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