Manufacturing 1 Exam 1
ladder symbol for Normally closed contacts
-switch -relay
ladder symbol for Normally open contacts
-switch -relay -other -ON/OFF -devices
Qualities of metals
- lustrous (shiny) - relatively hard - high density (are heavy for their size) - high tensile strength (resist being stretched) - high melting and boiling points - good conductors of heat and electricity
Types of composites
- metal matrix composites - ceramic matrix composites - polymer matrix composites
Cellular Manufacturing
Cellular a hybrid system that combines job shop with continuous flow line
Methods/Process Engineering
attempts to design the optimal processes to produce value with processes involving humans and machines.
Collaborative robots
-a robot that can be used in a robot/human shared space -purpose designed robots who can work in direct cooperation with a human within a defined workspace
Fatigue Failure
failure due to cyclic loading
Robot Singularity
for a standard six joint manipulator a kinematic singularity is a point in the workspace where the robot loses its ability to move the end effector in some direction no matter how it moves its joints. It typically occurs when two of the robot's joints line up, making them redundant
Stress
force per unit area
Brittle
hard but liable to break or shatter easily.
What makes up property enhancing processing?
heat treatment
Boolean Algebra: AND operators
if X and Y = 1 then x=1 & y = 1
Boolean Algebra: OR operators
if X or Y = 0 then x = 0 & y = 0, if either x = 1 or y = 1, then X or Y = 1
What kind of relationship does product variety and product quantity have?
inverse
AND (PLC Programming)
logical AND referenced with the previously entered component. This is interpreted as a series circuit relative to the previously entered component
NOT (PLC Programming)
logical NOT or inverse of the previously entered component
OR (PLC Programming)
logical OR referenced with the previously entered component. This is inpretreted as a parallel circuit relative to the previously entered component
Optimal
lowest cost, highest quality, most quality
Produce value
manufacture a product or service a customer
Composites
nonhomogeneous mixtures of the other three basic types
What does NC mean when referring to single line diagrams?
normally closed (closed circuit = creating a path for the current)
After reach hazard
occurs when a worker reaches into the point of operation on a power press after the downward motion of the press ram has been initiated
Manufacturing
the application of physical and chemical processes to alter the geometry properties and/or appearance of a given starting material to make parts or products; manufacturing also includes assembly of multiple parts to make products
Cycle time
the average time between the start of production of one unit and the start of production of the next unit of production
End Effector
the device at the end of a robotic arm designed to interact within the enviornment
Boolean Algebra: NOT operators
the negative, if x = 0, then not x = 1
Flow measurement
the quantification of bulk fluid movement
Takt time
the rate at which a finished product needs to be completed in order to meet customer demand. (synchronize the rate of production with the rate of demand)
Tension
the state of being stretched tight
Crystal lattice
the symmetrical three-dimensional arrangement of atoms inside a crystal.
Lead time
the time it takes for one unit to make its way through your operation from taking order to receiving payment. If the lead time is much higher than cycle time, it means you have a lot of units in your inventory
Plant Capacity
the total production quantity for a given time period - Units/day
Continuous control
the variables and parameters are continuous and analog
discrete control
these variables and parameters are discrete, mostly binary (0 or 1)
Takt Time equation
time (available seconds per working day)/volume (daily production requirement)
What does normal mean when referring to single line diagrams?
unactuated/unpowered state
Discrete Bimetallic Switch
uses a bimetallic strip to convert a temperature change into a mechanical displacement. The Switch consists of two strips of different metals which expand at different rates.
Manufacturing is a ________ __________ system.
value added
Ductility
when a material deforms under tensile stress
Servo Motor
rotary actuator that allows for precise control of angular position. It consists of a motor coupled to a sensor for position feedback (closed loop system)
Ultrasonic Sensor
sends ultrasonic waves from an emitter toward a sensing object, then receives the reflected waves with a detector. The sensor uses the resulting information to determine the presence of an object, or to measure the distance to the object (non-contact)
What does SPE stand for?
sensitive protective equipment
Rotary encoders
sensors that detect position and speed by converting rotational mechanical displacements into electrical signals and processing those signals
AND operator is a __________ circuit.
series
Input (PLCs)
signal from sensors
output (PLCs)
signal to actuator
Adding _________ improves the strength of the aluminum.
sillicon
Within the metal working industry, _____ ________ consistently rank as one of the most dangerous types of process equipment.
stamping press
STR (PLC Programming)
store a new input and start a new rung of the ladder
Secondary Industries
take the outputs of the primary industries and covert them into consumer and capital goods (manufacturing)
What are Resistance Temperature Detectors (RTDs)
temperature sensors that contain a resistor that changes resistance value as its temperature changes
Manufacture is derived from what latin word? Meaning What
Manu Factus meaning made by hand
Ductile
(of a metal) able to be drawn out into a thin wire.
Types of joints:
- linear joint (type L joint) - orthogonal joint (Type O Joint) - rotational joint (Type R joint) - Twisting joint (Type T joint) - Revolving joint (type V joint)
What do robot integrators do?
"make the robot do something" - Garnett (who also said the stuff to make the things"
Manufacturing industries generated ________ in GPD ( ________ percent of total U.S. gross domestic product) in 2013.
$2.1 trillion, 12.5
Quality measures
- Continuous control: Consistency, solution concentration, absence of contaminants, specification conformance - Discrete control: dimensions, surface finish, appearance, absence of defects, product reliability
Sensors
- Continuous control: flow meters, thermocouples, pressure sensors - Discrete controls: limit switches, photoelectric sensors, strain gauges, piezoelectric sensors
Actuators
- Continuous control: valves, heaters, pumps - discrete control: switches, motors, pistons
Product output measures
- Continuous control: weights, liquid volumes, solid volumes - discrete controls: numbers of parts and products
What does Design Engineering Consist of?
- Definition of product need; marketing information - Conceptual design and evaluation; feasibility study - Design analysis; codes/standards review; physical and analytical models - Prototype production; testing and evaluation
Manufacturing consists of what three forms of engineering?
- Design Engineering - Methods/Process Engineering - Production Engineering
Types of Control
- Discrete Control (on-off control, feedback, bang-bang) - Open Loop (No feedback) - Closed Loop (Feedback)
Components of robot integrations:
- EOAT/fixturing (positioning) - guarding, gates, safety systems - interface to the outside equipment
Five levels of automation/control in manufacturing
- Enterprise level - plant level - cell or system level - machine level - device level
Types of End Effectors:
- Grippers - Tools
Industrial Voltage
- Hand Tool: 110/120 volts @ 60 Hz - Macine Voltage: 120/208 volts, 3 phase, 120/240 volts, 3 phase, 277/480 volts, 347/600 volts, up to 13,200 volts
High Production
- Layout - Production Line - Single Model Production Line (little or no specialization) - Mixed-model production line (customization by module change, batching/campaigning)
Medium Production
- Layout -- Job shop/cellular - Job Shop (Process Layout) - Specialized/customized/complex product - Setup/Changeover is a concern - Batch or Campaigning
Low Production Manufacturing
- Layout Specialized/customized/complex product (Job Shop) - Fixed Position Layout - Large products, Modules/Process Layout
Properties of Composites
- Light Weight - High Strength to Weight Ratio - Often very strong in tension - Fire resistant - Low Thermal Conductivity - High Cost/Low Cost
Types of Tool EOATs
- MIG gun - spot welder - spray gun - nut runner - compliant tools
Types of Gripper EOATs
- Magnets - Vacuum Cups
Types of Engineering Materials
- Metals - Ceramics - Polymers - Composites
Household Power
- Normal loads: 110/120 volts @ 60 Hz - Large loads: 220/240 volts @ 60 Hz
Robot safety Clauses
- OSHA general duty clause - OSHA technical manual (OTM): section IV: Chapter 4 - Industrial Robot System Safety - OSHA STD 01-12-002: Guidelines for robotics safety - ANSI-RIA R15.06: "American National standard for Industrial Robots and Robot Systems - Safety Requirements" - RIA TR R15.406 "Technical Report for Industrial Robots and Robot Systems - Safety Requirements"
Robot Programming
- Off-Line, simulation - Unpowered Lead through - Powered lead through
Typical Automation migration strategy
- Phase 1: Manual production with single independent workstations - Phase 2: automated production stations with manual handling between stations - Phase 3: automated integrated production with automated handling between stations
Elements of an Automated System
- Power: usually electricity - program of instructions: Sequences, process parakeets, or regulatory set-points - control system: Equipment/System to carry out the instructions
Types of Industry
- Primary - Secondary - tertiary
What does Production Engineering Consist of?
- Production - Inspection and quality insurance - Packaging; marketing and sales literature - Product
What does Methods/Process Engineering of?
- Production drawings; instruction manuals - Material specification; process and equipment selection; safety review - pilot production
Typical Control Signals
- Push Buttons, Instrument Power (120 VAC @ 60 hz, 24 VDC) - Control Signal: Digital Signal (5 volts, +/- 0.25 volts), Discret Signals (120 VAC or 24 VDC), Analog Signals (0 -5 mV, 4-24 mA, 3-15psig)
3 Processes that make up processing operations
- Shaping processes - Property enhancing processes - surface processing operations
Pneumatic components: Cylinders
- Sizing based on amount of force required & the length of the stroke - F = P*A where F = force P = Air pressure and A = area (Determine the area of the piston, inside the cylinder)
Schematic of PLC
- Start scan - internal checks - scan inputs -execute program logic - update outputs
Continous Temperature Sensor (2 different ones)
- Thermocouple - Resistance Temperature Detectors (RTDs)
Types of Plastic
- Thermoplastic - Thermoset
Dual Palm Buttons
- Two-hand control can be used as a safeguarding device in the single-stroke mode of operation on part-revolution clutch presses and hydraulic press and press brakes - Requiring application of both of the operator's hands to machine operating controls and locating such controls at such a safety distance from the point of operation that the slide completes the downward travel or stops before the operator can reach into the point of operation with his hands
Interlock
- a feature that makes the state of two mechanisms or functions mutually dependent - used to prevent a machine from harming itself by preventing one element from changing state due to the state of another element and vice versa
2 types of discrete process controls
- logic control - sequence conrol
Measurement (Sensors) Devices
- accelerometer - Ammeter - Bimetallic Switch - Dynamometer - Float Transducer - Fluid Flow Sensor/Switch - Limit/Switch - Manometer - Optical Encoder - Ohmmeter - Photo Switch - Photometer - Proximity Sensor - Strain Gauge - Ultrasonic - RTD - Thermocouple
Closed Loop advantages (feedback driven)
- accurate - minimizes variability
Types of robots
- cartesian coordinate robot (gantry) - SCARA configuration - polar robot - delta robot - articulated arm robot (jointed-arm robot) -rectangular coordinate robot - cylindrical coordinate robot - spherical coordinate robot -Gantry Robot
what makes up surface processing operations?
- cleaning and surface treatments - coating and deposition processes
Control Valve
- continuous control - can be electric or hydraulic, but usually pneumatic - requires transducer (I/P)
How do we pick materials?
- cost of material/cost of processing - properties - yield strength, weight, hardness, melting point, corrosion resistance - processing - difficulty of processing , previous experience, available equipment - performance - life, durability, meeting product requirements
Closed loop disadvantages
- costly - difficult design - can be unstable
When not to automate:
- costs outweigh benefits - loss of in-process inspection (process must be well controlled) - limits of technology ( too complicated) - too complicated (limits of technology) - Labor: inadequate technical support (engineers/maintenance) - lack of project management skill
ceramics (types of)
- crystalline ceramics - glasses
Adding Silicon to the alloy does this (4 things).
- decreases machinability - improves metal flow - improves wear resistance - increases strength
Humans excel in:
- detection of certain forms of very low energy - sensitivity to an extremely wide variety of stimuli - perceiving patterns and making generalization about them - ability to store large amounts of information for long periods -- and recalling relevant facts at appropriate moments - ability to exercise judgement where events cannot be completely defined - improvising and adopting flexible procedures - ability to react to unexpected low-probability events -applying originality ini solving problems - ability to profit from experience and alert course of action - ability to perform fine manipulation, especially where misalignment appears unexpected - ability to continue to perform when overloaded - ability to reason inductively
Typical uses of robots
- die casting - forging - painting - welding - material handling (pick and place, palletizing)
Hydraulic Components
- electric motor directly coupled to the hydraulic pumps (electric energy is converted into hydraulic energy) - pumps force hydraulic oil through the piping into the hydraulic cylinders under high pressure - the hydraulic fluid flow is controlled by solenoid valves
Types of metals
- ferrous metals - nonferrous metals
Ways to measure flow?
- gear meters - turbine meters - pressure based - variable-area flow meters - ultrasonic - mass flow
Ceramic materials
- glasses (optical, composite reinforce, containers/household) - clay products (whiteware, structural) - refractories (bricks for high T furnaces) - abrasives ( sandpaper, cutting, polishing) - cements (composites, structural) - advanced ceramics ( engine rotors valves bearings, sensors)
Open loop controls disadvantages
- inaccurate - affect by system noise and performance
Adding Copper to the Alloy to the does this (3 things)
- increases hardness - increases strength - improves machinability
what are the 4 basic types of proximity switches?
- infrared - acoustic - capacitive - inductive
Machines excel in:
- monitoring performing routine, repetitive, or very precise operations - responding very quickly to control signals - storing and recalling large amount of information short time-periods - performing complex and rapid computations with high accuracy - Sensitivity to stimuli beyond the range of human sensitivity - doing many things at one time - exerting large amounts of force smoothly and precisely - insensitivity to extraneous factors - ability to repeat operations very rapidly, continuously, and precisely the same way over a long period of time - operating in environment which are hostile and beyond human tolerance - deductive process
Ceramic properties
- non-conductive - brittle (Fracturs) - Hard - Strong in compression - weak in shear and tension - high melting point
2 processes that make up assembly operations
- permanent joining processes - mechanical fastening
Types of safeguarding for robots:
- presence-sensing safeguarding devices - fixed barriers - interlocked barrier guards (gates for teaching)
Alloy
- pure aluminum is too ductile to use to manufacture engine blocks or heads - It is too soft to be machined - Typical Aluminum Alloy uses a three component aluminum alloy
Ways to program robots:
- robot controls (PLC, servo controls, input/output) - programming language (vendor specific, similar to CNC)
SPE used in robotics systems includes, but is not limited to:
- safety mat systems - safety light curtains - safety beams - safety laser scanners - safety vision systems
Open loop controls Advantages (No feedback)
- simple design - little maintenance
What makes up the shaping process
- solidification processes - particular processing -deformation process - material removal
When do we use a Robot?
- the three D's: dull, dirty, dangerous - The three H's: hot, heavy, hazardous
Working Envelope
- the work area created when a robot moves its end effector forward, backward, up and down - distances are determined by the length of a robot's arm and the design of its axes. Each axis contributes its own range of motion
Types of polymers
- thermoplastics - thermosets - elastomers
What makes up mechanical fastening
- threaded fasteners - permanent fastening methods
Types of photoswitches
- through-beam - retro-reflective - diffuse-reflective
What makes up permanent joining processing?
- welding - Brazing and soldering - adhesie bonding
Power and force limiting with Cobots:
- where incidental contact initiated by robot is limited in energy to not cause operator harm - forces robot can exert are limited - robot system design eliminates pinch-points, sharp edges, etc - robot compiles and reacts when contact is made
Things to consider when selecting a robot?
- work envelope - load carrying capacity - reach - speed of motion - repeatability - reliability - degrees of freedom
Effects of Automation
- worker safety -reduce labor costs - reduce manufacturing lead time - improve quality - increase labor productivity
The incidence rates for lost-time injuries in metal fabrication in 2015 were _____________ cases per 10,000 compared to U.S. private industry as a whole at 105.2 cases per 10,000 metal workers; amputations in the metal fabrication were _________ per 10,000 metal workers verses 0.6 per 10,000 workers in private industry.
-133.1 -0.6
Process time constraints
-Continuous control: seconds, minutes, hours - Discrete control: less than a second
Variables and parameters
-Continuous control: temperature, volume flow, rate, pressure - Discrete control: position, velocity, acceleration, force
On average, workers in manufacturing made ________ percent more than similar workers in the rest of the economy in 2012-2013.
10.9
In 2013 how many people were worked in manufacturing
12 million (or 8.8% of total U.S. Employment)
In a typical cost breakdown in Manufacturing what percent does Direct Labor take up?
15%
How fast does the robot move when using the teach pendant in teach mode?
250 mm/sec
In a typical cost breakdown in Manufacturing what percent does Indirect Labor take up?
30%
In a typical cost breakdown in manufacturing what percent does Design take up?
5%
In a typical cost breakdown in manufacturing what percent does Materials take up?
50%
Approximately ______ of ISY Graduates will work in manufacturing.
60%
What does ATC stand for:
Automatic Tool change
General Duty Clause
Each employer shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely o cause death or serious physical harm to his employees
What does EOAT stand for?
End of Arm Tooling
What is a robot?
Industrial robot as dined by ISO is an automatically controlled reprogrammable, multipurpose, manipulator programmable in three or more axes, which may be either fixed in place or mobile for use in industrial automation applications
Closed Loop Process
Input ->Process->Output I I I_______________I Adjustment
Open Loop Process
Input ->Process->Output ^ I Adjustment
What does NO mean when referring to single line diagrams
Normally open (open = open circuit)
Limit Switches
Operated by the motion of a machine part or presence of an object (Discrete position indication, contact closure)
OUT (PLC Programming)
Output component of the rung of the ladder diagram
Formula for power
P = I x K where I = Current (amps) E = voltage
OR operator is a _________ circuit.
Parallel
What is the plant Capacity?
Plant Capacity (annual) = Daily Capacity x (Working Days)
the two operations that make up manufacturing processes
Processing operations and assembly operations
PLC
Programmable logic controller
What does SCARA stand for?
Selectively compliant arm for robotic assembly
Compression
The action of compressing or being compressed
TMR (PLC Programming)
Timer component. Requires one input signal to initiate timing sequence. Output is delayed relative to input by a duration specified by the programmer in seconds. Resisting the timer is accomplished by interrupting (stopping) the input signal
A robot can only perform within the confines of its ___________ _____________.
Work Envelope
Stepper Motor
a DC motor that divides a full rotation into a number of equal steps. The motor's position can then be commended to move and hold at one of these steps without any position sensor for feedback (an open-loop controller)
ladder symbol for timer
a box that says TMR with the time below
Boolean algebra
a branch of algebra in which the values of the variables are 1 (true) or 0 (false)
polymers
a large molecule or macromolecule, composed of many repeated subunits (usually an organic compound (C, H) (Monomer -> polymer)
stress concentrator
a location in an object where stress is concentrated
Thermoset
a plastic that is irreversibly cured when heated
Thermoplastic
a polymer that becomes moldable above a specific temp and solidifies upon cooling
Photoswitch (or photo-electric switch)
a sensor that detects the presence of an object by changes in light (non-contact)
logic control system
a switching system whose output at any moment is determined exclusively but the value of its inputs (No memory, no consideration of previous inputs)
Logic controller
a switching system whose output is determined exclusively by the current input
Truth Tables
a tabulation of all the combination of input values to the corresponding logic output values
Strain
amount of deformation in the direction of the applied force divided by the initial length of the material
Proximity Switch
an electric switch operated by the presence of an object (Non-contact)
Solenoid valve
an electromechanical operated valve (discrete control)
Metals
an element/compound that exists as a crystalline substance and which reacts via metallic bonds
Programmable logic control
an industrial computer control system that continuously monitors the state of input devices and makes decisions based upon a custom program to control the state of output devices
Ceramics
an inorganic, non-matallic, often crystalline oxide, nitride or carbide material
ladder symbol for counter
box that says CTR
Humans and Machines
by selecting the sequences, tools, equipment, systems, facilities
ladder symbol for Output loads
circle - motor - lamp - solenoid - alarm
Manufacturing employs a higher share of workers without a ________ ________ than the economy overall
college degree
logic control
concerned with event driven changes to the system
sequence control
concerned with time-driven changes to the system
Tertiary Industries
constitute the service sector of the economy
CTR (PLC Programming)
counter component. Requires 2 inputs: one is the incoming pulse train that is counted by the CTR component, the other is the reset signal indicating a restart of the counting procedure.
Primary Industry
cultivate and exploit natural resources, such as agriculture and mining
What overlaps between Design Engineering and Methods/process Engineering?
prototype production; testing and evaluation
Hardness
resistance to permanent identitation
Personnel should be safetguarded from hazards associate with the ____________ ______________ (space) through the use of one or more safeguarding devices.
restricted envelope
Robot is based on the Czech word _________ for ________ ___________
robotoa, forced worker