NPTEL Online Certification Course on Automation in Manufacturing - PDF

NPTEL online certification course on Automation in Manufacturing Dr. Shrikrishna N. Joshi Associate Professor Department of Mechanical Engineering Indian Institute of Technology Guwahati Guwahati PIN 781 039 Assam, India C...

NPTEL online certification course on Automation in Manufacturing Dr. Shrikrishna N. Joshi Associate Professor Department of Mechanical Engineering Indian Institute of Technology Guwahati Guwahati PIN 781 039 Assam, India Course objectives ❖ To study the principles of automation, various automated equipment and systems that are used in the manufacturing industry ❖ To learn the fundamentals of mechatronics system and apply them in practice ❖ To design and develop innovative and useful automated equipment, products/systems required in manufacturing 2 Course outline Week Contents 1 Introduction: Importance of automation in the manufacturing industry. Use of mechatronics. Systems required. 2 Design of an automated system: Building blocks of an automated system, working principle and examples. 3 Fabrication: Fabrication or selection of various components of an automated system. Specifications of various elements. 4 Sensors: study of various sensors required in a typical automated system for manufacturing. Construction and principle of operation of sensors. 5 Microprocessor Technology: signal conditioning and data acquisition, use of microprocessor or micro controllers. Configurations. Working. 3 Course outline Week Contents Drives: electrical drives – types, selection criteria, construction and operating 6 principle. Mechanisms: Ball screws, linear motion bearings, cams, systems controlled by 7 camshafts. Mechanisms: Electronic cams, indexing mechanisms, tool magazines, and 8 transfer systems. 9 Hydraulic systems: hydraulic power pack, pumps, valves. 10 Hydraulic systems: designing of hydraulic circuits. Pneumatic systems: configurations, compressors, valves, distribution and 11 conditioning. 12 CNC technology: basic elements, interpolators and programming. 4 Week 1 Introduction Lecture 1 Basic concepts 5 Lecture outline ❖ Definition of automation in manufacturing ❖ Production systems Facilities Manufacturing Support Systems ❖ Manufacturing Systems Manual work system Worker-machine system Automated system ❖ Product life cycle: importance of automation 6 Production system ❖ A production system is a collection of people, equipment, and procedures organized to perform the manufacturing operations of a company Facilities Manufacturing support system 7 Facilities ❖ The factory ❖ Production facilities ❖ Material Handling Equipment ❖ Inspection Equipment ❖ Computer Systems ❖ Plant layout: the way the equipment is laid out ❖ Logical grouping of equipment and workers 8 Facilities ❖ Single production machine Paper cups Plastic chair Screws ❖ Collection of machines: a production line Assembly line Automotive Mobile phones 9 Manufacturing systems ❖ In terms of human participation in the processes performed by the manufacturing systems, three basic categories can be distinguished: 1. manual work systems 2. Worker-machine systems 3. automated systems 10 Manual work system ❖ One or more workers performing one or more tasks without the aid of powered tools. ❖ Manual material handling, screwdrivers and hammers ❖ Machinist -> file to round the edges ❖ Quality control inspector -> micrometer ❖ Material handling -> a dolly 11 Worker-machine systems ❖ A human worker operates powered equipment, such as a machine tool or other production machine ❖ Most widely used manufacturing system ❖ A machinist -> engine lathe to fabricate a part for a product ❖ A fitter -> arc welding work cell ❖ A rolling mill ❖ A mechanized conveyor 12 Automated systems ❖ A process is performed by a machine without the direct participation of a human worker. No human attention. ❖ A program of instructions + a control system + power to drive the process. ❖ Moulding machines run on automatic cycles, one or more workers are required to be present to continuously monitor the operation. https://www.weprofab.com/plastic-injection-molding-manufacturer/ As seen on 26 May 2020 13 Manufacturing support systems To utilize the production facilities effectively, the enterprise should -> ❖ design the processes and equipment ❖ plan and control the production orders ❖ satisfy product quality requirements People and procedures : do not directly contact the product, but they plan and control its progress through the factory (1) Business functions (2) Product design (3) Manufacturing planning (4) Manufacturing control 14 Maruti 800 (1983 – 2014) Product life HM Ambassador (1958 – 2014) Cycle Nokia 3310 (2002 - ?) Product life Product life has now been reduced to a few months /days 15 Challenges ❖ Customers demand the products with variety, multiple functions, ease in operations ❖ To survive and compete in the market ❖ To export and become the leader in the manufacturing ❖ Less lead-time in the manufacture of products Automation in manufacturing and assembly Effective and quick communication 16  Design and Manufacturing Process Design process Design Design Feasibility study with need specifications collecting information Design Design Design analysis, Analysis Design Design conceptu- documentation evaluation optimization model CAD + CAE alization Process Production Quality planning Production Packaging Shipping planning control Design and procurement of new tools Order Marketing materials NC, CNC, DNC programming Manufacturing process 17 Summary ❖ Definition of automation in manufacturing ❖ Production systems Facilities Manufacturing Support Systems ❖ Manufacturing Systems Manual work system Worker-machine system Automated system ❖ Product life cycle: importance of automation 18 What we will learn in Week 1: Lecture 2? ❖ Mechatronics ❖ Disciplines of mechatronics ❖ Mechatronics for replacement of mechanics: wrist watch ❖ Mechatronics based systems 19