CHAPTER 18

Computer Controlled
Manufacturing Processes
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 !ssues to address«.
!ntroduction to computer controlled
manufacturing systems.
Automation ± Types.
Numerical Control and Computer
Numerical Control concepts.
Classification of NC systems.
Robotics

 ° en components can be
manufactured manually w y
we need computers in Mfg?

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Need for computers in Mfg.
!n w ic case it is easy to move tool /
table on conventional mac ine?
(a)

(b)

(c)
m
Need for Computers in Mfg.
How do you Manufacture t is part?

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°


   .

¢
°


  

ë
 


—
Need for Computers in Mfg.
!ncreased productivity.
Reduced cost of labor and
dependence on labor s ortages.
!ncreased safety or reduced risk of
umans.
!mproved quality.
r
Need for Computers in Mfg.
Reduced manufacturing time.
Reduced in-process inventory.
Reduced dependence on
operator skills etc.

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° ere else computers can be
used in Manufacturing?
Drawing.
Design.
!nspection.
Supporting activities of Mfg. like
!nventory control, Sc eduling etc.

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 Automation
Automation can generally be defined as
t e process of following a predetermined
sequence of operations wit little or no
uman intervention, using specialized
equipment and devices t at perform and
control t e manufacturing process.

 Mec anization and Automation

÷  
 means somet ing is done
or operated by mac inery and not by
and.


 means a system in w ic
many or all of t e processes in t e
production, movement, and inspection of
parts and material are performed under
control by self-operating devices called



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Types of Automation
h 

 
  



h
 




cm
° at is Numerical Control (NC)?

NC is a met od of operating a mac ine

tool by means of numbers, letters of
alp abets, and symbols (r 


) referring to t e specific distances,

positions, functions or motions

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èasic components of NC System







 
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How NC mac ine tools work?

  heed Numerical Data into t e NC
system

  MCU (Mac ine Control Unit)
reads t e data, decode it, and c anges it
into t e electrical signals and transfer it to
t e mac ine tool

  Transducers on t e mac ine tool
converts t ese electrical signals into t e
actual movements of t e mac ine tool
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How automated mac ine tools work?

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 ° at does t e following
information indicate?
X+100, Y+50, S+900

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Advantages of NC Systems
Complex mac ining operations
Accuracy
!ncreased productivity
hlexibility
Greater operator efficiency

 Advantages of NC Systems
Greater operator safety
Greater mac ine tool safety
Less inspection required
Need of ig ly skilled/experienced
operator is avoided

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Disadvantages of NC Systems
Relatively ig initial investment.
Hig ly skilled and trained part
programmer is required.
More complicated maintenance.
Redundancy of labor?

CONVENT!ONAL VS
NC MACH!NES

=
CONVENT!ONAL VS
NC MACH!NES

m
CONVENT!ONAL VS
NC MACH!NES

‘
 CONVENT!ONAL VS
NC MACH!NES
operator
Mac ine tool

Conventional Mac ining System

!nput MCU Mac ine tool

operator

Simplified Numerical Control System

¢
 CONVENT!ONAL VS
NC MACH!NES
Cost
Skill of operator required.
Production rate.
Special tooling.
Downtime.
Maintenance.

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COORD!NATE SYSTEMS



 








Coordinate system for a prism.

—
COORD!NATE SYSTEMS ON A
MACH!NE

r
 PROGRAM ZERO PO!NT








Alternate locations of program zero point
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=




 ¢

 
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Define t e coordinate system for a

 


X + 50, Y+60, Z+30

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Classification of NC Systems
According to t e
  
 control
üPoint-to-Point (PTP) motion control
üContinuous or contouring motion control

According to t e    


ü!ncremental
ü Closed

According to t e
  




üOpen loop
üClosed loop
=

PTP & CONTOUR!NG SYSTEM

PTP CONTOUR!NG
==
 AèSOLUTE POS!T!ON!NG


 
=

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=

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Positional command X+70, Y+30 =m

 !NCREMENTAL POS!T!ON!NG







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Positional command X+50, Y+20 [higure (a)]

X+30, Y-10[higure (b)] =‘
 CLASS!h!CAT!ON èASED ON
CONTROL SYSTEM




! 
   
 



"
!
#

Open loop control system





! $ $ 


$




  
& 

X "
!
# 

%!




Closed loop control system =¢

i


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 ° at is a i

An 


is a general-purpose,
reprogrammable mac ine t at possesses
certain ant ropomorp ic, or uman
like, c aracteristics. T e most typical
uman like c aracteristics of present
day robots is t eir movable arm, capable
of moving in a t ree dimensional space.

=—
 Structure of a i

An 


is a manipulator
consisting of several rigid links
connected in series by revolute or
prismatic joints. One end of t e c ain is
attac ed to a supporting base, w ile t e
ot er end is free and equipped wit a


to perform specified tasks or wit a
  to manipulate objects. =r
Structure of industrial robot

 '
(!)** 


 




m

 ° y to use i
?
!ncreased 

compared to
uman workers.
!mproved 0

 output.
hewer rejects.
°orking in ostile environment.
mc
 ° y to use i
?
Good 


 in several
applications.
Less p ysical 
 for operator.
No labor problems.

 Applications of Robots in
Manufacturing
Mac ine Loading and Unloading
or Material Handling
Heat Treatment
horging

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Applications of Robots in
Manufacturing
Press °ork
°elding
Painting and Coating
Assembly and !nspection etc.

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Robotics scenario in !ndia
!s it true t at robotics is irrelevant
in t e !ndian context?
!f Robots can be used w ere it can
be used?
!nteresting statistics for you:
!n 1992 Robos in !ndia 100
Japan it was 3,50,000
m‘
Advantages of Computer
Controlled Mac ines
More  
 to uman workers.
Possibility to produce  
0

 products at
 
 .
Overall increase in 

.
Hig er 0

.
More
 
 to workers
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Limitations of Computer
Controlled Mac ines
T ese tec nologies increase


problems.
!t declines t e   
  of customer.
Automation can even disturb
t e  of country as a
w ole më