THE EVOLUTION OF MANUFACTURING FROM AUTOMATION TO INTELLIGENT SYSTEMS.pptx

Automated Manufacturing

1. The Evolution of Manufacturing: From Automation to Intelligent Systems Presented By :- 220130141001 – Tanshiq Agarwal 220130141002 – Ayushi Ambwani 220130141028 – Bhavya Patel 230133141009 – Lohit Patel

2. Contents Automation and Types Production Systems Automation in Production Systems Principles and Strategies of Automation Production Facilities Introduction to NC, CNC, and DNC Machine Tools Execution System Basic Configuration of CNC Machines Accuracy, Precision & Resolution CNC MCU (Machine Control Unit) Advantages, Capabilities & Limitations of CNC Intelligent Manufacturing Recent Trends in Automation

3. What is Automation? Automation refers to the technology by which a process or procedure is performed without human assistance. It involves the use of control systems and information technologies to reduce the need for human work in the production of goods and services. The goal is to improve efficiency, reliability, speed, and quality of production. Types of Automation Fixed Automation: Used for high production rates with a fixed sequence of operations. Examples include transfer lines and assembly machines. Programmable Automation: Suitable for batch production, where the sequence of operations can be changed using a program. Examples include numerically controlled (NC) machines and industrial robots. Flexible Automation: An extension of programmable automation, allowing for rapid changes in product design and production schedules with minimal downtime. Flexible manufacturing systems (FMS) are a prime example.

4. Production Systems A production system is the organized framework that combines manpower, machines, materials, methods, and money to manufacture goods or provide services efficiently. 1. Job Shop Production Nature: Highly customized, low-volume production. Layout: Process layout (machines grouped by function). Features: Wide variety of products Skilled labor required High flexibility, low efficiency Examples: Special-purpose machinery manufacturing. Types of Production Systems

5. 2. Batch Production Nature: Medium-volume production carried out in batches. Layout: Process or cellular layout. Features: Products manufactured in lots or groups Changeover/setup needed between batches Balances flexibility with efficiency Examples: Pharmaceuticals Textile and garment industries 3. Mass Production Nature: Large-scale production of standardized goods. Layout: Product layout (assembly line). Features: High-volume, continuous production Specialized machines & semi-skilled labor Low unit cost Examples: Automobile assembly lines Consumer electronics Type of Production Volume Variety Layout Type Examples Job Shop Low Very High Process Custom machinery Batch Production Medium High Process/Cellular Textile, pharma Mass Production High Low Product Cars, electronics Comparison Table

6. Automation in Production Systems: Principles and Strategies The integration of automation into production systems is driven by fundamental principles and strategic approaches aimed at optimizing manufacturing processes. Automation Principles

7. Automation Strategies

8. 📦 2. Material Handling Systems Systems for transporting, storing, and distributing materials within the plant. Types: Manual Handling: Carts, trolleys Mechanical Handling: Conveyors, cranes, hoists Automated Handling: AGVs (Automated Guided Vehicles), robotic arms Objective: Minimize handling time and improve workflow. Production Facilities: The Foundation of Manufacturing A production facility is an integrated system consisting of machines, equipment, layout, and supporting infrastructure designed to transform raw materials into finished products efficiently and economically. Key Elements of Production Facilities 🏭 1. Machine Tools Core equipment for shaping, cutting, and assembling products. Types: Conventional machines: Lathes, drilling, milling Automated machines: CNC, DNC, and robotic workstations Example: CNC milling machine for automotive engine parts.

9. 🗄️ 3. Storage Systems Provide safe and organized storage for raw materials, WIP (Work in Progress), and finished goods. Types: Temporary Storage: Buffers and racks for WIP Long-Term Storage: Warehouses with automated inventory control Recent Trend: Automated storage and retrieval systems (AS/RS). ✔️ 4. Quality Control Units Ensure that products meet required standards and tolerances. Methods: Online inspection using sensors & vision systems Offline inspection with CMM (Coordinate Measuring Machine) Benefits: Early defect detection reduces wastage.

10. Types of Facility Layouts 🔹 Process Layout (Functional Layout) Grouping similar machines together. Used for: Job shops, custom manufacturing. Advantage: High flexibility. Disadvantage: Longer material movement. Example: A tool room or repair shop. 🔹 Product Layout (Line Layout) Machines arranged in sequence of operations. Used for: Mass production. Advantage: High efficiency, low material handling. Disadvantage: Less flexible for product changes. Example: Automobile assembly line. 🔹 Cellular Layout (Group Technology) Machines grouped into cells for families of parts with similar processes. Advantage: Reduces setup time and WIP. Disadvantage: High planning effort required. Example: Machining cells in electronics manufacturing. 🔹 Fixed-Position Layout Product remains stationary; resources and workers move around it. Used for: Very large and heavy products. Example: Shipbuilding, aircraft manufacturing.

11. The Rise of NC, CNC, and DNC Machine Tools Numerical Control (NC) machines revolutionized manufacturing by introducing programmable automation. Subsequent advancements led to Computer Numerical Control (CNC) and Direct Numerical Control (DNC), significantly enhancing precision, flexibility, and integration. Introduction to NC Numerical Control (NC) is a method of automatically operating a machine tool, where the movements of the tool and workpiece are controlled by a program of instructions. These instructions are typically stored on punched tape or cards. NC machines brought unprecedented precision and repeatability to machining operations. Evolution to CNC Computer Numerical Control (CNC) machines integrate a dedicated computer (microprocessor) into the control unit. This allows for greater flexibility, easier program editing, storage of multiple programs, and improved diagnostic capabilities. CNC machines are the backbone of modern manufacturing, enabling complex geometries and efficient production. Advancement to DNC Direct Numerical Control (DNC) involves a central computer controlling multiple CNC machines simultaneously. Programs are downloaded to individual machines as needed, and real-time data can be uploaded back to the central computer for monitoring and analysis. DNC facilitates centralized control, program management, and data collection across a factory floor.

12. Introduction to NC Machines Definition: Numerical Control (NC) refers to the control of machine tools using numerical data encoded on punched tapes or cards. The data represents movements such as feed rate, spindle speed, tool path, and cutting depth. It eliminates manual intervention in machining processes. First Introduced: Developed in the 1950s at MIT for aerospace industry needs. Initially funded by the US Air Force to produce complex aircraft components with high accuracy. Marked the transition from manual machining to automated control. Working Principle: The part program is prepared manually and fed into the machine using punched tape. The NC controller reads instructions sequentially. Control signals are sent to the drive system to move the tool and workpiece. Operations are executed step by step with minimal human involvement.

13. Key Features High repeatability for identical parts. Automatic control reduces operator fatigue. Good dimensional accuracy compared to manual machining. Can handle complex machining tasks compared to traditional lathes or mills. Limitations of Early NC Machines Lack of Flexibility: Any design change required re-punching of the entire tape. No On-Machine Editing: The operator couldn’t modify the program once running. Limited Memory: Programs were stored only on physical media like tapes/cards. High Cost: Initial development and setup costs were very high. Maintenance Issues: Mechanical tape readers often failed.

14. CNC Machines Definition CNC stands for Computer Numerical Control . It is an advanced form of NC (Numerical Control) where a computer stores and executes the program instead of using punched tape. CNC systems interpret a digital program (G-code/M-code) and translate it into precise motions of the machine tool. Key Features High Precision: CNC machines can achieve tolerances up to ±0.002 mm. Ideal for industries requiring accuracy, such as aerospace and defense. Repeatability: Once a program is set, the same part can be produced repeatedly with identical quality. Complex Machining: CNC machines can produce intricate shapes (e.g., turbine blades, engine parts) that would be impossible with manual machines. Programmability: Programs can be easily stored, edited, and reused, reducing downtime between different jobs. CAD/CAM Integration: Designs from CAD software can be directly converted to machine instructions via CAM software. Applications Aerospace: Manufacturing turbine blades, fuselage components, and landing gear parts. Automotive: Production of engine blocks, gears, and precision transmission components. Tool & Die Making: Creating molds, dies, and fixtures with high accuracy. Medical Devices: Precision implants, surgical instruments, and prosthetics.

15. Definition Direct Numerical Control (DNC): A system where a central computer directly controls multiple CNC machines simultaneously by sending instructions in real-time. Unlike CNC, where each machine has its own program, in DNC the program is stored centrally and transmitted when needed. DNC Machines (Direct Numerical Control) Working Principle Central computer prepares and stores the part program. Program is transmitted to the CNC machine via a communication link. CNC machine executes the commands step-by-step. Feedback data (machine status, errors) is sent back to the central computer.

16. 🎯 Advantages of DNC Efficient control of multiple machines from one location Reduces errors caused by manual program loading Easier program management and updating Enables real-time diagnostics and monitoring Reduces downtime by quickly switching or updating part programs ⚠️ Limitations of DNC High setup cost and complex installation Requires stable and fast network for real-time streaming Centralized failure = production halt for all connected machines Needs skilled personnel for maintenance and operation 📌 Applications of DNC Aerospace: Manufacturing complex aircraft components. Automotive: Simultaneous production of precision engine parts. Mass Production Industries: Where large numbers of CNC machines need to be coordinated.

17. Execution Systems Explaination of Execution System Program Input Accepts the part program from external devices (USB, LAN, DNC system, or manual input). Reads G-codes, M-codes, tool paths, feed rates, and spindle speeds. Interpretation & Conversion Converts the part program into digital control signals. Breaks down commands into axis movements, spindle rotations, coolant controls, etc. Motion Execution Sends drive signals to servo motors and stepper motors . Controls linear and rotary axes with high precision. Executes auxiliary functions (tool changes, coolant on/off, spindle start/stop). Feedback & Monitoring Collects data from encoders, sensors, and probes. Continuously compares actual position with commanded position. Performs error correction for accuracy. The Execution System is the component of an automated or CNC-based production system that translates the programmed instructions into actual machine tool operations

18. CNC Machine Control Unit (MCU) The MCU is the brain of the CNC machine. It interprets the part program and converts it into electrical signals to control the machine tool's movements. Key functions of the MCU include: Major Functions of MCU Program Interpretation Reads input from storage media (USB, LAN, punch tape, or directly entered G-code). Decodes part program instructions (G-codes & M-codes). Control Signal Generation Converts interpreted commands into motion signals for drives (stepper/servo motors). Controls spindle speed, feed rate, coolant flow, and tool selection. Axis Coordination Synchronizes movement of multiple machine axes (X, Y, Z, and rotary). Maintains correct interpolation (linear, circular, helical paths). Feedback Monitoring Uses sensors/encoders to check tool position and speed. Compares actual position with commanded position. Corrects errors in real time (Closed-loop control).

19. Basic Structure of MCU MCU typically consists of two main units : Data Processing Unit (DPU) Reads and decodes the program. Interprets coordinates, speeds, and operations. Generates command signals for control. Control Loop Unit (CLU) Sends commands to servo drives and stepper motors. Receives feedback signals from encoders. Maintains precise control through real-time adjustments. Input & Output Devices of MCU Inputs: USB drive, LAN, punch tape reader, manual data input (MDI) panel. Outputs: Servo/stepper motor drives. Spindle motor. Tool changers, coolant system, safety devices.

20. Precision, Accuracy, and Resolution in Manufacturing These three terms are critical for evaluating the performance of machine tools and the quality of manufactured parts. While often used interchangeably, they have distinct meanings. Accuracy Accuracy refers to how close a measured value is to the true or actual value. In manufacturing, it's about how close the actual dimension of a produced part is to its intended design dimension. High accuracy means minimal systematic error or bias. Precision Precision refers to the repeatability or reproducibility of a measurement. It indicates how close multiple measurements of the same item are to each other, regardless of their closeness to the true value. High precision means low random error or scatter. Resolution Resolution is the smallest increment that a measuring instrument or a machine axis can detect or move. For a CNC machine, it's the smallest step the machine can make. Higher resolution allows for finer control and the ability to produce parts with very small features. Understanding the interplay between accuracy, precision, and resolution is fundamental to achieving high-quality manufacturing outcomes and optimizing machine performance.

21. Advantages, Capabilities, and Limitations of CNC CNC technology offers significant benefits to manufacturing but also comes with certain considerations. Advantages and Capabilities High Accuracy and Precision: Produces parts with tight tolerances and excellent repeatability. Flexibility: Easy to change part programs for different products, enabling small batch production and rapid prototyping. Reduced Setup Time: Automated tool changes and program loading minimize non-productive time. Complex Geometries: Capable of machining intricate shapes and contours that are difficult or impossible with manual methods. Increased Productivity: Higher cutting speeds, continuous operation, and reduced human intervention lead to greater output. Improved Safety: Operators are less exposed to hazardous machining operations. Reduced Labor Costs: Fewer operators are needed per machine. Consistent Quality: Eliminates human error, leading to uniform product quality.

22. Limitations High Initial Cost: CNC machines are significantly more expensive than conventional machines. Skilled Labor Requirement: Requires trained programmers, operators, and maintenance personnel. Maintenance Complexity: Repair and troubleshooting can be complex due to integrated electronics and software. Power Consumption: Can have higher energy demands compared to manual machines. Programming Time: For complex parts, the time required for programming can be substantial. Tooling Costs: Specialized tooling for CNC machines can be expensive. Not Always Optimal for Simple Tasks: For very simple, high-volume parts, dedicated fixed automation might be more cost-effective.

23. Intelligent Manufacturing: The Next Frontier Intelligent manufacturing represents a paradigm shift, integrating advanced technologies to create highly adaptive, efficient, and autonomous production systems. What is Intelligent Manufacturing? It's a broad concept that encompasses the use of artificial intelligence (AI), machine learning (ML), big data analytics, and the Internet of Things (IoT) to enable smart factories. These factories can self-optimize, self-adapt, and learn from new situations in real-time. Key Components AI & ML: For predictive maintenance, quality control, process optimization, and robotic decision-making. IoT: Connecting machines, sensors, and devices to collect vast amounts of real-time data. Big Data Analytics: Processing and interpreting data to gain insights and drive intelligent decisions. Cloud Computing: Providing scalable infrastructure for data storage and processing. Impact and Benefits Enhanced Efficiency: Optimized resource utilization and reduced downtime. Improved Quality: Real-time defect detection and prevention. Greater Flexibility: Rapid adaptation to market changes and customer demands. Predictive Maintenance: Minimizing unexpected breakdowns. Autonomous Operations: Machines making decisions and performing tasks independently.

24. Recent Trends in Manufacturing The manufacturing landscape is continuously evolving, driven by technological advancements and changing global demands. Here are some of the most significant recent trends: Industry 4.0 & Smart Factories The ongoing digital transformation of manufacturing, characterized by the integration of cyber-physical systems, IoT, and cloud computing to create highly interconnected and intelligent production environments. Additive Manufacturing (3D Printing) Growing adoption of 3D printing for prototyping, tooling, and even end-use parts, enabling complex geometries, customization, and on-demand production. Sustainable Manufacturing Increasing focus on reducing environmental impact through energy efficiency, waste reduction, circular economy principles, and the use of sustainable materials. Reshoring & Localized Production A trend towards bringing manufacturing closer to end markets to reduce supply chain risks, improve responsiveness, and support local economies. Human-Robot Collaboration (Cobots) The rise of collaborative robots that can work safely alongside human operators, combining the strengths of both for increased efficiency and flexibility. These trends collectively point towards a future of manufacturing that is more agile, resilient, intelligent, and environmentally conscious.

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