Basics of Mechanical Engineering (B.M.

E)
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Br o w n H i l l C o l l e g e o f E n g g . & Tech.

UNIT - 7 # Manufacturing System (MS) and Numerical Control (NC)

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Introduction to Manufacturing System Manufacturing system to be a collection of integrated equipment and human resources, whose function is to perform one or more processing and/or assembly operations on a starting raw material, part, or set of parts, the integrated equipment includes production machines and tools, material handling and work positioning devices, and computer systems. Human resources are required either full time or periodically to keep the system running. The manufacturing system is where the value-added work is accomplished on the part or product, the position of the manufacturing system in the larger production system. Examples of manufacturing systems include: a) b) c) d) e) One worker tending one machine, which operates on semi-automatic cycle A cluster of semi-automatic machines, attended by one worker A fully automated assembly machine, periodically attended by a human worker A group of automated machines working on automatic cycles to produce a family of similar parts A team of workers performing assembly operations on a production line

Automated manufacturing System Automated manufacturing systems operate in the factory on the physical product. They perform operations such as processing, assembly, inspection, or material handling, in some cases accomplishing more than one of these operations in the same system. They are called automated because they perform their operations with a reduced level of human participation compared with the corresponding manual process. In some highly automated systems, there is virtually no human participation. Examples of automated manufacturing systems include: a) Automated machine tools that process parts b) Transfer lines that perform a series of machining operations c) Automated assembly systems d) Manufacturing systems that use industrial robots to perform processing or assembly operations e) Automatic material handling and storage systems to integrate manufacturing operations f) Automatic inspection systems for quality control Automated Manufacturing Systems can be classified into three basic types: 1. Fixed automation 2. Programmable automation, and 3. Flexible automation 1. Fixed Automation: Fixed automation is a system in which the sequence of processing (or Assembly) operation is fixed by the equipment configuration. Each of the operation in the sequence is usually simple, involving perhaps a plain linear or rotational motion or an uncomplicated combination of the two; for example, the feeding of a rotating spindle. It is the integration and coordination of many such

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Basics of Mechanical Engineering Br o w n H i l l C o l l e g e o f E n g g . & (B.M.E) Tech. operations into one piece of equipment that makes the system complex. Typical features of fixed automation are: 1. High initial investment for custom-engineered equipment 2. High production rates 3. Relatively inflexible in accommodating product variety 2. Programmable Automation: In this the production equipment is designed with the capability to change the sequence of operation to accommodate different product configurations. The operation sequence is controlled by a program, which is a set of instructions coded so that they can be read and interpreted by the system. New programs can be prepared and entered into the equipment to produce new products. Some of the features that characterize programmable automation include: 1. 2. 3. 4. High investment in general purpose equipment Lower production rates than fixed automation Flexibility to deal with variations and changes in product configuration Most suitable for batch production

Programmable automated production systems are used in low- and medium-volume production. Examples of programmable automation include numerically controlled (NC) machine tool, industrial robots, and programmable logic controllers. 3. Flexible Automation: It is an extension of programmable automation. A flexible automated system is capable of producing a variety of products with virtually no time lost for changeover from on product style to the next. The feature of flexible automation as follow: 1. 2. 3. 4. High investment for a custom-engineered system Continuous production of variable mixtures of products Medium production rates Flexibility to deal with product design variations

Components of a Manufacturing System A manufacturing system consists of several components. In a given system, these components usually include: Production machines plus tools, fixtures, and other related hardware Material handling system Computer systems to coordinate and/or control the above components Human workers Classification of Manufacturing Systems We explore the variety of manufacturing system types and develop a classification scheme based on the factors that define and distinguish the different types. The factors are: Types of operations performed Notes Also Avail. On sachinchaturvedi.wordpress.com 2

Basics of Mechanical Engineering (B.M.E) Number of workstations and system layout Level of automation Part or product variety The four factors in our manufacturing systems classified S. No. Factor 1. 2. 3. Types of operations performed Alternatives

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Processing operations versus assembly operations Type of processing or assembly operation

Number of workstations and One station versus more than one station For more than one station, system layout Level of automation variable routing versus fixed routing Manual or semi-automated workstations that require full-time operator attention versus fully automated that require only periodic worker attention

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Part or product variety

All work units identical versus variations in work units that require differences in processing

EFFECTIVE ENVIRONMENT FOR MANUFACTURING SYSTEM

Flexibility in Manufacturing Systems Flexibility is the term used for the attribute that allows a mixed model manufacturing system to cope with a certain level of variation in part or product style without interruptions in production for changeovers between models. Flexibility is generally a desirable feature of a manufacturing system. Systems that possess it are called flexible manufacturing systems, or flexible assembly systems, or similar names. They can produce different part styles or can readily adapt to new part styles when the previous ones become obsolete. To be flexible, a manufacturing system must possess the following capabilities: 1. Identification of the different work units: Different operations are required on different part or product styles. The manufacturing system must identify the work unit to perform the correct operation. In a manually operated or semi-automatic system, this task is usually an easy one for the worker(s). In an automated system, some means of automatic work unit identification must be engineered. 2. Quick changeover of operating instructions: The instructions, or part program in the case of computer-controlled production machines, must correspond to the correct operation for the given part. In the case of a manually operated system, this generally means workers who (1) are skilled in the variety of operations needed to process or assemble the different work unit styles, and (2) know which operations to perform on each work unit style. In semi-automatic and fully automated systems, it means that the required part programs are readily available to the control unit.

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Basics of Mechanical Engineering Br o w n H i l l C o l l e g e o f E n g g . & (B.M.E) Tech. 3 . Quick changeover of physical setup: Flexibility in manufacturing means that the different work units are not produced in batches. For different work unit styles to be produced with no time lost between one unit and the next, the flexible manufacturing system must be capable of making any necessary changes in fixturing and tooling in a very short time. (The changeover time should correspond approximately to the time required to exchange the completed work unit for the next unit to be processed.) Reconfigurable Manufacturing Systems In an era when new product styles are being introduced with ever-shortening life cycles, the cost of designing, building, and installing a new manufacturing system every time a new part or product must be produced is becoming prohibitive, both in terms of time and money: One alternative is to reuse and reconfigure components of the original system in a new manufacturing system. In modern manufacturing engineering practice, even single model manufacturing systems are being built with features that enable them to be changed over to new product styles when this becomes necessary. These kinds of features include: 1. Ease of mobility: Machine tools and other production machines designed with a three point base that allows them be readily lifted and moved by a crane or forklift truck. The three-point base facilitates leveling of the machine after moving. 2. Modular design of system components: This permits hardware components from different machine builders to be connected together. 3. Open architecture in computer controls: This permits data interchange between software packages from different vendors. 4 . CNC workstations: Even though the production machines in the system are dedicated to one product, they are nevertheless computer numerical controlled to allow for upgrades in software, engineering changes in the part currently produced, and changeover of the equipment when the production run finally ends.
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Introduction to Numerical Control (NC) Numerical Control is a form of programmable automation in which the mechanical actions of a machine tool or other equipments are controlled by a programme containing coded alphanumeric data. The alphanumerical data represent relative positions between a work-head and a work-part as well as other instructions needed to operate the machine. The work-head is a cutting tool or other processing apparatus, and the work part is the object being processed. When the current job is completed, theprogram of instructions can be changed to process a new job. The capability to change the program makes NC suitable for low and medium production. It is much easier to write new programs than to make major alterations of the processing equipment. Numerical control can be applied to a wide variety of processes. The applications divide into two categories: Notes Also Avail. On sachinchaturvedi.wordpress.com 4

Basics of Mechanical Engineering (B.M.E)

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Machine tool applications, such as drilling, milling, turning, and other metal working Non-machine tool applications, such as assembly, drafting, and inspection The common operating feature of NC in all of these applications is control of the work-head movement relative to the work-part. The first NC machine was developed in 1952. (The development of NC owes much to the United States Air Force and the early aerospace industry. The first development work in the area of NC is attributed to John Parsons and his associate Frank Stulen at Parsons Corporation in Traverse City, Michigan.) F u n d a m e n t a l s o f N u m e r i c a l C o n t r o l ( N C) T e c h n o l o g y To introduce NC technology, we first define the basic components of an NC system. This is followed by a description of NC coordinate systems in common use and types of motion controls used in NC. B a s i c C o m p o n e n t s o f a n N C S y s t e m : An NC system consists of three basic components: 1. A program of instructions 2. A machine control unit, and 3. Processing equipment The general relationship among the three components is illustrated in below Figure

Program

Machine Control Unit

Processing Equipment A program of instructions: The program of instructions is the detailed step-by-step commands that direct the actions of the processing equipment. In machine tool applications, the program of instructions is called a part program, and the person who prepares the program is called a part programmer. In these applications, the individual commands refer to positions of a cutting tool relative to the worktable on which the work-part is fixtured. Additional instructions are usually included, such as spindle speed, feed rate, cutting tool selection, and other functions. A machine control unit: In modern NC technology, the machine control unit (MCU) consists of a microcomputer and related control hardware that stores the program of instructions and executes it by converting each command into mechanical actions of the processing equipment, one command at a Notes Also Avail. On sachinchaturvedi.wordpress.com 5

time. The related hardware of the MCU includes components to interface with the processing equipment and feedback control elements. The MCU also includes one or more reading devices for entering part programs into memory. The type of readers depends on the storage media' used for part programs in the machine shop (e.g., punched tape reader, magnetic tape reader, floppy disk drive). The MCU also includes control system software, calculation algorithms, and translation software to convert the NC part program into a usable format for the MCU Because the MCU is a computer, the term computer numerical control (CNC) is used to distinguish this type of NC from its technological predecessors that were based entirely on hard-wired electronics. Today, virtually all new MCUs are based on computer technology. Processing equipment: It performs useful work; it accomplishes the processing steps to transform the starting work-piece into a completed part. Its operation is directed by the MCU, which in turn is driven by instructions contained in the part program. In the most common example of NC, machining, the processing equipment consists of the worktable and spindle as well as the motors and controls to drive them Applications of Numerical Cont r o l ( N C) The operating principle of NC has many applications. There are many industrial operations in which the position of a work-head must be controlled relative to a part or product being processed. The applications divide into two categories: 1. Machine tool applications 2. Non-machine tool applications Machine tool applications are those usually associated with the metalworking industry. Non-machine tool applications comprise a diverse group of operations in other industries. It should be noted that the applications are not always identified by the name "numerical control"; this term is used principally in the machine tool industry.

Numerical Control (NC) Application and Char acteristics NC technology appropriate for low to medium production of medium to high varietyproduct: 1. B a t c h P r o d u c t ion 2. Repeat Or der 3. C o m p l e x p a r t G e o m etry 4. M u c h M e t a l n e e d t o b e r e m o v e d f r o m t h e w ork-part

5. M a n y S e p a r a t e M a c h i n i n g o p e r a t i o n s o n the part 6. The part is expen sive 7. E l e c t r i c a l W i r e W r a p M a chine 8. Drafting Mach ines

9. C o o r d i n a t e m e a s u r i n g m a c h i n e 10. T a p e l a yi n g m a c h i n e s f o r p o l ym e r c o m p o s i t e s 11. F i l a m e n t w i n d i n g m a c h i n e s f o r p o l ym e r c o m p o s i t e s Advantage of Numerical Contr ol (NC) 1. Nonproductive time is reduced 2. Greater accuracy and repeatability 3. Lower scrap rates 4. Inspection requirements are reduced 5. More-complex part geometries are possible 6. Engineering changes can be accommodated more gracefully 7. Simpler fixtures are needed 8. Shorter manufacture lead time 9. Reduced parts inventory 10. Less floor-space required 11. Operator skill-level requirements are reduced D i s a d v a n t a g e o f N u m e r i c a l C o n t r ol ( N C ) 1. Higher investment cost 2. Higher maintenance effort 3. Part programming. 4. Higher utilization of NC equipment Difference Between NC and CNC S. No. 1. 2. 3. 4. 5. NC NC Stands for Numerical Control In this NC stores only one part Here only one form of program input In NC no program editing at the time of machine tool Complex part geometry CNC CNC Stands for Computer Numerical Control Storage of more than one part Various form of program input Program editing at the time of machine tool Tool life monitoring

Basics of Mechanical Engineering (B.M.E) 6. Repeat order of programming 7. 8. 9. 10. 11. 12. In NC there is no Communication interference Here no On-line diagnostics for system breakdown Much metal needs to be removed from the work piece In this no Programming diagnostics There is no virtual method of diagnostics It is use for single part or product production

Br o w n H i l l C o l l e g e o f E n g g . & Tech. Fixed cycle and programming subroutine Communication interference On-line diagnostics for system breakdown Central start-up diagnostics Programming diagnostics Preventive maintenance notice Diagnostics for individual components

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