Automation and Robotic Module 2
Automation and Robotic Module 2
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SYSTEM CONFIGURATIONS.
Although Figure 2.1 shows the flow of work to be in a straight line, the work flow can
actually take several different forms:
(1) in-line,
(2) segmented in-line, and
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(3) rotary.
The in-line configuration consists of a sequence of stations in a straight line
arrangement, as in Figure 2.1.
This configuration is common for machining big workpieces, such as automotive
engine blocks, engine heads, and transmission cases. Because these parts require a large
number of operations, a production line with many stations is needed.
The in-line configuration can accommodate a large number of stations. In-line systems
can also be designed with integrated storage buffers along the flow path.
The segmented in-line configuration consists of two or more straight-line transfer
sections, where the segments are usually perpendicular to each other.
Figure 2.2 shows several possible layouts of the segmented in-line category.
Figure 2.2 Several possible layouts of the segmented in-line configuration of an automated
production line: (a) L-shaped, (b) U-shaped, and (c) rectangular. Key: Proc = processing
operation, Aut = automated workstation, Wash = work carrier washing station.
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There are a number of reasons for designing a production line in these configurations
rather than in a pure straight line:
(1) available floor space may limit the length of the line,
(2) a workpiece in a segmented in-line configuration can be reoriented to
present different surfaces for machining, and
(3) the rectangular layout provides for swift return of work-holding fixtures to
the frontof the line for reuse.
Figure 2.3 shows two transfer lines that perform metal machining operations on
automotive castings.
The first line, on the left-hand side, is a segmented in-line configuration in the shape of
a rectangle. Pallet fixtures are used in this line to position the starting castings at the
workstations for machining. It is a palletized transfer line.
The second line, on the right side, is a conventional in-line configuration. When
processing on the first line is completed, the parts are manually transferred to the second
line, where they are reoriented to present different surfaces for machining. In this line
the parts are moved individually by the transfer mechanism, using no pallet fixtures. It
is a free transfer line.
Figure 2.3 Two machining transfer lines. On the left is a segmented in-line configuration that
uses pallet fixtures to locate the work parts. The return loop brings the pallets back to the
front of the line. On the right, the second transfer line is an in-line configuration. The manual
station between the lines is used to reorient the parts, represented as ovals. Pallet fixtures are
represented as rectangles.
In the rotary configuration, the work parts are attached to fixtures around the
periphery of a circular worktable, and the table is indexed (rotated in fixed angular
amounts) to present the parts to workstations for processing.
A typical arrangement is illustrated in Figure 2.4. The worktable is often referred to as
a dial, and the equipment is called a dial-indexing machine. Although the rotary
configuration does not seem to belong to the class of production systems called
“lines,” its operation is nevertheless very similar.
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By comparison with the in-line and segmented in-line configurations, rotary indexing
systems are commonly limited to smaller work parts and fewer workstations, and they
cannot readily accommodate buffer storage capacity.
On the positive side, the rotary system usually involves a less expensive piece of
equipment and typically requires less floor space.
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The forward motion of the parts is stopped at each station using pop-up pins or other
stopping mechanisms.
Figure 2.5 Side view of chain or steel belt driven conveyor (“overand- under” type)
for linear work part transfer by using work carriers.
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Cart-on-track conveyors also provide asynchronous parts movement and are designed
to position their carts within about ±0.12 mm (±0.005 in ), which is adequate for
many processing situations.
Many machining type transfer lines utilize walking-beam transfer systems, in which
the parts are synchronously lifted up from their respective stations by a transfer beam
and moved one position ahead, to the next station.
The transfer beam lowers the parts into nests that position them for processing at their
stations. The beam then retracts to make ready for the next transfer cycle. The action
sequence is depicted in Figure 2.6.
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CONTROL FUNCTIONS.
Three basic control functions can be distinguished in the operation of an automated
production line:
(1) sequence control,
(2) safety monitoring, and
(3) quality control.
The purpose of sequence control is to coordinate the sequence of actions of the
transport system and associated workstations.
The various activities of the production line must be carried out with split-second
timing and accuracy.
On a transfer line, for example, theparts must be released from their current
workstations, transported, located, and clamped into position at their respective next
stations.
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Then the work heads must be actuated to begin their feed cycles, and so on. The
sequence control function in automated production line operation includes both logic
control and sequence control.
The safety monitoring function ensures that the production line does not operate inan
unsafe manner.
Safety applies to both the human workers in the area and the equipment itself.
Additional sensors must be incorporated into the line beyond those required for
sequence control, in order to complete the safety feedback loop and avoid hazardous
operation.
For example, interlocks must be installed to prevent the equipment from operating
when workers are performing maintenance or other duties on the line.
In the case of machining transfer lines, cutting tools must be monitored for breakage
and/or excessive wear to prevent feeding a defective cutter into the work.
In the quality control function, certain quality attributes of the work parts are
monitored.
The purpose is to detect and possibly reject defective work units produced on the line.
The inspection devices required to accomplish quality control are sometimes
incorporated into existing processing stations.
In other cases, separate inspection stations are included in the line for the sole purpose
of checking the desired quality characteristic.
LINE CONTROLLERS.
Programmable logic controllers (PLCs) are the conventional controllers used on
automated production lines today.
Personal computers (PCs) equipped with control software and designed for the factory
environment are also widely used.
Computer control offers the following benefits:
Opportunity to improve and upgrade the control software, such as adding
specific control functions not anticipated in the original system design
Recording data on process performance, equipment reliability, and product
quality (in some industries product quality records must be maintained for
legal reasons)
Diagnostic routines to expedite maintenance and repair when line breakdowns
occur and to reduce the duration of downtime incidents
Generation of preventive maintenance schedules to reduce the frequency of
downtime occurrences
A PC provides a more convenient interface than a PLC between the operator
and the automated line.
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The trunnion machine gets its name from a vertically oriented worktable, or trunnion,
to which are attached work holders to fixture the parts for machining.
Since the trunnion indexes around a horizontal axis, this provides the opportunity to
perform machining operations on opposite sides of the work part. Additional work
heads can be located around the periphery of the trunnion to increase the number of
machining directions.
Trunnion machines are more suitable for smaller work parts than the other rotary
machines discussed here
Figure 2.10 Standard feed units used with in-line or rotary transfer machines:
(a) horizontal feed drive unit, (b) angular feed drive unit, and (c) vertical column unit.
The controls for the system are either designed by the machine builder or sublet as a
separate contract to a controls specialist.
Transfer lines and indexing machines constructed using this building-block approach
are sometimes referred to as unitized production lines.
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REFERENCES:
2nd
Computer Based Industrial
4 Krishna Kant EEE-PHI edition,2010
Control
Tiess Chiu
An Introduction to Automated Chang &
5 Richard A.
Process Planning System
Wysk.
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