Computer Integrated Manufacturing

1
Computer Integrated Manufacturing

• Problem definition a solution found in an
• Enterprise
• External challenges (Niche market entrants,
  competition, suppliers, global economy, cost of
  money, Internet and customers)
• Customer order-winning and order-qualifying
  criteria drive the market.
• The enterprise must develop a manufacturing
  strategy to win
• orders based on the criteria in the marketplace.
  The enterprise
• must change. Change to improve their performance
  on the six
• Worldwide standards

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Six Worldwide Standards

• Design Manufacturing lead time by product
• Inventory turns by product
• Setup times on production equipment
• Output/productivity by product per employee
• Total quality and level of rework
• Number of suggestions by product for improvements
  per day per employee

3
Customer demand is always for

• A quality product
• Wide product selection
• Frequent product improvements
• New models on a regular basis.
• Satisfying the six enterprise standards
• is necessary to meet these demands of
• customers.

4
Robotics Computer-integrated Manufacturing

• Robot
• A robot is an automatically controlled,
  reprogrammable, multipurpose, manipulative
  machine with several reprogrammable axes, which
  may be either fixed in place or mobile for use in
  industrial automation applications.
• Reprogrammable
• Robots motion is controlled by a written
  program.
• Program can be modified to change the motion
  of the
• robot arm in real time.
• Multipurpose
• Robot is able to perform many different
  functions,
• depending on the program in memory and
  tooling at
• the end of arm (welding, pick and place,
  painting,
• inspection etc,).

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SME (Society of Manufacturing Engineers (SME)
defines CIM as follows

• The integration of the total manufacturing
  enterprise through
• the use of integrated systems and data
  communications
• coupled with new managerial philosophies that
  improve
• organizational and personnel efficiency.
• CIM is a new approach to Manufacturing
  Management, and
• corporate operation.
• CIM includes
• Robotics, CNC, CAD, CAM and just-in-time (JIT)
  Production
• and assures
• Commitment to total enterprise quality,
  continuous
• improvement, customer satisfaction, use of common
  database
• for all product information with every department
• participating, removal of communication barriers,
  and the
• integration of enterprise resources.

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Manufacturing System classification

• Project
• Job shop
• Repetitive
• Line and
• Continuous
• Classification into these groups requires a
  detailed
• analysis and evaluation of production operations.
  
• Refer CIM wheel

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Project

• Products are complex
• Production quantities are often just one unit.
• Such as
• Oil refineries
• Large buildings
• Cruise ships
• Large aircraft
• Products are similar usually are not identical
• Layout is fixed-position (Figure 1.6 (a))
• Product remains in one location and production
  equipment and parts are moved to it.
• Production and assembly equipment must be mobile
  and
• very few robot applications are found in this
  type (project)

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Job Shop

• Production quantities (lot sizes) are small
• Size and weight of parts are small
• Pats are moved or routed between fixed production
  work cells for manufacturing processing.
• Most often used are lathes, mills, grinders etc,
• Production equipment layout is job shop layout or
  process layout (Figure 1.6 (b))
• Less than 20 repeat production on the same part
• Noncomplex products
• Intensive movement of the product between
  machines
• Opportunities for Robotic applications are
  present but limited by the high variation in
  parts and products.

9
Repetitive

• Orders for repeat business is 100
• Customer contracts for multiple years
• High product volume with production quantities
  vary over large range
• Little variation in the routings of parts between
  production machines
• Plant layout either Figure 1.6 (b) or 1.6 (c)
• Product example
• 10,000 water pumps per week
• Contract for 3 years
• Special-purpose production machines, automated
  systems with robots are integrated into the
  process

10
Line

• Delivery time required by the customer is often
  shorter than the total time to build all
  individual parts of the product.
• Product has many different options or models
• Inventory of subassemblies is usually present
• Example
• Car assembly
• Truck assembly etc,
• Plant Layout is Product-flow layout (Figure 1.6
  (c))
• Robots are frequently used to perform assembly
  tasks.

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Continuous

• Time required for manufacture is longer than
  customer waiting time
• Demand is predictable
• Product inventory is always present
• High production volumes
• Products have few options
• Plant layout is limited to one or just a few
  different products
• Plant layout is Product-flow type (Figure 1.6
  (c))
• Example
• input chemicals output Nylon thread
  (continuous flow)
• Electrical components
• Parts for automotive industry
• Robots can handle high-speed high-volume
  operation of this type

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Manufacturing System Characteristics
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Robot and System Integration (Goals objectives
of the study)

• System overview for hardware software found in
  an automated work cell and CIM system
• Basic operation of PLC and CNC
• Controller architectures for non-servo robots
• Issues of integration when a PLC is used for
  multi-axis robot in a work cell with switches,
  sensors, network connections to other systems
• Controller architectures for servo robots
• Functions of a sensor interface automated work
  cell
• Function operation of the enterprise data
  interface
• Typical architecture for an automated work cell
  with cell controller, product tracking, servo
  and/or non-servo robots, switches, sensors, PLCs,
  and process machines

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Hardware overview

• Hardware is distributed across the enterprise
• Host, area, cell, production machines, computer
  peripheral devices, networks, network interface
  devices
• Ethernet (in most shop floors applications) and
  token ring network hardware
• Gateway to Internet and World Wide Web
• Host computers
• Mainframe machines with large data storage
• Area-level computers
• Midsized machines, workstations or
  micro-computers
• Cell controllers
• Industrial PCs
• Production Machine control
• Microcomputers, microprocessors, microcontrollers
  and PLCs

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Software overview

• Every computer (machine controller to Host) has
  an operating system (DOS, UNIX, Windows NT)
• Computers sharing the network must have network
  software (network software permits communication
  between active computer nodes ex. Cell-control
  application program could request a robot program
  file from the host)
• All computers in the CIM network have one or more
  application program running under the OS
• Through network software, applications can access
  data from other computers and applications vary
  in departments
• Word processing, Desk-top publishing e-mail
  (Front office)
• CAD, FEM, Word processing, e-mail (Product Design
  dept.)
• Access to drawings in the data base (Marketing
  dept.)
• Internet browser to retrieve Web data and
  intranet information and data (all departments)

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Architecture of Automated cells

• Area controller at the top
• Microprocessor-controlled devices at the
  bottom
• PLCs for sequential control of the cell and some
  production machines
• Robot controllers to drive servo robots
• Computer Numerical Control (CNC) for process
  machines

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Cell controllers

• Industrial computers with standard chips
• Latest Intel type processors
• For operation in harsh production environments
• Internal Hard Drives and Floppy Drives for data
  program storage
• Internal memory (RAM)
• Keyboards
• Pointing devices
• Monitors
• Network cards

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Cell control software structure
Cell control software structure

• OS software for most cell controllers
• Windows NT or UNIX (for multiple application
  programs concurrently)
• Multitasking and multithreading feature
• Multiple programs at the same time.
• ex Cell controller can run one program to
  collect quality data from a smart
  gauge
• Second program downloads a program
  to a CNC machine to cut another part
• This flexibility requires multitasking Operating
  Systems

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Cell control software structure
(continued.)

• Cell controller
• interface (standard serial data networks)
• (Serial/parallel, IEEE 802.3 (ethernet), IEEE
  802.4 (token ring)
• General-purpose instrumentation bus (GPIB)
• Intelligent Machines and Devices

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Work-Cell controller Software Layers

• Proprietary network cards
• Programmable logic controllers

• Network card
• Token ring
• Ethernet

• Serial interface cards
• RS232
• RS422

• Other applications
• Data collection
• DNC support
• PLC program generation
• Robot program generation
• Process loop control
• Quality analysis

Work-cell management software
Serial interface support
Network software
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Work-Cell Management Software

• Production monitoring
• Process monitoring
• Equipment monitoring
• Program distribution
• Alert alarm management
• Statistical quality statistical process control
• Data and event logging
• Work dispatching and scheduling
• Tool tracking and control
• Inventory tracking and management
• Report generation on cell activity
• Problem determination
• Operator support
• Off-line programming and system checkout

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Programmable Logic Controller
Programmable Logic controller
PLC Power supply

• Lamps
• Relays
• Motor controllers
• Solenoid valves
• Machine inputs
• Other inputs

• Switches
• Sensors
• Machine
• outputs
• Other
• outputs

PLC input modules
PLC processor
PLC Output modules
Standard networks
PLC Communications modules
Proprietary networks
Smart I/O interfaces
PLC special Purpose modules
Remote racks
ASCII I/O interfaces
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• continues