Unit 11. Automating. Manufacturing. Systems. Manufacturing

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This sample chapter is for review purposes only. Copyright The Goodheart-Willcox Co., Inc. All rights reserved.

brief history of automation. Name a device that has revolutionized factory automation. List five reasons for employing automation. Name at least three components of CIM. Explain what CAD and CAM are.

These efforts can be divided into two tasks: Designing products for efficient manufacture Making products more efficiently Green Link Green Lighting in Facilities It takes a lot of energy to power

But have you ever thought of how much electricity is used to provide light inside all of the manufacturing facilities and office buildings in the world?

This decreases energy consumption while increasing the morale of the workforce. Fluorescent light fixtures have always used less electricity than incandescent bulbs.

Changing to the newer fixtures decreases energy consumption by 20 percent.

1 This sample chapter is for review purposes only. Copyright The Goodheart-Willcox Co., Inc. All rights reserved. Unit 11 Automating Systems 407 Chapter 34 Automation in 34 Automation in 35 Computers and Production 36 Computer Systems in Product Objectives After studying this chapter, you will be able to: Give a brief history of automation. Name a device that has revolutionized factory automation. List five reasons for employing automation. Name at least three components of CIM. Explain what CAD and CAM are. Throughout the history of manufacturing, people have sought more efficient ways to make products. These efforts can be divided into two tasks: Designing products for efficient manufacture Making products more efficiently Green Link Green Lighting in Facilities It takes a lot of energy to power the manufacturing industry. You might think of huge furnaces melting steel or trucks and ships carrying cargo around the globe. But have you ever thought of how much electricity is used to provide light inside all of the manufacturing facilities and office buildings in the world? The greenest way to provide light inside of these facilities is to let in the natural light of the sun. Facilities are being designed and retrofitted to let in more natural light. This decreases energy consumption while increasing the morale of the workforce. Fluorescent light fixtures have always used less electricity than incandescent bulbs. For that reason, fluorescent lights are much more common in commercial facilities. But older style fluorescent fixtures are being replaced with newer, smaller, style fluorescent fixtures. Changing to the newer fixtures decreases energy consumption by 20 percent. Compact fluorescent lights (CFLs) are used to replace traditional incandescent lightbulbs in industrial as well as residential applications. LEDs (light-emitting diodes) were once used only as indicator lights on electronic devices. As LED technology advanced, they became more common in applications like automobile taillights, traffic signals, and flashlights. LEDs are now being used in light fixtures. They are ideal for use in manufacturing facilities because they use very little energy, create very little heat, and last for a long time. Although divided, these tasks are not independent. Often the work of one directly impacts the other. For example, Eli Whitney s work in producing muskets with interchangeable parts required design changes. Musket parts were designed so that all like parts were exactly alike so they could be easily manufactured. The parts were made so that any like part would fit any musket. This enabled the muskets to be assembled more efficiently. Thus, the first task impacted the second. This interdependence must be addressed if a company is to compete in the world market. See Figure Key to this focus is automatic or automated manufacture, which is often called automation. Automation is the application of control to an apparatus, a process, or a system by means of mechanical or electronic devices. Automation uses computer and automatic controls to replace direct human control. Development of Automated It is difficult to trace automated manufacture to any specific event or invention. Ideas for automatic manufacturing machines have many roots. Early efforts to accomplish automation used strictly mechanical controls. automation. Replacement of human control for a machine, process, or system, with control by mechanical or electronic devices.

408 Unit 11 Automating Systems Chapter 34 Automation in 409 Efficient Design Efficient Manufacture World-Class Product Figure 34-1.

) One of the earliest attempts in factory automation came around 1800.

A typical warship of that age required over 1400 blocks. At that time, each block was individually made by artisans working on lathes, drills, and other machines.

After six years of hard work, the world saw its first large-scale, mass production, manufacturing line. However, mass production did not extend to other industries for another 50 years.

This industrial revolution ushered the Western world into what became known as the industrial age. Even earlier roots of factory automation trace back to mechanized toys.

Archytas of Tarentum, dates back to about 350 B.C. Soon after 350 B.C., Hero of Alexandria began to experiment with pneumatics and hydraulics.

2 408 Unit 11 Automating Systems Chapter 34 Automation in 409 Efficient Design Efficient Manufacture World-Class Product Figure Manufacturers must develop efficient designs and manufacturing processes to produce worldclass products. (American Petroleum Institute, Reynolds Metals Co., Deere and Co.) One of the earliest attempts in factory automation came around At that time there was a growing need for blocks (pulleys) to raise and lower sails, move heavy cargo, and position cannons on ships. See Figure A typical warship of that age required over 1400 blocks. At that time, each block was individually made by artisans working on lathes, drills, and other machines. In England, Henry Maudslay undertook the task to produce blocks using an automated production line. After six years of hard work, the world saw its first large-scale, mass production, manufacturing line. However, mass production did not extend to other industries for another 50 years. Furthermore, its adoption was not in England, but in America. Such a movement, marked by revolutionary changes in production, is called an industrial revolution. This industrial revolution ushered the Western world into what became known as the industrial age. Even earlier roots of factory automation trace back to mechanized toys. They were developed to entertain members of high society. One such toy, a wooden model of a pigeon designed by Figure This is the Cutty Sark, an early sailing ship that brought tea from India. Archytas of Tarentum, dates back to about 350 B.C. Soon after 350 B.C., Hero of Alexandria began to experiment with pneumatics and hydraulics. He developed a number of water-driven mechanisms including automatic temple doors and singing mechanical birds. His work was applied to many mechanical toys, music boxes, and musical clocks developed in Europe during the eighteenth century. These devices had mechanisms that used disks. The disks had ridges or holes that encoded a program (detailed operating instructions) that guided the apparatus. The program code held on the disk caused the item to chime or move according to a set plan. The idea of programmed cards or disks was adapted in 1804 by the French loom maker, J. M. Jacquard. His looms used a series of punched cards to program the machine to automatically produce a set pattern in fabrics and carpets. In 1822, Babbage proposed building a machine called the Difference Engine to automatically calculate mathematical tables. The Difference Engine was only partially completed when Babbage conceived the idea of another, more sophisticated machine called an Analytical Engine. Later, Herman Hollerith applied this principle to an automatic data-recording and accounting machine using punched cards. This invention was first used for the 1890 United States census. It reduced the time needed to tabulate the results of the census by 50%. His punched cards became the forerunner of the computer card, which was used to enter data in early computers. In the twentieth century, the idea of a punched-tape program was tried on manufacturing machines. These machines, called numerical control (NC) machines, became the backbone for the second industrial revolution the automation age. The arrival of modern factory automation came with the recent development of the computer. This useful machine is the dominant feature of the computer revolution, which impacts our lives every day. Its advent brought us out of the automation age and moved us into the information age. See Figure Control Machines Computers Process Data Figure Computers can be used to control machines and processes. They can also process written, graphic, and numerical data.

410 Unit 11 Automating Systems Chapter 34 Automation in 411 Academic Link Computer science is the study of the design of computers and their processes.

Partic ular interest is placed on making processes efficient and providing them with some form of intelligence.

3 410 Unit 11 Automating Systems Chapter 34 Automation in 411 Academic Link Computer science is the study of the design of computers and their processes. It is a young discipline that is evolving rapidly from its beginnings. In its most general form, computer science is concerned with the understanding of information transfer and transformation. Partic ular interest is placed on making processes efficient and providing them with some form of intelligence. Computer science includes theoretical studies, experimental methods, and engineering design all in one discipline. This differs from other physical sciences that separate the understanding and advancement of the Figure This is an example of an early computer. (John W. Mauchly Papers; Rare Book and Manuscript Library, University of Pennsylvania) Reducing manufacturing costs Increasing product quality and consistency Enhancing manufacturing flexibility Improving marketability of products science from the applications of the science in fields of engineering design and implementation. In computer science there is a natural intermingling of the theoretical concepts of computability and mathematical efficiency with the modern practical advancements in electronics, which continue to stimulate advances in the discipline. It is this close interaction of the theoretical and design aspects of the field that binds them together into a single discipline and makes computer science a rewarding area of study. This period in history began in 1945 with the development of the first electronic computer. It was called the ENIAC (Electrical Numerical Integrator and Calculator). See Figure From this dramatic start, came the mainframe computer, the minicomputer, and the microcomputer that operate today in almost every facet of the public and private community. Components of an Automated System All efforts to automate manufacturing are guided by a few basic goals. These include: Reducing the reaction time to changes in market demands These goals have caused most manufacturing companies to adopt laborand material-saving practices, programs, and systems. A number of these are * Artificial Intelligence (AI) * Computer-Aided Design (CAD) and Computer-Aided (CAM) * Flexible System (FMS) * Process Automation * Just-In Time (JIT) * Resource Planning II (MRP II) * Materials Requirement Planning (MRP) * Basic Machine Controls Figure Computer use in manufacturing extends from relatively simple to highly complex tasks. listed in Figure The complexity of the systems increases as they move upward on the chart. The simplest are mechanical, numerical, and computer machine controls. These range from simple tracer lathes to complex, computercontrolled machining centers. The most complex is artificial intelligence in which computers are programmed to process data and make decisions. This is a radical departure from the normal computer tasks of data processing. All of the various components presented in Figure 34-5 are used to make up a package called computer-integrated manufacture (CIM). CIM is defined by the National Research Council as all activities from the recognition of a need for a product; through the conception, design, and development of the product; and on through production, marketing, and support of the product in use. All of these activities use written, numeric, or graphic data. This data is integrated into a working system by computers. The result is diverse operations integrated into a single, dynamic system. CIM is an ultimate goal of many manufacturing enterprises. It is only beginning to be implemented into manufacturing companies today. The two main components of CIM are computer-aided design (CAD) and computer-aided manufacturing (CAM). See Figure CAD is a computer-based system used for creating, modifying, and communicating a plan or product design. Activities performed by CAD, as shown in Figure 34-7, include: Engineering design. This is the preparation and documentation of various product design ideas and solutions. Design analysis. This is the evaluation of product designs using computer-simulated tests, such as for stress, heat transfer, and deflection. Design presentation. This is the preparation of engineering drawings that are used to communicate approved designs to manufacturing personnel. Some references say CAD stands for computer-aided drafting. Some say that CAD is strictly a drafting tool. They refer to a system that also has design and analyzing capabilities as computer-aided drafting and design (CADD). CAD computer-integrated manufacture (CIM). An approach in which all steps in producing a product, from recognition of need for it through manufacture and marketing, are integrated into a single, dynamic computer-controlled system. computer-aided design (CAD). A computer-based system used to create, modify, and communicate a plan or product design. Engineering Design Design Analysis Design Presentation (Engineering Drawings) CAM Computer Process Control Computer Numerical Control Robotic Control Adaptive Control Support Production Scheduling Inventory Control Material Requirement Planning Numerical Control Tapes Figure CAD and CAM are important parts of computer-integrated manufacture.

412 Unit 11 Automating Systems Figure 34-7. Computer-aided design is used for engineering design, design analysis, and design presentation activities.

CAM is the use of computer technology in the management and control of manufacturing operations. CAM operation is concerned with one or both of the following: Computer process control.

This is the processing of data including such things as machine status, part counts, and processing variables.

Computers may be used to direct machines through a series of steps to process materials. Also, computers may gather and process data about the effectiveness of an operation.

Summary companies are rapidly automating their operations in an effort to remain competitive in the world market. Computers are being used to make product design and manufacturing more efficient.

4 412 Unit 11 Automating Systems Figure Computer-aided design is used for engineering design, design analysis, and design presentation activities. Controlling Processes More recent practice accepts CAD as standing for all drafting, design, and analyzing functions. CAM is the use of computer technology in the management and control of manufacturing operations. CAM operation is concerned with one or both of the following: Computer process control. This is the process of using mechanical and electronic means (NC machines and robots, for example) to change the shape, size, or composition of materials. support. This is the processing of data including such things as machine status, part counts, and processing variables. CAM uses a computer to assist in monitoring and controlling either or both components of manufacturing operations. See Figure Computers may be used to direct machines through a series of steps to process materials. Also, computers may gather and process data about the effectiveness of an operation. Much more may be said about CAD and CAM operations. They will be the focus of the next two chapters of this book. Summary companies are rapidly automating their operations in an effort to remain competitive in the world market. Computers are being used to make product design and manufacturing more efficient. Two major systems are widely used in industry today. They are CAD and CAM. Unified into a total system, they are a part of CIM. Key Words All of the following words have been used in this chapter. Do you know their meanings? automation computer-aided design (CAD) computer-aided manufacture (CAM) computer-integrated manufacture (CIM) Test Your Knowledge Please do not write in this text. Place your answers on a separate sheet. 1. True or False? Automation evolved as a result of a desire for more efficient ways to manufacture products. 2. Name three roots of automation. 3. What modern device revolutionized factory automation? Chapter 34 Automation in True or False? One reason manufacturers choose to automate is to increase product quality and consistency. 5. List three components of CIM. 6. Which of the following tasks do CAD systems help designers and engineers complete? a. Engineering design. b. Design analysis. c. Design presentation. d. All of the above. 7. What are the two major functions of a CAM system? STEM Activities 1. Prepare a bulletin board, poster, or handout that shows the major tasks of CAD and CAM systems. 2. Visit a local manufacturing company to observe CAD and/or CAM systems in operation. Write a brief report about what you observed. Providing Support Figure Computer-aided manufacturing involves controlling operation and processing manufacturing data. (Battenfeld Inc., AT&T Co.) computer-aided manufacture (CAM). A system that uses computer technology in the management and control of manufacturing operations.

5 414 Unit 11 Automating Systems Career Link Assembler and Fabricator Assemblers and fabricators produce a wide range of finished goods from manufactured parts or subassemblies. They produce intricate manufactured products, such as aircraft, automobile engines, computers, and electrical and electronic components. Assemblers may work on subassemblies or the final assembly of an array of finished products or components. For example, electrical and electronic equipment assemblers put together or modify missile control systems, radio or test equipment, computers, machine-tool numerical controls, radar, or sonar, and prototypes of these and other products. Electromechanical equipment assemblers prepare and test equipment or devices such as appliances, dynamometers, or ejectionseat mechanisms. Coil winders, tapers, and finishers wind wire coil used in resistors, transformers, generators, and electric motors. Engine and other machine assemblers construct, assemble, or rebuild engines and turbines, and office, agricultural, construction, oilfield, rolling mill, textile, woodworking, paper, and food wrapping machinery. Aircraft structure, surfaces, rigging, and systems assemblers put together and install parts of airplanes, space vehicles, or missiles, such as wings or landing gear. Structural metal fabricators and fitters align and fit structural metal parts according to detailed specifications prior to welding or riveting. Assemblers and fabricators involved in product development read and interpret engineering specifications from text, drawings, and computer-aided drafting systems. They also may use a variety of tools and precision measuring instruments. Some experienced assemblers work with engineers and technicians, assembling prototypes or test products.

Automated Manufacturing

Chapter 22 Automated Manufacturing LEARNING OBJECTIVES After studying this chapter, students will be able to: Define the term automation. Describe several automated production systems. Define the term