Computer Integrated

Manufacturing
(CIM)
Lecturer: TRAN MANH SON
 Instructor: Dr. Tran Manh Son
 Email: [email protected]
 Phone: 0919 1971 39
Rules in Class

 Attend at least 80% of class hours

 Complete all home-works and assignments (If any)
Assessment

 Assignment (50%)
 After each chapter will have one assignment/homework.
 Final Project (50%)
 Student have to complete a small project and present in
the class.
Textbook and References

 [1] Hệ thống sản xuất tích hợp, Đặng Thiện Ngôn, Lê Chí
Cương.
 [2] Automation Production System, and Computer
Integrated Manufacturing, Mikell P. Groover, 2015
 Sofware:
 Factory_IO
Contents of This course

 Chapter 1: Introduction
 Chapter 2: Life Cycle of Product
 Chapter 3: Elements of CIM
 Chapter 4: Group Technology Layout
 Chapter 5: Computer Aided Process Planning
 Chapter 6: Product Data Management
 Chapter 7: Quality Management and Fault Diagnosis
 Chapter 8: Just-in-Time Manufacturing, Lean
Manufacturing, and Agile Manufacturing.
Chapter 3: Elements of CIM
Contents of Chapter 3

 3.1 Computer aided design – CAD

 3.2 Computer aided manufacturing - CAM
 3.3 Numerical Control NC/CNC
 3.4 Robots
 3.5 PLC
 3.6 Flexible Manufacturing System – FMS
 3.7 Transportation
 3.8 Storage system
3.1 Computer aided design –
CAD
3.1 Computer aided design – CAD

3.1 Computer aided design – CAD
 Manufacturing support system: procedures and system
used to manage production and solve the technical and
logistics problems associated with designing the products,
planning, ordering materials, controlling work in process,…
=> CAD/CAM
 If the product design is good, another question is whether
the product can be proceduced at low cost? The design
contribute high rate to the cost of the product.
3.1 Computer aided design – CAD
 The design process
3.1 Computer aided design – CAD
 Recognition of need: deficiency by an engineer/new
product opportunity by a saleperson
 Problem definition: thorough specification of the item
(physical, function, cost, quality, performance)
 Synthesis and analysis: conceptualized, analyzed,
improved, resigned, analyzed again,…
 Evaluation: measuring the design against the specifications
including assessment performance, quality, reliability,…
 Presentation: documenting the design by means of
drawings, material specs, assembly lists,…
3.1 Computer aided design – CAD
 Computer-aided design (CAD): any design activity that
involves the effective use of computer systems to create,
modify, analyze, optimize, and document a design
engineering.
a. Geometric modelling: the use of a CAD system to develop
a mathematical description of the geometry of an object
(contained in computer memory)
b. Engineering analysis: some form of engineering analysis
must be performed such as stress-strain, heat transfer, or
dynamic simulation. Computer-aided engineering (CAE)
offer:
• Mass properties analysis: computation of features of a
solid object as its volume, surface area, weight, and
center of gravity.
3.1 Computer aided design – CAD
• Interference checking: CAD software examines 3-D
geometric models consisting of multiple components to
identify interferences between components
• Tolerance analysis: to assess how the tolerances may
affect the product’s function and performance, to
determine how tolerances may influence the ease or
difficulty of assembling the product, to assess how
variations in component dimensions may affect the
overall size of the assembly
• Kinematic and dynamic analysis: Kinematic analysis
studies the operation of mechanical linkages and
analyzes their motions. Dynamic analysis extends
kinematic analysis by including the effects of the mass of
each linkage member and the resulting acceleration
forces as well as any externally applied forces
3.1 Computer aided design – CAD
c. Design Evaluation and Review: CAD features that are
helpful in evaluating and reviewing a proposed design:
• Automatic dimensioning: determine precise distance
measures between surfaces on the geometric model
• Error checking: used to review the accuracy and
consistency of dimensions and tolerances
• Plant layout design score: some software packages are
available for facilities design, that is, designing floor
layout, physical arrangement of equipment. Also
provide one or more numerical scores for each plant
layout design, help to choose a proper one.
3.1 Computer aided design – CAD
d. Automated Drafting: CAD systems can be used to prepare
highly accurate engineering drawings, on the other hand,
increases productivity in the drafting function by about
fivefold over manual preparation of drawings
 Advantages of CAD:
 Increase performance, reduce the time of synthesis,
analysis
 Improve the quality of the design process
 Improve the quality of the design engineering
documentation. Resulting from CAD system, the
drawings are more standard, error-less and easier to
read
 Provide the ability to set up database for production
such as geometric, dimension, material,..of the product
3.2 Computer-Aided Manufacturing – CAM
Computer-aided manufacturing (CAM) involves the effective
use of computer technology in manufacturing planning and
control, and can be divided into two categories: (1) manufacturing
planning and (2) manufacturing control.
1. Manufacturing planning: are those in which the computer is
used directly to support the production function, but there is
no direct connection between the computer and the
process. The computer is used to provide information for the
effective planning and management of production activities.
Some of important applications of this category:
a. Computer-aided process planning (CAPP) - hoạch định
quy trình sản xuất): is concerned with the preparation of
route sheets that list the sequence of operations and work
center required to produce the product and its
components.
3.2 Computer-Aided Manufacturing – CAM
b. CAD/CAM NC part programming
c. Computerized machinability data systems: One of the
problems with operating a metal cutting machine tool is
determining the speeds and feeds that should be used
for a given operation. Computer programs are available
to recommend the appropriate cutting conditions for
different materials and operations (e.g., milling, drilling)
d. Computerized work standards: The time study
department has the responsibility for setting time
standards on direct labor jobs performed in the factory.
Establishing standards by direct time study can be a
tedious and time-consuming task. There are several
commercially available computer packages for setting
work standards. These computer programs use standard
time data that have been developed for basic work
elements that comprise any manual task. The program
sums the times for the individual elements required to
perform a new job in order to calculate the standard
time for the job.
3.2 Computer-Aided Manufacturing – CAM
e. Cost estimating: The computer is programmed to
apply the appropriate labor and overhead rates to
the sequence of planned operations for the
components of new products. The program then
adds up the individual component costs from the
engineering bill of materials to determine the overall
product cost
f. Production and inventory planning: The production
and inventory planning functions include
maintenance of inventory records, automatic
reordering of stock items when inventory is depleted,
production scheduling, maintaining current priorities
for the different production orders, material
requirements planning, and capacity planning
3.2 Computer-Aided Manufacturing – CAM
g. Computer-aided line balancing: Finding the best
allocation of work elements among stations on an
assembly line is a large and difficult problem if the
line is of significant size
2. Manufacturing control: concerned with computer
systems to control and manage the physical operations
in the factory
a. Process monitoring and control: concerned with
observing and regulating the production equipment
and manufacturing processes in the plant
b. Quality control: Quality control includes a variety of
approaches to ensure the highest possible quality
levels in the manufactured product
3.2 Computer-Aided Manufacturing – CAM
c. Shop floor control: “Shop floor control” refers to
production management techniques for collecting
data from factory operations and using the data to
help control production and inventory in the factory
d. Inventory control: Inventory control is concerned with
maintaining the most appropriate levels of inventory in
the face of two opposing objectives: minimizing the
investment and storage costs of holding inventory,
and maximizing service to customers
e. Just-in-time production systems: Just-in-time (JIT) refers
to a production system that is organized to deliver
exactly the right number of each component to
downstream workstations in the manufacturing
sequence just at the time when that component is
needed. JIT is one of the pillars of lean production
3.2 Computer-Aided Manufacturing – CAM
Planning Control
CAM
Computer-aided Process monitoring
process planning control

CAD/CAM NC
programing Quality control

Computerized Shop floor control

machinability data

Computerized work
Inventory control
standards

Cost estimating Just-in-time production

Production and
inventory planning
Computer-aided line
balancing
3.3 Computer Numerical
Control (NC/CNC)
3.3 CNC

3.3 CNC
 Numerical control (NC):
• Form of programmable automation in which mechanical
actions of a machine tool or other equipment are
controlled by a program containing coded alphanumeric
data
 Application of NC:
• Machine tool applications: drilling, milling, turning,
and other metal working
• Other applications: assembly, rapid prototyping, and
inspection
3.3 CNC
3.3 CNC
3.3.1 Basic components:
Part program is the set
of detailed step-by-step
commands that direct
the actions of the
processing equipment

Machine control unit (MCU) is a Processing equipment:

microcomputer storing the program
of instructions and executes it by
converting each command into
mechanical actions of the
processing equipment, one
command at a time.
3.3 CNC
The CNC Machine Control Unit
3.3 CNC
 Controls for Machine Tool Axes and Spindle Speed:
• Control the position and velocity (feed rate) of each
machine axis
• The rotational speed of the machine tool spindle
 Sequence Controls for Other Machine Tool Functions:
• Coolant
• Fixture clamping
• Tool changer
• Interlocks
• emergency warnings
3.3 CNC
 Basic structure of CNC:
3.3 CNC
 Basic structure of CNC:
3.3 CNC
3.3.2 NC Coordinate Systems
3.3 CNC
3.3.2 NC Coordinate Systems
• To program the NC processing equipment  must define
a standard axis system (the work head to the work part)
 Two axis systems used in NC:
• Flat work parts
• rotational parts.
 Coordinate systems are based on the Cartesian
coordinates
3.3 CNC
3.3.2 NC Coordinate Systems  Three linear axes (x, y,
z)
 x- and y-axes are used
to move and position
the worktable
 z-axis is used to con-
trol the vertical position
of the cutting tool

• Three rotational axes (a,

b, c)
• a-, b-, and c-rotational
axes specify angular
positions about the x-,
y-, and z-axes
3.3 CNC
3.3.3 Motion Control Systems
Motion Control

Continuous
Point-to-Point
path
3.3 CNC
 Absolute Positioning
 the work head locations are always defined with respect
to the origin of the axis system
 Incremental Positioning
 The next work head position is
defined relative to the
present location
3.3 CNC
3.3.4 CNC Software: interpret the NC part programs and generate
the corresponding control signals
CNC Software to drive the machine tool axes

operating system
software
operate the communication
machine interface soft- link between the CPU
ware and the machine tool

application software

the NC part programs that are written

for machining (or other) applications
3.3 CNC
3.3.5 Distributed Numerical Control
3.3 CNC
3.3.6 Machine Tool Applications
 Machining Operations and NC Machine Tools.
 Machining: manufacturing process in which the geometry
of the work is produced by removing excess material
 Create a wide variety of shapes and surface finishes
 Relatively high production rates to yield
 Highly accurate parts
 Relatively low cost.
3.3 CNC
3.3.6 Machine Tool Applications
 Four common types of machining operations:

(a) turning

(b) drilling
3.3 CNC
3.3.6 Machine Tool Applications
 Four common types of machining operations:

(c) peripheral milling

(d) surface grinding.
3.3 CNC
3.3.6 Machine Tool Applications
3.3 CNC
3.3.6 Machine Tool Applications
 NC for Other Metalworking Processes (besides machining)
 Punch presses for sheet metal hole punching (đục)
Presses for sheet metal bending (uốn)
Welding machines
Thermal cutting machines, such as oxy-fuel cutting,
laser cutting, and plasma arc cutting
Wire EDM: Electric discharge wire cutting operates
3.3 CNC
3.3.7 Advantages and Disadvantages of NC
 Advantages of NC.
• Nonproductive time is reduced
• Greater accuracy and repeatability.
• Inspection requirements are reduced.
• More complex part geometries are possible.
• Shorter manufacturing lead times
• Reduced parts inventory.
• Less floor space.
• Operator skill requirements are reduced.
3.3 CNC
3.3.7 Advantages and Disadvantages of NC
 Disadvantages of NC.
• Higher investment cost.
• Higher maintenance effort.
• Part programming.
3.3 CNC
3.3.8 ANALYSIS OF POSITIONING SYSTEMS
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS

Open-loop positioning system

3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS

Closed-loop positioning system

3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
 Open-loop positioning system:
uses a stepper motor to rotate the leadscrew or ball
screw
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
possible step angles

 alpha = step angle, °;

ns = the number of step angles for the motor, which
must be an integer
The angle of the motor shaft rotates is given by

Am = angle of motor shaft rotation, °; np = number of

pulses received by the motor; and alpha = step
angle, °/pulse
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
 The angle of the screw rotation

 As = angle of screw rotation, °; and rg = gear ratio



 Nm = rotational speed of the motor, rev/min

( revolutions per minute); and Ns = rotational speed of the screw,
rev/min.
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
 Linear movement of the worktable

 X: x_position
 p: pitch of screw
 As/360: number of screw revolution
 Pulses required to achieve a specified x-position
increment
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS

 Ns = screw rotational speed, rev/min; fp = pulse train

frequency, Hz; and ns = steps per revolution or pulses per
revolution
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
 Closed-loop positioning system:
 uses servomotors and feedback measurements to ensure
that the worktable is moved to the desired position.
 An optical encoder is a device for measuring rotational
speed that consists of a light source and a photodetector
on either side of a disk
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
 Closed-loop positioning system:
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
 closed-loop positioning system:
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
 closed-loop positioning system:
3.3 CNC
 3.3.8 ANALYSIS OF POSITIONING SYSTEMS
 closed-loop positioning system:
3.3 CNC
 3.3.10 Precision in Positioning Systems
Precision in positioning System

Control resolution Accuracy repeatability

 Control resolution: the distance separating two adjacent

addressable points in the axis movement, which depends
on limitations of electromechanical components and/or
the number of bits used by the controller.
 Addressable points: are locations along the axis to which
the worktable can be specifically directed to go
3.3 CNC
3.3.10 Precision in Positioning Systems
3.3 CNC
3.3.10 Precision in Positioning Systems

CR1 = control resolution of electromechanical components ,

mm (in); p = leadscrew pitch, mm/rev (in/rev); ns = number of steps
per revolution; and rg = gear ratio between the motor shaft and
the screw
3.3 CNC
3.3.10 Precision in Positioning Systems

 CR2 = control resolution of the computer control system,

mm (in); and L = axis range, mm (in).
 Control Revolution of Positioning system
3.3 CNC
3.3.10 Precision in Positioning Systems
 Accuracy: the maximum possible error between desired
target point and the actual position

 Ac = accuracy, mm (in); CR = control resolution, mm (in);

and s = standard deviation of the error distribution
 Accuracies in machine tools are generally expressed for
a certain range of table travel, for example, {±0.01 mm}
for 250 mm
3.3 CNC
3.3.10 Precision in Positioning Systems
 Repeatability: the ability of the positioning system to
return to a given addressable point that has been
previously programmed
3.3 CNC
 3.3.10 Precision in Positioning Systems
3.3 CNC
 3.3.10 Precision in Positioning Systems
3.3 CNC
 3.3.11 Programming
NC part programming consists of planning and documenting
the sequence of processing steps to be performed by an NC
machine
Part programming can be accomplished using a variety of
procedures ranging from highly manual to highly automated
methods: (1) manual part programming, (2) computer-assisted
part programming, (3) CAD/CAM part programming, and (4)
manual data input
3.3 CNC
a. Manual part programming
The programmer prepares the NC code using a low-
level machine language which is based on binary numbers
The NC coding system must also provide for
alphabetical characters and other symbols
A word specifies a detail about the operation, such as x-
position, y-position, feed rate, or spindle speed
A block is one complete NC instruction which specifies
the destination for the move, the speed and feed of the
cutting operation, and other commands that determine
explicitly what the machine tool will do
3.3 CNC

N: sequence number prefix

X, Y: x- and y- axes
G-: preparatory words
M-: auxiliary functions
3.3 CNC
The words in a block are usually given in the following
order:
• sequence number (N-word)
• preparatory word (G-word)
• coordinates (X-, Y-, Z-words for linear axes, A-, B-, C-words for
rotational axes)
• feed rate (F-word)
• spindle speed (S-word)
• tool selection (T-word)
• miscellaneous command (M-word)
3.3 CNC
3.3 CNC
3.3 CNC
3.3 CNC
3.3 CNC
3.3 CNC
b. Computer-Assisted Part Programming
The program is written in English-like statements that are
subsequently converted to the low-level machine language
 The Part Programmer’s Job: defining the geometry of the
part and specifying the tool path and operation sequence
3.3 CNC

The point is defined by a symbol (P4), and its coordinates are

given in the order x, y, z (x=35 mm, y=90 mm, z=0)
For line:
L1=LINE/P1, P2
For circle:

The statements are taken from APT, stands for automatically

programmed tooling
3.3 CNC
 Computer Tasks in Computer-Assisted Part Programming:
Computer role: (1) input translation, (2) arithmetic and cutter
offset computations, (3) editing, and (4) post-processing. The
output of post-processing is a part program consisting of G-
codes, x-, y-, z- coordinates, S, F, M and other functions.
3.3 CNC
c. CAD/CAM: the NC part programming
Advantages of NC part programming using CAD/CAM include:
(1) the part program can be simulated off-line on the CAD/CAM
system to verify its accuracy; (2) the time and cost of the
machining operation can be determined by the CAD/CAM
system; (3) the most appropriate tooling can be automatically
selected for the operation; and (4) the CAD/CAM system can
automatically insert the optimum values for speeds and feeds for
the work material and operations
3.3 CNC
 CAD/CAM Part Geometry Definition:
The Objective of CAD/CAM is to integrate the design
engineering and manufacturing. When the same CAD/CAM
system is used to perform NC part programming, the
programmer can retrieve the part geometry model from the
CAD database and use that model to construct the
appropriate cutter path.
=> Eliminates one of the time-consuming steps in computer-
assisted part programming: geometry definition.
3.3 CNC
 CAD/CAM Tool Part Generation and Simulation:
• Tool path specifications for the various operations to be
performed such as select an appropriate cutting tool.
• Tool path definition: Individual statements in APT or other
part programming language are entered, and the
CAD/CAM system provides an immediate graphic display
of the action resulting from the command, thereby
validating the statement
3.3 CNC
d. Manual Data Input:
To have the machine operator perform the part programming
task at the machine tool. The operator manually enters the part
geometry data and motion commands directly into the MCU.
=> Due to the risk of programming errors as jobs become more
complicated, MDI is usually applied for relatively simple parts.
3.3 CNC
G41: Bù bán kính dao
3.3 CNC
G42: Bù bán kính dao
3.3 CNC
.
3.3 CNC
3.3 CNC
.
3.3 CNC
3.3 CNC
A machinable grade of aluminum is to be milled on a
CNC milling machine with a 25-mm diameter four-tooth
end mill. Cutting speed is 100 m/min and feed is 0.075
mm/tooth. To program the machine tool, convert these
values to (a) rev/min and (b) mm/min, respectively.
 Solution:
a) Spindle speed = 100,000/(pi*25) = 1273 rev/min
b) Feed rate = f(mm/tooth)*z(tooth/rev)*s(rev/min)
= 0.075*4*1273 = 382 (mm/min)
3.4 Robotics
3.4 Robotics
 Advantages of robots
 Robots can be substituted for humans in hazardous or
uncomfortable work environments.
 A robot performs its work cycle with a consistency and
repeatability that cannot be attained by humans.
 Robots can be reprogrammed..
 Robots are controlled by computers and can therefore be
connected to other computer systems to achieve
computer integrated manufacturing.
3.4 Robotics
3.4.1 Classification
3.4 Robotics
 3.4.1 Classification

3.4 Robotics
 3.4.2 Common Robot Configurations
Joints and Links
3.4 Robotics
3.4.2 Common Robot Configurations
 Joints and Links
3.4 Robotics
3.4.2 Common Robot Configurations
 Wrist Configurations:
 The robot’s wrist is used to establish the
orientation of the end effector.
 Robot wrists usually consist of two or three joints
that almost always consist of R and T type rotary
joints.
3.4 Robotics
 3.4.2 Common Robot Configurations
Wrist
3.4 Robotics
3.4.2 Common Robot Configurations
 Work Volume.
 The work volume (also known as work envelope) of the
manipulator is defined as the three-dimensional space
within which the robot can manipulate the end of its wrist.
3.4 Robotics
3.4.3 Robot Programming
There are three programming methods: (1) leadthrough
programming, (2) computer-like robot programming
languages, and (3) off-line programming
a. Leadthrough Programming
 Powered leadthrough: involves the use of a teach
pendant (handheld control box)
 Manual leadthrough: a special programming device
often substitutes for the actual robot during the teach
procedure
3.4 Robotics
3.4.3 Robot Programming
3.4 Robotics
3.4.3 Robot Programming
b. Robot Programming Languages
The use of textual programming languages became an
appropriate programming method as digital computers
took over the control function in robotics
MOVE P1
which commands the robot to move from its current position to
a position and orientation defined by the variable name P1
c. Simulation and Off-line Programming: Off-line
programming permits the robot program to be prepared
at a remote computer terminal and downloaded to the
robot controller for execution without interrupting
production
3.4 Robotics
3.4.4 Robot Accuracy and Repeatability
The characteristics are defined at the end of the wrist
and in the absence of any end effector attached to the
wrist
 Control resolution
 Accuracy
 Repeatability
3.4 Robotics
3.4.4 Robot Accuracy and Repeatability
3.4 Robotics
3.4.4 Robot Accuracy and Repeatability
3.5 PLCs
3.5 PLCs
 A programmable logic controller (PLC) can be defined
as a microcomputer-based controller
 Stored instructions in programmable memory to
implement
 Logic,
 Sequencing,
 Timing, counting,
 Arithmetic functions
 through digital or analog input/ output (I/O) modules, for
controlling machines and processes
3.5 PLCs
 Components of the PLC
3.5 PLCs
 Processor is the central processing unit (CPU) of the PLC. It
executes the various logic and sequence control functions by
operating on the PLC inputs to determine the appropriate
output signals.
 CPU is the memory unit, which contains the programs of logic,
sequencing, and I/O operations
 A power supply of 120 VAC is typically used to drive the PLC
(some PLCs operate on 240 VAC). The power supply converts
the 120 VAC into direct current (DC) voltages of {5 V}.
3.5 PLCs
 The input/output module provides the connections to the
industrial equipment or process that is to be controlled
Inputs to the controller are signals from limit switches,
push-buttons, sensors, and other on/off devices.
Outputs from the controller are on/off signals to
operate motors, valves, and other devices required to
actuate the process
3.5 PLCs
 PLC Operating Cycle
(1) input scan
(2) program scan
(4) communication
(5) diagnostic
(3) output scan
The time to perform the scan is called the scan
time
3.5 PLCs
 Simple example: what does the output Y0 look like?
3.5 PLCs
Programming the PLC
Ladder Logic Diagram
Function Block Diagrams
Sequential Function Charts
Instruction List
Structured Text
3.5 PLCs
3.5 PLCs
3.5 PLCs
3.5 PLCs
 What is a PAC:
Including PC features in their controller products to
distinguish them from conventional PLCs. Programmable
Automation Controllers (PAC), like a PLC, but it has
additional capabilities such as analog control, data
processing, advanced mathematical functions, networks
connectivity, and data integration
How are they programmed? Ladder, C, or C++?
Thank You For Your Listening