPACITIES GREATER THAN ONE

 Machining centers:
 Variousdesigns of parts storage unit
interfaced to automatic pallet changer (or
other automated transfer mechanism)
 Turning centers:
 Industrial robot interface with parts carousel
 Plastic molding or extrusion:
 Hopper contains sufficient molding compound
for unattended operation
 Sheet metal stamping:
 Starting material is sheet metal coil
 STORAGE CAPACITIES GREATER THAN ONE

Machining center and automatic pallet changer with pallet holders

arranged radially; parts storage capacity = 5
 STORAGE CAPACITIES GREATER THAN ONE

Machining center and in-line shuttle cart system with pallet holders
along its length; parts storage capacity = 16
STORAGE CAPACITIES GREATER THAN ONE

Machining center with pallets held on indexing table; parts storage

capacity = 6
STORAGE CAPACITIES GREATER THAN ONE

Machining center and parts storage carousel with parts loaded onto
pallets; parts storage capacity = 12
 CNC MACHINING CENTER

“Machine tool capable of performing multiple

operations that use rotating tools on a
workpart in one setup under NC control”
 Typical operations: milling, drilling, and related
operations
 Typical features to reduce nonproductive time:
 Automatic tool changer
 Automatic workpart positioning
 Automatic pallet changer
CNC HORIZONTAL MACHINING CENTER
 CNC TURNING CENTER

“Machine tool capable of performing multiple

operations on a rotating workpart in one
setup under NC control”
 Typical operations:
 Turning and related operations, e.g., contour
turning
 Drilling and related operations along workpart axis
of rotation
CNC TURNING CENTER
AUTOMATED STAMPING PRESS

Stamping press on automatic cycle producing stampings from sheet

metal coil
 CNC MILL-TURN CENTER

“Machine tool capable of performing multiple

operations either with single point turning
tools or rotating cutters in one setup under NC
control”
 Typical operations:
 Turning, milling, drilling and related operations
 Enabling feature:
 Capability to control position of c-axis in addition
to x- and z-axis control (turning center is limited to
x- and z-axis control)
PART WITH MILL-TURN FEATURES

Example part with turned, milled, and drilled features

SEQUENCE OF OPERATIONS OF A MILL-TURN
CENTER FOR EXAMPLE PART

(1) Turn smaller diameter, (2) mill flat with part in programmed angular
positions, four positions for square cross section; (3) drill hole with
part in programmed angular position, and (4) cutoff of the machined
piece
LEAN MANUFACTURING:

 The method to allocate machines to a

worker is fundamentally different in Lean
manufacturing. In LM, the machines are
typically arranged in a U-shaped cell, and a
worker tends as many workstations as
allowed within the Tact time.
 Total service + repositioning time ≤ Takt
time AND
 Machine + service time ≤ Takt time

 In LM, the machines are not necessarily

 UNIT IV
INDUTRIAL APPLICATIONS
 UNIT IV
ASSIGNMET
 Unit-IV

1.

a). What are the principles of material handling system?

b). Describe the use of Material Handling Equipment in Machine Tools.

2. Explain the various problems encountered in interfacing handling and storage systems with
manufacturing units.

3. a)Describe the following automated guided vehicle system with the help of simple sketch:

(i) Driverless automated guided train (ii) Unit load carrier.

b) Enumerate the differences between asynchronous conveyors and continuous motion

conveyors.

4. Explain the importance of automated work-in-process storage systems. [6]

b) Discuss the automated Storage/Retrieval Systems (AS/RS) controls, and the special
features and applications of AS/RS.

5. a) Explain the role of AS/RS in material handling systems. [8]

b) With neat sketch explain about fork lift truck.

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT IV
SHORT ‘Q’ & TUTORIAL
 UNIT-IV

1. What is a material-handling system?

A material-handling system can be simply defined as an integrated system involving such
activities as handling, storing, and controlling of materials.
The word material has very broad meaning, covering all kinds of raw materials, work in
process, subassemblies, and finished assemblies.
The primary objective of using a material handling system is to ensure that the material in the
right amount is safely delivered to the desired destination at the right time and at minimum
cost.
The material handling system is properly designed not only to ensure the minimum cost and
compatibility with other manufacturing equipment but also to meet safety concerns.

2.What are the three parts of the material handling system?

These include:
 Automated storage and retrieval systems.
 Automatic guided vehicles (AGVs)
 Automatic identification and data collection.
 Casters and wheels.
 Controls.
 Conveyors.
 Dock equipment.
 Ergonomics
2. What is the function of a materials handling system?
Material Handling is the movement, storage, control and protection of materials, goods and products
throughout the process of manufacturing, distribution, consumption and disposal. The focus is on the
methods, mechanical equipment, systems and related controls used to achieve these functions.
4. What are the Principles of Material Handling ?
1. Orientation principle: study the system relationships thoroughly prior to preliminary planning
in order to identify existing methods and problems, physical and economic constraints, and to
establish future requirements and goals.
2. Planning principle: establish a plan to include basic requirements, desirable options, and
consideration of contingencies for all MH and storage activities.
3. System principle: integrate the handling and storage activities that are economically viable
into a coordinated system of operation including receiving, inspection, storage, production,
assembly, packaging, warehousing, shipping, and transportation.
4. Unit load principle: handle product in as large a unit load as practical.
5. Space utilization principle
6. Standardization principle
5. What are the different types of Material Handling Equipment and explain
briefly?

DEPARTMENT OF MECHANICAL ENGINEERING

 1. Industrial trucks include hand trucks such as two-wheeled, four-wheeled, hand lift, and
forklift and powered trucks such as forklift, tractor-trailer trains, industrial crane trucks,
and side loaders.
2. Conveyors such as belt, chute, roller, wheel, slat, chain, bucket, trolley, tow, screw,
vibrating, and pneumatic.
3. Monorails, hoists, and cranes such as bridge, gantry, tower, and stacker. Automated
guided vehicle systems such as unit load carriers, towing, pallet trucks, fork trucks, and
assembly line.
4. Automated storage and retrieval systems (AS/RS) such as unit load, mini-load, person-
on-board, deep lane, and storage carousel systems.

6. What is automated guided vehicle system?

An automated guided vehicle system is a battery-powered driver-less vehicle with
Programming capabilities for destination, path selection, and positioning.
The AGVS belongs to a class of highly flexible, intelligent, and versatile material handling
systems used to transport materials from various loading locations to various unloading locations
throughout the facility.

7. Why an AS/RS?
 An AS/RS is highly space efficient. Space now occupied by raw stock, work in process,
or finished parts and assemblies can be released for valuable manufacturing space.
 Increased storage capacity to meet long-range plans.
 Improved inventory management and control.
 Quick response time to locate, store, and retrieve items.
 Reduced shortages of inventory items due to real-time information and control.
 Reduced labor costs due to automation.
 Improved stock rotation.

8. What are the different Type of AS/RS and explain briefly?
1. Unit load AS/RS: is used to store and retrieve loads that are palletized or stored in standard-
size containers.
2. Mini-load AS/RS: is designed to handle small loads such as individual parts, tools, and
supplies.
The system is suitable for use where there is a limit on the amount of space that can be utilized
and where the volume is too low for a full-scale unit load system and tool high for a manual
system.
3. Person-on-board AS/RS: allows storage of items in less than unit load quantities.
4. Deep-lane AS/RS: is another variation on the unit load system. The items are stored in
multi-deep storage with up to 10 items per row rather than single or double deep. This leads to
a high density of stored items.
5. Automated item retrieval system
9. What are the Design parameters should be consider for an AS/RS?
1. Determining load sizes
2. Determining the dimensions of an individual storage space

DEPARTMENT OF MECHANICAL ENGINEERING

 3. Determining the number of storage spaces considering
Dedicated storage
Randomized storage
4. Determining the system throughput and number of S/R machines
Speed of S/R machine
Mix of single- and dual-cycle transaction
Percent utilization of the storage racks
Arrangement of stored items
AS/RS control system speed
Efficiency
10. What are the Functions of storage systems ?
Receiving, identification and sorting, dispatching to storage, placing in storage, storage,
retrieving from storage, order accumulation, packing, shipping, and record keeping for raw
materials, purchased parts, work in process, finished product, pallets, fixtures, tools, spare
parts, rework and scrap, office supplies, and so forth have traditionally been considered the
functions of storage systems.
An AS/RS attempts to achieve these functions by automating most of these procedures in a
cost-effective and efficient manner.

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT V
FUNDAMENTALS OF INDUSTRIAL CONTROLS
Objective:
 To know product families often consists of workstations comprising CNC machine
tools.

Outcome:
 Student gets exposure on portable power tools.

Fundamentals of Industrial controls: Review of control theory, logic controls, sensors and
actuators, Data communication and LAN in manufacturing.
Business process Re-engineering: Introduction to BPE logistics, ERP, Software configuration
of BPE.

UNIT-V
Fundamentals of Industrial controls:
Logic Control Systems
To begin the discussion of industrial logic control systems, consider the simple pneumatic
system shown in Figure LC-1. The pneumatic cylinder moves in a linear dimension until it
reaches the limit switch at the extended end. The cylinder is controlled with a simple two
position, four-way solenoid valve as shown. The solenoid valve shown is activated by an
electrical current passing through the solenoid coil. This type of simple ON/OFF
programming has traditionally been done by relay control systems.

A relay control system for the simple system of Figure LC-1 is also shown. This schematic
diagram represents a type of programming frequently referred to as "ladder logic" by
industrial electricians. The two parts of a relay are both shown in this diagram. Electrical
relays (Figure LC-2) have a control circuit and one or more sets of outputs. The coil of the
relay forms part of an electromagnet which activates a set of contacts (contacts similar to
"points" in an pre-70's auto). Electrical current passing through the coil of the relay (the
"control relay") closes one of these sets of contacts (CR-1B) which allows current to flow
through the pneumatic valve solenoid, SOL-A. Another set of contacts, CR-1A in Figure LC-
1, is used to "hold" the contacts closed once they have been energized, by providing an
alternate path for electrical current through the control relay. A momentary contact push-
button PB-1 (normally open or N.O.) is provided for initiating motion. When PB-1 is pressed,
current flows through the actuating circuit of relay CR-1, which closes the output contacts
(CR-1A and CR-1B). When PB-1 is released, these contacts remain closed due to electrical

DEPARTMENT OF MECHANICAL ENGINEERING

current path through the closed relay contacts CR-1A and the normally closed limit switch
LS-1. Relay CR-1 remains energized until the limit switch LS-1 activated by the cylinder.
Oncethis limit switch is activated, the current flow through the control relay CR-1 is
interrupted, and the contacts CR-1A and CR-1B both open. The solenoid SOL-A is de-
energized, therefore the spring shifts the solenoid back to the right position, which causes the
cylinder to retract. The circuit is inactive until a subsequent pressing of the push-button PB-1.
Figure LC-3 shows the most common components of ladder logic diagrams. Input elements
include limit switches, momentary contact push-buttons, pressure switches, manual switches,
and relay contacts. Typical outputs include solenoid coils, control relay coils, pilot lights, and
annunciators (or horns). Note that each of the inputs is available in both normally open (NO)
and normally closed (NC) configurations. This distinction is easily explained by observing
the limit switch configurations. A normally closed limit switch will carry current if it is not
activated (the "normal" state). If a normally closed limit switch is pressed, then it no longer
will carry current. A normally open limit switch is the opposite - it will not carry current
inactivated, it must be pressed to allow current to flow through it.

DEPARTMENT OF MECHANICAL ENGINEERING

Sensors
Sensor is a device that when exposed to a physical phenomenon (temperature, displacement,
force, etc.) produces a proportional output signal (electrical, mechanical, magnetic, etc.). The
term transducer is often used synonymously with sensors. However, ideally, a sensor is a
device that responds to a change in the physical phenomenon. On the other hand, a transducer
is a device that converts one form of energy into another form of energy. Sensors are
transducers when they sense one form of energy input and output in a different form of
energy. For example, a thermocouple responds to a temperature change (thermal energy) and
outputs a proportional change in electromotive force (electrical energy). Therefore, a
thermocouple can be called a sensor and or transducer.
Classification of Sensors

There are several classifications of sensors made by different authors and experts. Some are
very simple and some are very complex. The following classification of sensors may already
be used by an expert in the subject but this is a very simple classification of sensors.
In the first classification of the sensors, they are divided in to Active and Passive. Active
Sensors are those which require an external excitation signal or a power signal.
Passive Sensors, on the other hand, do not require any external power signal and directly
generates output response.
The other type of classification is based on the means of detection used in the sensor. Some
of the means of detection are Electric, Biological, Chemical, Radioactive etc.
The next classification is based on conversion phenomenon i.e. the input and the output.
Some of the common conversion phenomena are Photoelectric, Thermoelectric,
Electrochemical, Electromagnetic, Thermo optic, etc.
The final classifications of the sensors are Analog and Digital Sensors. Analog Sensors
produce an analog output i.e. a continuous output signal with respect to the quantity being
measured.
Digital Sensors, in contrast to Analog Sensors, work with discrete or digital data. The data in
digital sensors, which is used for conversion and transmission, is digital in nature.

DEPARTMENT OF MECHANICAL ENGINEERING

Different Types of Sensors
The following is a list of different types of sensors that are commonly used in various
applications. All these sensors are used for measuring one of the physical properties like
Temperature, Resistance, Capacitance, Conduction, Heat Transfer etc.
 Temperature Sensor
 Proximity Sensor
 Accelerometer
 IR Sensor (Infrared Sensor)
 Pressure Sensor
 Light Sensor
 Ultrasonic Sensor
 Smoke, Gas and Alcohol Sensor
 Touch Sensor
 Color Sensor
 Humidity Sensor
 Tilt Sensor
 Flow and Level Sensor
Temperature Sensor

One of the most common and most popular sensor is the Temperature Sensor. A Temperature
Sensor, as the name suggests, senses the temperature i.e. it measures the changes in the
temperature.

In a Temperature Sensor, the changes in the Temperature correspond to change in its physical
property like resistance or voltage.
There are different types of Temperature Sensors like Temperature Sensor ICs (like LM35),
Thermistors, Thermocouples, RTD (Resistive Temperature Devices), etc.
Temperature Sensors are used everywhere like computers, mobile phones, automobiles, air
conditioning systems, industries etc.
A simple project using LM35 (Celsius Scale Temperature Sensor) is implemented in this
project: TEMPERATURE CONTROLLED SYSTEM.

DEPARTMENT OF MECHANICAL ENGINEERING

Proximity Sensors

A Proximity Sensor is a non-contact type sensor that detects the presence of an object.
Proximity Sensors can be implemented using different techniques like Optical (like Infrared
or Laser), Ultrasonic, Hall Effect, Capacitive, etc.

Some of the applications of Proximity Sensors are Mobile Phones, Cars (Parking Sensors),
industries (object alignment), Ground Proximity in Aircrafts, etc.
Proximity Sensor in Reverse Parking is implemented in this Project: REVERSE PARKING
SENSOR CIRCUIT.
Infrared Sensor (IR Sensor)

IR Sensors or Infrared Sensor are light based sensor that are used in various applications like
Proximity and Object Detection. IR Sensors are used as proximity sensors in almost all
mobile phones.

DEPARTMENT OF MECHANICAL ENGINEERING

There are two types of Infrared or IR Sensors: Transmissive Type and Reflective Type. In
Transmissive Type IR Sensor, the IR Transmitter (usually an IR LED) and the IR Detector
(usually a Photo Diode) are positioned facing each other so that when an object passes
between them, the sensor detects the object.
The other type of IR Sensor is a Reflective Type IR Sensor. In this, the transmitter and the
detector are positioned adjacent to each other facing the object. When an object comes in
front of the sensor, the sensor detects the object.
Different applications where IR Sensor is implemented are Mobile Phones, Robots, Industrial
assembly, automobiles etc.
A small project, where IR Sensors are used to turn on street lights: STREET LIGHTS
USING IR SENSORS.
Ultrasonic Sensor

An Ultrasonic Sensor is a non-contact type device that can be used to measure distance as
well as velocity of an object. An Ultrasonic Sensor works based on the properties of the
sound waves with frequency greater than that of the human audible range.

DEPARTMENT OF MECHANICAL ENGINEERING

Using the time of flight of the sound wave, an Ultrasonic Sensor can measure the distance of
the object (similar to SONAR). The Doppler Shift property of the sound wave is used to
measure the velocity of an object.
Arduino based Range Finder is a simple project using Ultrasonic Sensor: PORTABLE
ULTRASONIC RANGE METER.

TYPES OF THE ACTUATORS

DEPARTMENT OF MECHANICAL ENGINEERING

Actuator is something that converts energy into motion. It also can be used to apply a force.
An actuator typically is a mechanical device that takes energy — usually energy that is
created by air, electricity or liquid — and converts it into some kind of motion. That motion
can be in virtually any form, such as blocking, clamping or ejecting. An actuator is the
mechanism by which an agent acts upon an environment. The agent can be either an artificial
intelligence agent or any other autonomous being (human, other animal, etc.). Actuators
typically are used in manufacturing or industrial applications and might be used in devices
such as motors, pumps, switches and valves.
Energy Sources
Perhaps the most common type of actuator is powered by air and is called a pneumatic
cylinder or air cylinder. This type of actuator is an air-tight cylinder, typically made from
metal that uses the stored energy of compressed air to move a piston when the air is released
or uncompressed. These actuators are most commonly used in manufacturing and assembly
processes. Grippers, which are used in robotics, use actuators that are driven by compressed
air to work much like human fingers. An actuator also can be powered by electricity or
hydraulics. Much like there are air cylinders, there also are electric cylinders and hydraulic
cylinders in which the cylinder converts electricity or hydraulics into motion. Hydraulic
cylinders, which use liquids, are often found in certain types of vehicles.
Electrical Actuators

DEPARTMENT OF MECHANICAL ENGINEERING

Electrical Actuator is an electromechanical device that converts electrical energy into
mechanical energy. Most electric actuators operate through the interaction of magnetic fields
and current-carrying conductors to generate force. The reverse process, producing electrical
energy from mechanical energy, is done by generators such as an alternator or a dynamo;
some electric actuators can also be used as generators, for example, a traction motor on a
vehicle may perform both tasks. Electric actuators and generators are commonly referred to
as electric machines.
Applications
Electric actuators are found in applications as diverse as industrial fans, blowers and pumps,
machine tools, household appliances, power tools, and disk drives. They may be powered by
direct current, e.g., a battery powered portable device or motor vehicle, or by alternating
current from a central electrical distribution grid or inverter. Small actuators may be found in
electric wristwatches. Medium-size motors of highly standardized dimensions and
characteristics provide convenient mechanical power for industrial uses.
The very largest electric actuators are used for propulsion of ships, pipeline compressors, and
water pumps with ratings in the millions of watts. Electric actuators may be classified by the
source of electric power, by their internal construction, by their application, or by the type of
motion they give.
Fail Safe Actuators

DEPARTMENT OF MECHANICAL ENGINEERING

Fail Safe Actuator is for larger valves with higher torque requirements, requiring reliable fail
safe operation utilizing a unique in-built air reservoir giving fail safe action without the
torque losses inherent of spring designs. By using the time proven air accumulator system,
and modern design techniques, produces air chamber modules with all the pneumatic
circuitry safety protected within. Fail safe actuators maintains the highest seen air supply
pressure within the chamber modules, to be released upon control demand.
This design also prevents closure creeping when air supply pressures drop, which occurs with
all spring return designs. Torque output is constant in the powered stroke with only a small
drop off on the fail stoke. The available torques are proportional to the air supply pressure.
Spring changes for various air supply pressures need not be made.
The fail safe actuator operates as a double acting actuator in both directions until there is a
loss of supply pressure. When this loss occurs, the compressed air stored in the chambers
powers the actuator to close the valve. This makes the fail safe actuator series suitable for use
in ON/OFF and modulating control situations while still providing the fail safe requirement.
Applications
 Wellhead
 Flow line
 Header
 Pipeline system
 Casing relief blow down valve.
DATA COMMUNICATIONS
Data communications are the exchange of data between two devices via some form of
transmission medium such as a wire cable. For data communications to occur, the
communicating devices must be part of a communication system made up of a combination
of hardware (physical equipment) and software (programs). The effectiveness of a data
communications system depends on four fundamental characteristics: delivery, accuracy,
timeliness, and jitter.
1. Delivery. The system must deliver data to the correct destination. Data must be received by
the intended device or user and only by that device or user.
2. Accuracy. The system must deliver the data accurately. Data that have been altered in
transmission and left uncorrected are unusable.
3. Timeliness. The system must deliver data in a timely manner. Data delivered late are
useless. In the case of video and audio, timely delivery means delivering data as they are
produced, in the same order that they are produced, and without significant delay. This kind
of delivery is called real-time transmission.
4. Jitter. Jitter refers to the variation in the packet arrival time. It is the uneven delay in the
delivery of audio or video packets.
Components:
A data communications system has five components.

DEPARTMENT OF MECHANICAL ENGINEERING

1. Message. The message is the information (data) to be communicated. Popular forms of
information include text, numbers, pictures, audio, and video.
2. Sender. The sender is the device that sends the data message. It can be a computer,
workstation, telephone handset, video camera, and so on.
3. Receiver. The receiver is the device that receives the message. It can be a computer,
workstation, telephone handset, television, and so on.
4. Transmission medium. The transmission medium is the physical path by which a message
travels from sender to receiver. Some examples of transmission media include twisted-pair
wire, coaxial cable, fiber-optic cable, and radio waves
5. Protocol. A protocol is a set of rules that govern data communications. It represents an
agreement between the communicating devices.

Local Area Network (LAN):

LAN is usually privately owned and links the devices in a single office, building or campus
of up to few kilometers in size. These are used to share resources (may be hardware or
software resources) and to exchange information. LANs are distinguished from other kinds of
networks by three categories: their size, transmission technology and topology.
LANs are restricted in size, which means that their worst-case transmission time is bounded
and known in advance. Hence this is more reliable as compared to MAN and WAN.
Knowing this bound makes it possible to use certain kinds of design that would not otherwise
be possible. It also simplifies network management.
.

DEPARTMENT OF MECHANICAL ENGINEERING

Local Area Network Topologies
Business process re-engineering (BPR):
Business process re-engineering (BPR) is a business management strategy, originally
pioneered in the early 1990s, focusing on the analysis and design of workflows and business
processes within an organization. BPR aimed to help organizations fundamentally rethink
how they do their work in order to dramatically improve customer service, cut operational
costs, and become world-class competitors.
BPR seeks to help companies radically restructure their organizations by focusing on the
ground-up design of their business processes. According to early BPR proponent Thomas
Davenport (1990), a business process is a set of logically related tasks performed to achieve a
defined business outcome. Re-engineering emphasized a holistic focus on business objectives
and how processes related to them, encouraging full-scale recreation of processes rather than
iterative optimization of sub-processes.

Introduction to Logistics
Logistics is the management of the flow of goods, information and resources between the
point of origin and the point of consumption. It is a business concept that evolved during the
1950s due to the increasing complexity of supplying businesses with materials and
transporting products in an increasingly globalized supply chain. The complexity led to a call
for experts in the process who are called logisticians.
Logistics can be defined as “having the right item in the right place, at the right time, in the
right quantity, at the right price and in the right condition, for the right customer”.
There are two fundamentally different forms of logistics: one optimizes a steady flow of
materials through a network of transport links and storage areas, while the other coordinates
an effective sequence of resources in order to carry out a project.
Work in logistics involves the integration of information, transportation, inventory,
warehousing, material handling, packaging, human resources and sometimes security. The
goal is to manage the life cycle of a project from birth to completion. For example, a

DEPARTMENT OF MECHANICAL ENGINEERING

logistician would have to ensure that the supply chains work so that raw materials and/or
parts arrive at a factory or on site in time and in the correct order. It would be veryinefficient
and wasteful if the roof tiles were delivered before the foundations have been dug and the
walls built on a construction site, or, if large quantities of paper were delivered to a printer
who had nowhere clean and dry to store it. These are very simple examples of an extremely
complex and detailed process.
The main functions of a qualified logistician include inventory management, purchasing,
transportation, warehousing, consultation and organizing and planning of these activities.
Logisticians combine a professional knowledge of each of these functions to coordinate
resources in an organization.
Enterprise resource planning (ERP):
Enterprise resource planning (ERP) is business process management software that allows an
organization to use a system of integrated applications to manage the business and automate
many back office functions related to technology, services and human resources.
The need for enterprise resource planning (ERP) software grew with big business’ mandate
for a centralized solution to manage all information system requirements. An ERP may
consist of many different business modules, including:
 Manufacturing
 Human Resources/Payroll
 Sales
 Inventory
 Supply Chain/Partners
 Finance and Accounting
 CRM
In short, an ERP solution allows each department or business domain to be managed centrally
while operating independently. Advantages include interoperability of data, increased
communication and increased data reliability through the use of a single database.
ERP also enhances the quality of enterprise-wide decision making. For example, a
customized order may move from the sales department to inventory control, then on to
invoicing to finance and manufacturing. By using an ERP, this type of process is an efficient
and continuous series of events that allows for easy individual order tracking.
1. Business Process Engine (BPE):
A business process engine (BPE) is a software framework that enables the execution and
maintenance of process workflows. It provides business process interaction and
communication between different data/process sources spread across one or more IT
applications and services.
A BPE is a business process management (BPM) solution component used to oversee the
technical architecture of business process integration, interlinking and interprocessing. BPE
works with all of the different application infrastructure layers, including front end,
middleware, backend and external business applications. It facilitates the integration of their
processes, inter and intra system communication, process data routing, data transformation
and merging. A BPE dynamically monitors and adjusts changes applied to data, as well as
associated processes and process workflows.
A BPE also may be used to create new business processes, business rules and deployment
capability for all connected applications without disruption or downtime.

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT V
POWER POINT PRESENTATION SLIDES
AUTOMATION AND CONTROL TECHNOLOGIES IN
THE PRODUCTION SYSTEM
COMPONENTS OF MANUFACTURING SYSTEM

 Production machines, tools, fixtures and other

related hardware
 Material handling system

 Computer system to coordinate and control the

above components
 Human workers
1. PRODUCTION MACHINES
The machines can be classified as
(1) Manually operated: Directed by human workers

(2) Semi-automated:performs a portion of the work

cycle under some form of program control, and a
human worker tends to the machine for the
remainder of the cycle, by loading and unloading it
or performing some other task each cycle.
(3) Fully automated:has a capacity to operate for
extended periods of time with no human attention.
2. MATERIAL HANDLING SYSTEM

(1) loading and unloading work units

(2) positioning the work units at each station.
(3) transporting work units between stations
(4) Temporary storage function
TYPES OF ROUTING IN MULTIPLE STATION
MANUFACTURING SYSTEMS

(a) Variable routing (b) Fixed routing

 3. COMPUTER CONTROL SYSTEM
Communicate instructions to workers. In manually operated workstations that
perform different tasks on different work units, processing or assembly
instructions for the specific work unit must be communicated to the
operator.
Download part programs to computer-controlled machines ( e.g-, CNC machine
tools).
Material handling system control. This function is concerned with controlling the
material handling system and coordinating its activities with those of the
workstations.
Schedule production. Certain production scheduling functions are
accomplished at the site of the manufacturing system.
Failure diagnosis. This involves diagnosing equipment malfunctions, preparing
preventive maintenance schedules, and maintaining spare parts inventory.
Safety Monitoring. This function ensures that the system does not operate in an
unsafe condition. The goal of safety monitoring is to protect both the human
workers manning the system and the equipment comprising the system.
Quality Control. The purpose of this control function is to detect and possibly
reject defective work units produced by the system.
Operations management. Managing the overall operations of the manufacturing
4. HUMAN RESOURCES
In many manufacturing systems, humans perform some
or all of the value-added work that is accomplished on
the parts or products. In these cases, the human
workers are referred to as Direct labor
In manufacturing systems that are fully automated, direct
labor is still needed to perform such activities as
loading and unloading parts to and from the system,
changing tools, resharpening tools, and similar
functions.
Human workers are also needed for automated
manufacturing systems to manage or support the
system as computer programmers, computer
operators, part programmers for CNC machine tools
CLASSIFICATION OF MANUFACTURING SYSTEMS

(1) Types of operations performed,

(2) Number of workstations and system layout,
(3) Level of automation, and
(4) Part or product variety
1. TYPES OF OPERATIONS PERFORMED

1. Processing operations on individual units

2. Assembly operations to combine the
individual parts in to assembled entities
2.NUMBER OF WORK STATIONS AND SYSTEM LAYOUT
Type I Single station. This is the simplest case,
consisting of one workstation (n = 1), usually
including a production machine that can be
manually operated, semi-automated, or fully
automated.
Type II Multiple stations with variable routing. This
manufacturing system consists of two or more
stations (n > 1) that are designed and arranged to
accommodate the processing or assembly of
different part or product styles.
Type III Multiple stations with fixed routing. This
system has two or more workstations ( n > 1) ,
which are laid out as a production line.
3. LEVEL OF AUTOMATION
Manning level of a work station (Mi) is proportion of
time that a worker is in attendance at the station. If
Mi = 1 for station I, it means that one worker must
be at the station continuously.
The average manning level of multi station is equal

Mi = average manning level

Wu = number of utility workers assigned to the systems
Wi = number of workers assigned to I
W= total number of workers assigned to the system
AUTOMATION IN THE CLASSIFICATION
SCHEME
Type I M Single-station manned cell. The basic case is one machine
and one worker (n = l,w = 1).The machine is manually operated
or semi-automated,and the worker must be in continuous
attendance at the machine.
Type I A Single station automated cell. This is a fully automated
machine capable of unattended operation (M < 1) for extended
periods of time (longer than one machine cycle ). A worker must
periodically load and unload the machine or otherwise service it.
Type II M Multi-station manual system with variable routing. This has
multiple stations that are manually operated or semi-automated.
The layout and work transport system allow for various routes to
be followed by the parts or products made by the system. Work
transport between stations is either manual or mechanized.
Type II A Multi-station automated system with variable routing. This
is the same as the previous system; except the stations are fully
automated (n > 1, w; = 0, I M < 1). Work transport is also fully
automated.
AUTOMATION IN THE CLASSIFICATION SCHEME
CONT……
Type II H Multi-station hybrid system with variable routing. This
manufacturing system contains both manned and automated stations.
Work transport is manual, automated, or a mixture (hybrid).
Type III M Multi-station manual system with faxed routing. This
manufacturing system consists of two or more stations (n > 1), with one
or more workers at each station ( w>=1 ). The operations are
sequential, thus necessitating a fixed rout- ing, usually laid out as a
production line. Work transport between stations is either manual or
mechanized.

Type III A Multi-station automated system with fixed routing. This system
consists of two or more automated stations (n > 1, wi> = 0, M < 1)
arranged as a production line or similar configuration. Work transport is
fully automated.
Type III H Multi-station hybrid system with fixed routing. This system
includes both manned and automated stations (n > 1, wi> = 1 for some
stations, wi = 0 for other stations, M > 0). Work transport is manual,
automated, or a mixture (hybrid).
 Classification of Manufacturing Systems

( a) single station manned cell, (b) single station automated cell, ( c) multi-station manual system with
variable routing, ( d) multi-station automated system with variable routing, (e) multi-station hybrid sys-
tem with variable routing, (f) multi-station manual system with serial operations, (g) multi-station
automated system with serial operations, and (h) multi-station hybrid system with serial operations.
Key: Man = manned station, Aut = automated station.
4. PART OR PRODUCT VARIETY
Examples of possible variations that a manufacturing
system may have to cope with include:
 variations in type and/or color of plastic of molded
parts in injection molding
 variations in electronic components placed on a
standard size printed circuit board
 variations in the size of printed circuit boards handled
by a component place
 variations in geometry of machined parts
 variations in parts and options in an assembled
product on a final assembly line
 MODEL VARIATIONS

1. Single model: All parts or products made by the manufacturing systems are identical
2. Batch model: different parts or products made by the system, but they are made in
different batches because a changeover in physical setup and/or equipment
programming is required between models
3. Mixed model case: , different parts or products are made by the manufacturing
system, but the system is able to handle these differences without the need for a
changeover in setup and/or program.
 FLEXIBILITY IN MANUFACTURING SYSTEMS
Identification of the different work units. Different operations are required on
different part or product styles. The manufacturing system must identify the
work unit to perform the correct operation. In a manually operated or semi-
automatic system, this task is usually an easy one for the worker(s). In an
automated system, some means of automatic work unit identification must be
engineered.
Quick changeover of operating instructions. The instructions, or part program in
the case of computer-controlled production machines, must correspond to the
correct operation for the given part. In the case of a manually operated system,
this gener- ally means workers who (1) are skilled in the variety of operations
needed to process or assemble the different work unit styles, and (2) know
which operations to perform on each work unit style. In semi-automatic and
fully automated systems, it means that the required part programs are readily
available to the control unit.
Quick changeover of physical setup. Flexibility in manufacturing means that the
dif- ferent work units are not produced in batches. For different work unit styles
to be pro- duced with no time lost between one unit and the next, the flexible
manufacturing system must be capable of making any necessary changes in
fixturing and tooling in a very short time. (The changeover time should
correspond approximately to the time required to exchange the completed work
unit for the next unit to be processed. )
RECONFIGURABLE MANUFACTURING
SYSTEMS
Ease of mobility. Machine tools and other production
machines designed with a three- point base that allows
them be readily lifted and moved by a crane or forklift truck.
The three-point base facilitates leveling of the machine
after moving.
Modular design of system components. This permits hardware
components from dif- ferent machine builders to be
connected together.
Open architecture in computer controls. This permits data
interchange between soft- ware packages from different
vendors.
CNC workstations. Even though the production machines in
the system are dedicat- ed to one product, they are
nevertheless computer numerical controlled to allow jor
upgrades in software, engineering changes in the part
currently produced, and changeover of the equipment when
the production run finally ends
 UNIT V
INDUTRIAL APPLICATIONS
 UNIT V
ASSIGNMET
 Unit-V

1.

a). Explain the situations where adaptive control can be beneficially applied?

b). What are the limitations of adaptive control?

2.

a). Explain how various parameters such as cutting force, temperatures are controlled using
adoptive control concept.
b). Explain the process of adaptive control constraint (ACC).
3. Explain about Sensors and Actuators
4. Data communication and LAN manufacturing
5. Explain Business Process Re-engineering

DEPARTMENT OF MECHANICAL ENGINEERING

 UNIT V
SHORT ‘Q’ & TUTORIAL
 UNIT-V

1. What is a Sensor?
It is a device that converts signals from one energy domain to electrical domain. The definition of the
Sensor can be understood if we take an example in to consideration. The simplest example of a sensor is
an LDR or a Light Dependent Resistor. It is a device, whose resistance varies according to intensity of
light it is subjected to. When the light falling on an LDR is more, its resistance becomes very less and
when the light is less, well, the resistance of the LDR becomes very high.

2. What are the Different Types of Sensors?

The following is a list of different types of sensors that are commonly used in various
applications. All these sensors are used for measuring one of the physical properties like
Temperature, Resistance, Capacitance, Conduction, Heat Transfer etc.

 Temperature Sensor
 Proximity Sensor
 Accelerometer
 IR Sensor (Infrared Sensor)
 Pressure Sensor
 Light Sensor
 Ultrasonic Sensor
 Smoke, Gas and Alcohol Sensor
 Touch Sensor
 Color Sensor
 Humidity Sensor
 Tilt Sensor
 Flow and Level Sensor

1. What is an actuator and classify the types of actuators?

An actuator is a component of a machine that is responsible for moving and controlling a mechanism or
system, for example by opening a valve. In simple terms, it is a "mover".

An actuator requires a control signal and a source of energy. The control signal is relatively low energy
and may be electric voltage or current, pneumatic or hydraulic pressure, or even human power. Its main
energy source may be an electric current, hydraulic fluid pressure, or pneumatic pressure. When it
receives a control signal, an actuator responds by converting the signal's

4. What is LAN in manufacturing?

A local area network (LAN) is a computer network that interconnects computers within a limited
area such as a residence, school, laboratory, university campus or office building. Ethernet and Wi-
Fi are the two most common technologies in use for local area networks.

5. What do you mean by data communication?

DEPARTMENT OF MECHANICAL ENGINEERING

Data communications (DC) is the process of using computing and communication technologies
to transfer data from one place to another, and vice versa. It enables the movement of electronic or
digital data between two or more nodes, regardless of geographical location, technological medium
or data contents.

6. What do you mean by logistics?

Logistics management is the part of supply chain management that plans, implements, and
controls the efficient, effective forward, and reverse flow and storage of goods, services, and
related information between the point of origin and the point of consumption in order to meet
customer's requirements.

DEPARTMENT OF MECHANICAL ENGINEERING