Industrial Revolutions and Advanced Manufacturing

Industrial Revolutions

• First (Industry 1.0): 18th century England, use of steam (trains, printing, factories)
• Second (Industry 2.0): 19th/20th century Europe, use of oil and electricity, production, telephone, radio, television, assembly lines
• Third (Industry 3.0): 1970s-2008 (USA and West), new energies and ICT in production
• Fourth (Industry 4.0): Today, digital revolution, biotechnologies, nanotechnologies, 3D printing
• Society 5.0: Interdependence of man and machine, cognitive computing, human customization, personalization for humans

Advanced Manufacturing Technology (AMT)

• AMT defined as adopting hard and soft technologies to improve manufacturing capabilities.
• AMT classifications based on the technology's objective and functionality.
• Different types of AMT used for various manufacturing purposes.
• Understanding technology and its optimal utilization is crucial.
• Rapid technological advancements offer opportunities but are also risky.

Advanced Manufacturing Technology (AMT) Classification

• Direct AMT: cutting, joining, reshaping, transporting, storing materials (e.g., CNC, DNC, robotics, FMS, AS/RS, AMHS, AGV, RP)
• Indirect AMT: product design, scheduling production, process planning (e.g., CAD, MRP, SPC, BC, MRP II)
• Administrative AMT: administrative support, integrating factory operations with the organization (e.g., ERP, ABC, OA)

Levels of AMT (examples)

• Stand-alone machine tools (controlled by computers)
• Manufacturing cells (machines grouped to produce parts)
• Linked cells (cells form islands with computer networks)
• Integrated activities (all activities, including marketing, integrated in an information network)

Computer Numerical Control (CNC)

• Implemented in the early 1950s.
• Controlling machine components using coded numerical instructions.
• Components include a servo drive, power electronics, servo motor, mechanical transmission, current control, velocity control, position control, trajectory generation.

Adaptive Control (AC)

• Automatically adjusts processing parameters (in machining, for example). Parameters include forces, temperature, surface finish, dimensions.
• Aims to optimize production rate, product quality, and minimize manufacturing costs.
• System constantly monitors parameters and adjusts variables accordingly to keep all parameters within the specified range.

Industrial Robots

• Replacing humans in repetitive, dangerous, and boring tasks, especially in assembly operations.
• Enhanced with sensory perception and movements similar to humans.
• Recent innovation is cobots (collaborative robots) that interact with humans.

Automated Assembly Systems

• Systems developed to replace human assembly operators.
• Human operators may still be involved in some processes, especially for complex tasks.
• Emphasis on designing products for easier and faster assembly by machinery.
• Systems include learning human assembly tasks from observation, robotic embodiment of scripts. (e.g., Hand Grasp Type Recognition, Object Recognition, Robot Retargeting. 3D model building, Robot Action, Finite State Machine.

Group Technology (GT)

• Grouping similar parts and manufacturing processes for efficient and economical production.
• Classifying parts based on design and manufacturing similarities.
• Standardizes design and processing plans for new parts.

Cellular Manufacturing (CM)

• Workstations consisting of several manufacturing cells with various machines, controlled by a central robot or system.
• Each machine performs a particular operation, including inspection.

Flexible Manufacturing Systems (FMS)

• Interconnecting manufacturing cells with a central computer.
• Enables efficient production of diverse parts via quickly changing manufacturing sequences.
• Flexible design adapting to market demand changes.

Expert Systems (ES)

• Complex computer programs capable of tasks like solving real-life problems (like human experts).
• Includes modeling, simulating production facilities, monitoring machine performance, diagnosing issues, and financial planning.
• Uses knowledge bases (KB), control programs, robotics, sensor data processing with cameras, etc

Additive Manufacturing

• Also known as 3D printing, additive processes.
• Building objects by adding thin layers.
• Unlike subtractive methods, additive methods create desired shapes.
• Works with various materials (e.g., plastic, metal, concrete, living cells).
• Includes methods like Material Jetting, Powder Bed Fusion, Sheet Lamination, Material Extrusion, Directed Energy Deposition, VAT Photopolymerization, Binder Jetting.

Artificial Neural Networks (ANN)

• Simulating human brain processes.
• Capabilities include modeling and simulating production facilities, monitoring, and controlling manufacturing operations.
• Diagnosing problems, financial planning, and strategic manufacturing decisions.
• Includes robotics, robotic process automation (RPA), machine learning, neural networks, computer vision, natural language processing, soft computing, and digital twins.

Explore the evolution of industrial revolutions from the 18th century to the present day, focusing on key technologies and societal impacts. Additionally, learn about Advanced Manufacturing Technology (AMT) and its critical role in enhancing manufacturing capabilities in today's rapidly changing landscape.