Lecture 2 Year 2

1
Lecture 2 - Year 2

• Machining Centre

2
Lecture 2 - What we will cover

• Summary of Lecture 1 Automation Areas
• Application Areas for Programmable Automation
• Customer Demands on Suppliers
• Automation of the Cutting Process

3
Lecture 1 Automation Areas

• Surgery
• Aerospace
• Pharmaceutical
• Automotive

4
Brief History
1945 - Automation coined by Ford employee.
1962
1954
Present
1980s
1990s
1910
1913
1920 - 1940
1957
1970
1976

• Present
• Huge highly competitive industry. Drive for
  higher production rates, low cost high
  quality. Typically 200-300,000 cars per year per
  line.
• Industry uses over 50 of all industrial robots
  globally 60 of these for spot welding.

• 1910.
• Cars built in small workshops
• Skilled workers.
• No automation.
• High cost. Low volume. Up to 10 days per car.

• 1913.
• Mass production techniques introduced.
• Large moving assembly line.
• One task per worker
• Standardised parts.

• 1980-1990s
• Sensor based machines
• Integrated manufacturing systems
• Unattended cells
• AI

• 1954
• First highly automated factories
• Ford reduces work force from 117 to 40

• 1962
• First industrial robot saw service
• Stacking metal from die-casting m/c

• 1970s
• Microprocessors
• Mini-computer control industrial robots

• 1957
• First comercially available NC machines

• 1976
• First spray painting robots

• 1970
• First integrated manufacturing system
• First spot welding of auto bodies.

• 1920- 40
• Automatic transfer machines integrated into
  assembly lines.

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Application Areas forProgrammable Automation

• The type of process.
• Application areas.
• Process needs.

6
Customer Demands

• Highest quality and precision.
• Product variety.
• Product design changes.
• Batch sizes.
• Delivery.
• Prices.
• Market change.

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Extremes - Traditional Processing

• Transfer Lines
• Job Shop

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Objective of Automation

• Maximise.
• Utilise.
• Machine tool earns money when cutting.
• Automation can aid in reducing down-time.

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Machine Down time

• Technical Reasons.
• Organisational Time Losses.

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How can Automation Help

• Automation of the cutting process.
• Automation of set-up.
• Organisational Losses.

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Automation of theCutting Process

• CNC applications.
• Multi-spindle operations.
• Multi-axis operations.

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3 Major Axis - Machining CentreSOURCE -
PROFESSOR, D J WILLIAMS - MANUFACTURING SYSTEMS
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Automation for Preparation

• Load / Unload.
• Tool exchanges.
• Piecepart exchange.

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Tool Changer Tool Magazine SOURCE -
PROFESSOR, D J WILLIAMS - MANUFACTURING SYSTEMS
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Pallet Changer SOURCE - PROFESSOR, D J WILLIAMS
- MANUFACTURING SYSTEMS
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Loop Pallet Changer
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Features - NC Machining

• Components with a high level of accuracy.
• Programmable.
• Can be programmed off-line.
• Expected to run unmanned for extended periods.

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Organisational Losses

• Flexible production equipment.
• Integration of stores, processes transport
  functions.

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Levels of Automation
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Level 1 - NC Stand Alone

• NC - Numerical Control
• Lowest level of Automation.
• Axis of Machine - Computer Controlled
• Set-up for a new piecepart is manual.

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Level 2 - Stand AloneCNC Tool Exchange

• Tool exchange included.
• Computer Numerical Control.

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Level 3 CNC Tool andPiecepart Exchange

• PLCs used above level 1 automation.
• Automatic control of part tool exchange
  functions.

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Level 4 Connection to DNC Host

• Storage computer for NC programs.
• Before programs loaded manually using tape.
• This is the first step for CIM.

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Level 5 FMS

• Several stand-alone machines brought together.
• Host computer to lots of DNCs.

HOST
DNC
DNC
DNC
NC
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Conclusion

• Machine Tool Automation.
• Peripheral Automation to increase cutting time.
• Tool Pallet Changers.
• Levels of automation 1-5.