IndustryAutomative additive m 4-VER.pptx

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1. Industry 4.0-UNIT 3 Presented by Dr. ABHISHEK KUMAR Associate Professor, Mechanical Engineering Department, School of Technology ( SoT ), Pandit Deendayal Petroleum University, Raisan , Gandhinagar - 382 007, Gujarat, INDIA Off:079-23275438

2. Contents Automation systems Additive manufacturing Micro Electro Mechanical Systems Smart factories Advanced Robotics Autonomous and swarms Self propelled Vehicles Drones 3D-printing Space crafts Mechanical Engineering Department 2

3. Manufacturing systems Manufacturing is the process of transforming Raw materials into Finished products. Manufacturing Processes Casting Rolling Forging Machining Mechanical Engineering Department 3

4. Automation systems Fixed automation Flexible automation Programmable automation Mechanical Engineering Department 4

5. Mechanical Engineering Department 5

6. Fixed Automation Fixed automation  systems, or “hard  automation ,” are typically used for production systems with exclusively allocated equipment and high-production needs. The equipment in a  fixed automation  system is manufactured and designed to perform only one set of operations on one part with high levels of efficiency. Mechanical Engineering Department 6

7. Flexible automation Flexible automation  (FA) is a type of manufacturing  automation  which exhibits some form of “ flexibility ”. Most commonly this  flexibility  is the capability of making different products in a short time frame. This “process  flexibility ” allows the production of different part types with overlapping life-cycles. Mechanical Engineering Department 7

8. Programmable automation Programmable automation  allows for machine configurations and operation sequences that can change based on signals sent from electronic controls. With a  programmable automation  system, products can be produced in batches through the reprogramming of machine operations and sequences. Mechanical Engineering Department 8

9. Additive Manufacturing The term “ additive manufacturing ” refers technologies that grow three-dimensional objects one superfine layer at a time. Each successive layer bonds to the preceding layer of melted or partially melted material.  Laser Beam Melting (LBM) Electron Beam Melting (EBM) Laser Metal Deposition (LMD) Mechanical Engineering Department 9

10. Laser Beam Melting (LBM) Also known as Selective Laser Sintering/Melting In this process, metal powder, fed by a hopper, is spread in very thin layers with a layer thickness of about 50-100 micro meters, across an area with dimensions reaching from 50 mm X 50 mm to 800 mm X 400 mm. For uniform distribution of metal powder, a levelling system is used. Laser beam with a power source between 20 Watts and 1 KW, with a wavelength of 1060 nm to 1080 nm in the near infrared, spot size between 50 micro meters to 180 micro meters, is directed with a speed of 15 m/s, across the deposited metal powder. Mechanical Engineering Department 10

11. Laser Beam Melting (LBM) Energy supplied by laser to the powder layer causes the metal powder to melt and form a melt pool. This will fuse with the already solidified layer during solidification. Build plate is lowered after solidification, Again, another layer of powder is applied, melted and solidified. This process is repeated until the production of the component is completed. The entire process is carried out in a closed chamber filled with inert gas. For protecting molten metal, Nitrogen or Argon is supplied to the chamber. Mechanical Engineering Department 11

12. Selective Laser Melting Mechanical Engineering Department 12

13. Electron Beam Melting (EBM) In this process, metal powder, fed by a hopper, is spread in very thin layers by means of a Rake, with a layer thickness of about 50-200 micro meters. In this process, electron beam is used as a heat source for melting evenly distributed metallic powder. Electron beam is generated by means of an electron gun, focussed by electronic lenses, accelerated by applying 60 KV, is directed by a magnetic scan coil in the x-y plane on the build plate, to reach the desired location. By using a beam current of 30 mA and with a scan speed of 10 4 mm/s, temperature of more than 700 C can be achieved for Ti-6Al-4V. Once the solidification of the molten metal is done, build plate is lowered. Again, a new layer of metal powder is spread, electron beam scanning is done, once the solidification is complete, the entire process is repeated until the production of entire component is complete. During the entire process, vacuum of the order lower than 10 -2 Pa is used. By pumping Helium, system pressure is increased to 1Pa. Mechanical Engineering Department 13

14. Electron Beam Melting Mechanical Engineering Department 14

15. Laser Metal Deposition Figure 3 shows the experimental setup In this process, metal powder is supplied by means of a co-axial or multi-jet nozzle over melted metal, simultaneously, Nd- YaG diode or CO2 laser is used as an energy source for melting metal powder. Also, the molten metal is protected from oxidation by using Argon or Helium gas. The main advantage of this technique is that higher build rate and larger build volumes are possible. Mechanical Engineering Department 15

16. Laser Metal Deposition (LMD) Mechanical Engineering Department 16

17. Micro-Electro-Mechanical Systems Micro-Electro-Mechanical Systems, or MEMS, is a technology that in its most general form can be defined as miniaturized mechanical and electro-mechanical elements (i.e., devices and structures) that are made using the techniques of microfabrication. The critical physical dimensions of MEMS devices can vary from well below one micron on the lower end of the dimensional spectrum, all the way to several millimeters. Likewise, the types of MEMS devices can vary from relatively simple structures having no moving elements, to extremely complex electromechanical systems with multiple moving elements under the control of integrated microelectronics. Mechanical Engineering Department 17

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25. Micro-Electro-Mechanical Systems Mechanical Engineering Department 25 Mask, Etched grooves

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30. Micro Electro Mechanical Systems-MEMS Mechanical Engineering Department 30

31. Smart Factories Smart factories are one of the major components of Industry 4.0. Integration of real-world objects such as machines with networks and the virtual world objects has resulted in cyber-physical systems (CPS). In a smart factory, all smart objects (e.g. operators, equipment, material, etc.,) interact promptly for achieving the organizational objectives Mechanical Engineering Department 31

32. Smart Factories Cloud services realize product manufacturing as a service available over the Internet Mechanical Engineering Department 32

33. Smart factories Radio Frequency Identification Devices (RFID) as one of the components of IoT technologies are used for object or asset tracking both in manufacturing as well as logistics operations RFID technology is making it possible for tracking objects in real-time Thus, it helps all the elements of the supply chain to receive updates and be in synchronization Mechanical Engineering Department 33

34. Smart Factories Optimize steel production with Artificial Intelligence(AI) Predict Supply chain disruptions using AI Strengthen customer experience with IoT and AI Minimize equipment downtime Real time checking the company’s health Machine to Machine interaction without human intervention Maximize production throughput Mechanical Engineering Department 34

35. Advanced Robotics Mechanical Engineering Department 35

36. Advanced Robotics Advanced robotics  systems are ready to transform industrial operations. Compared with conventional robots,  advanced  robots have superior perception, integrability, adaptability, and mobility. These improvements permit faster setup, commissioning, and reconfiguration, as well as more efficient and stable operations. Mechanical Engineering Department 36

37. Autonomous and swarms Flocks of birds, schools of fish, swarms of insects, and now... swarms of robots. Inspired by their biological counterparts, robot swarms comprise many individuals that together accomplish a task each individual robot alone cannot. Autonomous Swarms - the combination of swarm robotics and blockchain technology - is one of the 2019 emerging technology trends covered in Info-Tech's 2019 CIO Trend Report. Mechanical Engineering Department 37

38. Autonomous and swarms Autonomous swarms combine the technology of swarm robotics with a blockchain-based back end. Not to be confused with collaborative robotics (several robots working together as an assembly line), swarm robotics involves multiple copies of the same robot, working independently in parallel to achieve a goal too large for any one robot to accomplish. The blockchain is a distributed ledger technology that creates an immutable, decentralized record of information. . Mechanical Engineering Department 38

39. Autonomous and swarms Storing information this way creates advantages such as auditability, trust, efficiency and security. By leveraging the benefits of both swarm robotics and blockchain, Autonomous Swarms has the potential to enter into new use cases - such as city cleanup, agriculture, traffic surveillance - where trust and information security are key challenges to automation Mechanical Engineering Department 39

40. Autonomous and swarms Why use Autonomous Swarms? As the business’s technological steward, today's IT leader must help their organization adopt emerging technologies with an eye to their long-term impact, by focusing on both business and human benefits. Business benefits of Autonomous Swarms:  Scale - Every agent within a robotic swarm is designed to act autonomously, with the overall swarm behavior emerging organically as a consequence of these individual tasks. This makes it simple to increase or decrease swarm size simply by adding or removing agents.  Decentralized Decision-Making - Blockchain technology allows multiple robotic agents to reach consensus without the need for a central authority through "voting". This makes the swarm more resilient and simplifies the job of a human controller.  Consistent Results - The blockchain enables swarms to perform their jobs more robustly, with less potential for error and malicious interference. This leads to more consistent and dependable results for businesses. Mechanical Engineering Department 40

41. Autonomous and swarms Human benefits of Autonomous Swarms:  Dangerous Situation Avoidance - Robot swarms are ideally suited to take over dangerous or undesirable jobs such as landmine detection, dangerous machinery maintenance and city cleanup, where automation can greatly improve the quality of life of human workers.  Resistance to Hacking - In applications where robots are in close proximity to humans and their data, the resistance to malicious attacks afforded by blockchain means greater peace of mind for the people whose data robotic swarms may be handling.  Error Avoidance - Consistency and dependability result from the decision-making and auditability possibilities blockchain opens for robotic swarms. For humans, this means less worry about errors in handling tasks such as pesticide use in crops. Mechanical Engineering Department 41

42. Autonomous and swarms Key dependencies of Autonomous Swarms: As an emerging technology, Autonomous Swarms raise new considerations for businesses looking to deploy it. These questions must be resolved before Autonomous Swarms can be deployed at scale: 1. Autonomy's guiding principles - As swarms grow larger, the question of how to monitor and control so many agents becomes more pressing. As we entrust more of the robots’ operation to algorithmic decision-making, we must be clear on the underlying safety and privacy assumptions, definitions of “harm,” and the robots’ role in protecting human interests. Mechanical Engineering Department 42

43. Autonomous and swarms 2. Readiness for automation – Human cognitive processing limits, coupled with the large number of agents in typical robotic swarms, necessitate some degree of algorithmic automation. The key consideration becomes: which aspects of the swarm’s operation to leave up to the algorithm, and which key factors to keep under human surveillance. Define the rules the govern autonomous behavior with an eye to difficult cases. Mechanical Engineering Department 43

44. Autonomous and swarms 3. Regulation of collected data – With increasing automation comes the collection of staggering amounts of data. Most of the civilian use cases, such as robotic food delivery, or even street cleanup, has the potential to collect human data, either through necessity, such as recording a delivery address, or by accident, such as by capturing a passer-by in a robot’s vision. The potential for privacy violations and their prevention must be a key consideration in the development of any swarm robotics strategy. Mechanical Engineering Department 44

45. 3D-printing What is 3D Printing? Traditional manufacturing methods depend on cutting and moulding technologies to create a limited number of structures and shapes needing to be formed from several parts assembled. Shaping and forming processes are performed through different stages, ranging from casting to cutting at various stages depending on the complexity of the component being manufactured. The traditional method of shaping is through material removal, which is referred to as subtractive manufacturing (SM). Examples of SM processes include milling, drilling, and grinding. Manufacturing plastic and metal objects, in particular, is generally a wasteful process with a lot of surplus materials and chunky parts. However, Additive Manufacturing (AM) technologies transform this process by building near-net-shape components one layer at a time using data from 3D CAD (computer-aided design) models. These 3D models can be very complex figures, being confined only by a person’s imagination with higher structural integrity and more durability. Mechanical Engineering Department 45

46. 3D-printing According to their first standard, ASTM F2792-10, AM is defined as ‘The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing technologies. Creating a 3D object from a digital model using a 3D printer has been one of the largest innovations of recent years. The idea is to build the object layer by successive layer until it is complete. Each of these printed layers is a thinly-sliced, horizontal cross-section of the eventual object. Printing begins with a digital file in which the final shape has been coded and the computer software slices the design into multilayers. These layers are then printed on top of each other until the 3D object is created. Mechanical Engineering Department 46

47. 3D-printing As 3D printing has become less expensive, more accessible and new materials have become available, the technology has quickly gained momentum. With the market entry of compact open-source desktop 3D printers, the application areas of 3D printers have broadened from small-scale commercial or educational purposes to household use. 3D printing is most commonly used for rapid prototyping of new products. The ability to rapidly produce new prototypes for testing, often in less than 48 hours after a design revision, greatly accelerates the prototyping process. Mechanical Engineering Department 47

48. 3D-printing-Types Bio-Based 3D Printing Recent advances in 3D printing technology have enabled tissue engineering applications in which organs and body parts are built using inkjet techniques. Biocompatible materials, cells, and supporting components are printed into complex 3D functional living tissues to address the need for tissues and organs suitable for transplantation. As of 2013, scientists began printing ears, livers, and kidneys with living tissue. Mechanical Engineering Department 48

49. 3D-printing-Types Polymer-Based 3D Printing Today’s 3D printing technology is mainly based on polymers as they can be easily processed. Polymers can be processed at low temperatures relative to metals and ceramics. The most commonly utilized polymer-based composites are high performance, lightweight materials that are produced by dispersing strong additives/fibres in a polymer matrix. Mechanical Engineering Department 49

50. 3D-printing-Types Metallic Based 3D Printing In metallic based 3D printing, parts are manufactured by a laser fusing high-performance metals, layer by layer directly from a 3D digital data. Created objects are strong and lightweight with complex internal features, such as undercuts, channels through sections, tubes within tubes, and internal voids. It’s an accurate and cost-effective method for the production of prototype components and the economical manufacture of small series parts for testing purposes or as final production components for use in many different environments, without the investment in time and money of conventional tooling. Metal 3D printing is mainly used for applications such as the automotive and aerospace industry. Mechanical Engineering Department 50

51. Drone An unmanned aerial vehicle (UAV) (or  uncrewed aerial vehicle,commonly known as a drone) is an aircraft without a human pilot on board. UAVs are a component of an unmanned aircraft system (UAS), which include a UAV, a ground-based controller, and a system of communications between the two.  The flight of UAVs may operate with various degrees of autonomy: either under remote control by a human operator or autonomously by onboard computers referred to as an autopilot. Mechanical Engineering Department 51

52. Drone Applications While drones originated mostly in military applications, their use is rapidly finding many more applications including – aerial photography, product deliveries, agriculture, policing surveillance, infrastructure inspections Mechanical Engineering Department 52

53. Drone Combat – providing attack capability for high-risk missions Reconnaissance – Unmanned reconnaissance aerial vehicle providing battlefield intelligence. Target and decoy – providing ground and aerial gunnery a target that simulates an enemy aircraft or missile. Logistics – delivering cargo. Civil and commercial UAVs – agriculture, aerial photography, data collection. Research and development – improve UAV technologies. Mechanical Engineering Department 53

54. Spacecraft A  spacecraft  is a vehicle or machine designed to fly in outer space. A type of artificial satellite,  spacecraft  are used for a variety of purposes, including communications, Earth observation, meteorology, navigation, space colonization, planetary exploration, and transportation of humans and cargo. Mechanical Engineering Department 54

55. Spacecraft-Types Communication Satellites Supports telecommunication, television broadcasting, satellite news gathering, societal applications, weather forecasting, disaster warning and Search and Rescue operation services. Earth Observation Satellites The largest civilian remote sensing satellite constellation in the world - thematic series of satellites supporting multitude of applications in the areas of land and water resources; cartography; and ocean & atmosphere. Mechanical Engineering Department 55

56. Spacecraft-Types Scientific Spacecraft Spacecraft for research in areas like astronomy, astrophysics, planetary and earth sciences, atmospheric sciences and theoretical physics. Navigation Satellites Satellites for navigation services to meet the emerging demands of the Civil Aviation requirements and to meet the user requirements of the positioning, navigation and timing based on the independent satellite navigation system. Mechanical Engineering Department 56

57. Spacecraft-Types Experimental Satellites A host of small satellites mainly for the experimental purposes. These experiments include Remote Sensing, Atmospheric Studies, Payload Development, Orbit Controls, recovery technology etc.. Small Satellites Sub 500 kg class satellites - a platform for stand-alone payloads for earth imaging and science missions within a quick turn around time. Student Satellites ISRO's Student Satellite programme is envisaged to encourage various Universities and Institutions for the development of Nano/Pico Satellites. Mechanical Engineering Department 57

58. THANKS Mechanical Engineering Department 58