ASSIGNMENT NO.

Subject : AUTOMATION [ATM230213]

Q1) State the reasons/benefits/advantages for the implementation/use of:
i.​Automated production systems
ii.​Automated assembly systems

i.​Automated Production Systems:

1.​ Increased Productivity: Automation allows continuous operation (24/7), leading to higher
output.
2.​ Improved Quality: Machines ensure consistent and precise manufacturing, reducing
human error.
3.​ Reduced Labor Costs: Fewer workers are needed, lowering long-term operational costs.
4.​ Enhanced Safety: Dangerous or repetitive tasks are handled by machines, reducing worker
injuries.
5.​ Better Process Control: Automation enables real-time monitoring and control of
production parameters.
6.​ Efficient Use of Materials: Automation minimizes waste by optimizing the use of raw
materials.
7.​ Flexibility in Production: Advanced systems can be reprogrammed quickly for new tasks or
products.

ii.​Automated Assembly Systems:

1.​ Higher Assembly Speed: Machines perform tasks faster than manual labor.
2.​ Consistency and Accuracy: Components are assembled with high precision every time.
3.​ Reduced Human Error: Automation minimizes variability caused by fatigue or distraction.
4.​ Lower Operational Costs: Once installed, automated systems have lower recurring costs.
5.​ Compact Layout: Automated lines can be designed in a more space-efficient manner.
6.​ Integration with Quality Control: Automated inspection can be included within the
assembly process.
7.​ Scalability: Easy to scale up production by adding more automated units or lines.

Q2) Explain with help of relevant diagram/s General Configuration of:

i.​ Automated production line
ii.​ Automated assembly line

Automated production line

An automated production line typically involves interconnected workstations where parts are
transferred using mechanized transport systems, often employing in-line, segmented, or rotary
configurations, with control systems and sensors ensuring efficient and automated processes.

Here's a more detailed breakdown:

Key Components and Configurations:

●​ Workstations:

These are dedicated areas where specific tasks are performed, which can involve specialized
machinery, robots, or human operators.

●​ Control Systems:
These act as the "brain" of the system, coordinating the operation of different machines and
components to ensure a streamlined workflow.

●​ Sensors:

These monitor and regulate the production line, providing real-time data on various parameters
like temperature, speed, and product quality.

●​ Work Handling Devices:

These transfer parts between workstations, often using conveyors, robots, or other mechanized
systems.

●​ Common Configurations:

●​ In-line: Workstations are arranged in a straight line, suitable for large workpieces
and accommodating a large number of workstations.

●​ Segmented In-line: Consists of two or more straight-line transfer sections, often

arranged in an "L" shape.

●​ Rotary Indexing: Parts are transferred between stations using a rotating table,
suitable for high-volume production.

How it Works:

1.​ Raw materials or partially processed parts enter the automated production line.

2.​ Parts are moved automatically between workstations by the work handling devices.

3.​ At each workstation, specific tasks are performed, such as machining, assembly, or
testing.

4.​ The control system monitors and regulates the entire process, ensuring efficiency and
quality.

5.​ Finished products exit the production line.

Automated assembly line

A general automated assembly line configuration typically involves interconnected workstations,

often using conveyor belts or other automated transport systems, where robotic arms, sensors,
and control systems work together to perform repetitive assembly tasks efficiently.

Here's a more detailed breakdown:

Key Components:
 ●​ Workstations:

Dedicated areas where specific assembly tasks are performed, potentially involving specialized
machinery, robots, or human operators.

●​ Conveyor Systems:

Automated transport systems (conveyor belts, AGVs, etc.) that move parts or products between
workstations.

●​ Robots:

Robotic arms or other automated devices used to perform assembly tasks, such as gripping,
placing, or welding components.

●​ Sensors:

Devices that monitor the assembly line, providing real-time data on temperature, speed, pressure,
product quantity/quality, and other variables to the control system.

●​ Control Systems:

The "brain" of the assembly line, coordinating the operation of different machines and
components to ensure a streamlined workflow.

●​ Software:

Software is used to manage and control the entire automation process, including programming
robots and coordinating the flow of materials.

●​ Vision Systems:

Specialized camera systems with image processing software that can inspect parts for defects,
check alignment, read barcodes, and guide robots.

Common Configurations:

●​ In-line: Workstations arranged in a straight line, with parts moving sequentially through
each station.

●​ Rotary/Carousel: Workstations arranged in a circular or carousel format, allowing for

multiple products to be processed simultaneously.

●​ Single-station cell: A single workstation that performs a complete assembly

task. How it Works:

i.​ Raw materials or components are fed into the assembly line.

ii.​ Sensors monitor the process, providing feedback to the control system.

iii.​ Robots or other automated devices perform the assembly tasks at each workstation.

iv.​ Conveyor systems move the parts or products between workstations.

v.​ The control system coordinates the entire process, ensuring efficient and accurate
assembly.
 vi.​ The finished product is then removed from the assembly line

Q3) Explain the various work part transport systems with help of relevant diagram/s
and example/s(application/s):
i.​ Continuous transfer
ii.​ Synchronous transfer
iii.​ Asynchronous transfer

A continuous transport system uses a continuously moving conveyor that operates at constant
velocity, as in Figure 15.2(a). This method is common on manual assembly lines. The conveyor
usually runs the entire length of the line. However, if the line is very long, such as the case of an
automobile final assembly plant, it is divided into segments with a separate conveyor for each
segment.

Continuous transport can be implemented in two ways: (1) work units are fixed to the conveyor,
and (2) work units are removable from the conveyor. In the first case, the product is large and
heavy (e.g., automobile, washing machine) and cannot be removed from the conveyor. The
worker must therefore walk along with the product at the speed of the conveyor in order to
accomplish the assigned task.

In the case where work units are small and lightweight, they can be removed from the conveyor
for the physical convenience of the operator at each station. Another convenience for the worker
is that the assigned task at the station does not need to be completed within a fixed cycle time.
Each worker has flexibility to deal with technical problems that may be encountered with a
particular work unit. However, on average, each worker must maintain a production rate equal to
that of the rest of the line. Otherwise, the line produces incomplete units, which occurs when
parts that were supposed to be added at a station are not added because the worker ran out of
time
In synchronous transport systems, all work units are moved simultaneously between stations
with a quick, discontinuous motion, and then positioned at their respective stations. Depicted in
Figure 15.2(b), this type of system is also known as intermittent transport, which describes the
motion experienced by the work units. Synchronous transport is not common for manual lines,
due to the requirement that the task must be completed within a certain time limit. This can
cause undue stress on the assembly workers and result in incomplete products. Despite its
disadvantages for manual assembly lines, synchronous transport is often ideal for automated
production lines, in which mechanized workstations operate on a constant cycle time

In an asynchronous transport system, a work unit leaves a given station when the assigned task
has been completed and the worker releases the unit. Work units move independently, rather
than synchronously. At any moment, some units are moving between workstations while others
are positioned at stations, as in Figure 15.2(c). With asynchronous transport systems, small
queues of work units are permitted to form in front of each station. This system tends to be
forgiving of variations in worker task times.
Q4) Explain the various configurations of automated production lines with help of
relevant diagram/s and example/s(application/s):
i.​ Inline configuration
ii.​ Segmented inline configuration
iii.​ Rotary Configuration

Inline configuration
The in-line configuration consists of a sequence of stations in a straight line arrangement, as in
Figure 16.1. This configuration is common for machining big workpieces, such as automotive
engine blocks, engine heads, and transmission cases. Because these parts require a large number
of operations, a production line with many stations is needed. The in-line configuration can
accommodate a large number of stations. In-line systems can also be designed with integrated
storage buffers along the flow path

Segmented inline configuration

The segmented in-line configuration consists of two or more straight-line transfer sections, where
the segments are usually perpendicular to each other. Figure 16.2 shows several possible layouts
of the segmented in-line category. There are a number of reasons for designing a production line
in these configurations rather than in a pure straight line: (1) available floor space may limit the
length of the line, (2) a workpiece in a segmented in-line configuration can be reoriented to
present different surfaces for machining, and (3) the rectangular layout provides for swift return
of work-holding fixtures to the front of the line for reuse.

Figure 16.3 shows two transfer lines that perform metal machining operations on automotive
castings. The first line, on the left-hand side, is a segmented in-line configuration in the shape of a
rectangle. Pallet fixtures are used in this line to position the starting castings at the workstations
for machining. It is a palletized transfer line. The second line, on the right side, is a conventional
in-line configuration. When processing on the first line is completed, the parts are manually
transferred to the second line, where they are reoriented to present different surfaces for
machining. In this line the parts are moved individually by the transfer mechanism, using no pallet
fixtures. It is a free transfer line.
Rotary Configuration
In the rotary configuration, the work parts are attached to fixtures around the periphery of a
circular worktable, and the table is indexed (rotated in fixed angular amounts) to present the
parts to workstations for processing. A typical arrangement is illustrated in Figure 16.4. The
worktable is often referred to as a dial, and the equipment is called a dial-indexing machine.
Although the rotary configuration does not seem to belong to the class of production systems
called “lines,” its operation is nevertheless very similar. By comparison with the in-line and
segmented in-line configurations, rotary indexing systems are commonly limited to smaller work
parts and fewer workstations, and they cannot readily accommodate buffer storage capacity. On
the positive side, the rotary system usually involves a less expensive piece of equipment and
typically requires less floor space.

Work part transport mechanisms can be divided into two categories: (1) linear transport systems
for in-line and segmented in-line systems, and (2) rotary indexing mechanisms for dial-indexing
machines. Some of the linear transport systems provide synchronous movement, while others
provide asynchronous motion. The rotary indexing mechanisms all provide synchronous motion.

Q5) Explain the various work part transfer/transport mechanisms with help of relevant
diagram/s and example/s(application/s):
i.​ Linear transfer/transport mechanisms (Walking beam transfer bar
system, Powered roller conveyor system and Chain-drive conveyor
system)
ii.​ Rotary transfer/transport mechanisms (Rack and pinion mechanism,
Geneva mechanism)
Linear Transfer Systems. Most of the material transport systems described in Chapter 10 provide a
linear motion, and some of these are used for parts transfer in automated production lines. These
include powered roller conveyors, belt conveyors, chaindriven conveyors, and cart-on-track
conveyors (Section 10.2.4). Figure 16.5 illustrates the possible application of a chain driven or belt
conveyor to provide continuous or intermittent movement of parts between stations. Either a
chain or flexible steel belt is used to transport parts using work carriers attached to the conveyor.
The chain is driven by pulleys in either an “over-and-under” configuration, in which the pulleys
turn about a horizontal axis, or an “around-the-corner” configuration, in which the pulleys rotate
about a vertical axis.

The belt conveyor can also be adapted for asynchronous movement of work units using friction
between the belt and the part to move parts between stations. The forward motion of the parts is
stopped at each station using pop-up pins or other stopping mechanisms. Cart-on-track conveyors
also provide asynchronous parts movement and are designed to position their carts within about
+-0.12 mm {+-0.005 in}, which is adequate for many processing situations.

Many machining type transfer lines utilize walking-beam transfer systems, in which the parts are
synchronously lifted up from their respective stations by a transfer beam and moved one position
ahead, to the next station. The transfer beam lowers the parts into nests that position them for
processing at their stations. The beam then retracts to make ready for the next transfer cycle. The
action sequence is depicted in Figure 16.6.
Rotary transfer/transport mechanisms (Rack and pinion mechanism, Geneva mechanism

c)​Geneva mechanism:

The Geneva mechanism uses a continuously rotating driver to index the table

If the driven member has six slots for a six-station dial indexing machine, each turn of the driver
will cause the table to advance one-sixth of a turn.
Q6) Explain the various reasons and features of storage buffers with help of relevant
diagram/s and example/s(application/s)

Q7) Explain the three basic control functions for automated production line with help of
relevant diagram/s and example/s(application/s):
i.​ Sequence control
ii.​ Safety monitoring
iii.​ Quality control

Sequence control
The purpose of sequence control is to coordinate the sequence of actions of the transport system
and associated workstations. The various activities of the production line must be carried out with
split-second timing and accuracy. On a transfer line, for example, the parts must be released from
their current workstations, transported, located, and clamped into position at their respective
next stations. Then the work heads must be actuated to begin their feed cycles, and so on. The
sequence control function in automated production line operation includes both logic control and
sequence control

Safety monitoring
The safety monitoring function ensures that the production line does not operate in an unsafe
manner. Safety applies to both the human workers in the area and the equipment itself.
Additional sensors must be incorporated into the line beyond those required for sequence
control, in order to complete the safety feedback loop and avoid hazardous operation. For
example, interlocks must be installed to prevent the equipment from operating when workers are
performing maintenance or other duties on the line. In the case of machining transfer lines,
cutting tools must be monitored for breakage and/or excessive wear to prevent feeding a
defective cutter into the work
Quality control
In the quality control function, certain quality attributes of the work parts are monitored. The
purpose is to detect and possibly reject defective work units produced on the line. The inspection
devices required to accomplish quality control are sometimes incorporated into existing
processing stations. In other cases, separate inspection stations are included in the line for the
sole purpose of checking the desired quality characteristic. Inspection principles and practices,
and the associated inspection technologies

Q8) Explain the various configurations of automated assembly lines/systems with help
of relevant diagram/s and example/s(application/s):

i.​Inline assembly system

The in-line assembly machine, Figure 17.1(a), is a series of automatic workstations located along
an in-line transfer system. It is the assembly version of the machining transfer line. Synchronous
and asynchronous transfer systems are the common means of transporting base parts from
station to station with the in-line configuration.

ii.​Dial type assembly machine

In the typical application of the dial-type machine, Figure 17.1(b), base parts are loaded onto
fixtures or nests attached to the circular dial. Components are added and/or joined to the base
part at the various workstations located around the periphery of the dial. The dialindexing
machine operates with a synchronous or intermittent motion, in which the cycle consists of the
service time plus indexing time. Dial-type assembly machines are sometimes designed to use a
continuous rather than intermittent motion. This is common in beverage bottling and canning
plants, but not in mechanical and electronics assembly.
iii.​Carousel assembly system

As seen in Figure 17.1(c), the carousel assembly system represents a hybrid between the circular
work flow of the dial-type assembly machine and the straight work flow of the in-line system. The
carousel configuration can be operated with continuous, synchronous, or asynchronous transfer
mechanisms to move the work around the carousel. Carousels with asynchronous transfer of work
are often used in partially automated assembly systems

iv.​Single station assembly system

In the single-station assembly machine, Figure 17.1(d), assembly operations are performed on a
base part at a single location. The typical operating cycle involves the placement of the base part
at a stationary position in the workstation, the addition of components to the base, and finally the
removal of the completed assembly from the station. An important application of single-station
assembly is the component placement machine, widely used in the electronics industry to
populate components onto printed circuit boards. For mechanical assemblies, the single-station
cell is sometimes selected as the configuration for robotic assembly applications. Parts are fed
into the single station, and the robot adds them to the base part and performs the fastening
operations. Compared with the other three system types, the cycle time is longer in a single-
station assembly system because all of the assembly tasks are performed sequentially instead of
simultaneously. Hence, production rates are inherently slower.

Q9) Explain the various hardware elements of parts delivery system at an assembly
work station with help of relevant diagram/s and example/s(application/s):
i.​Hopper
ii.​Parts feeder
iii.​Selector and/or Orientor
iv.​Feed track
v.​Escapement and placement device

1.​ Hopper. This is the container into which the components are loaded at the
workstation. A separate hopper is used for each component type. The components are usually
loaded into the hopper in bulk. This means that the parts are randomly oriented in the hopper.
2.​ Parts feeder. This is a mechanism that removes the components from the hopper one at a
time for delivery to the assembly work head. The hopper and parts feeder are often combined
into one operating mechanism. A vibratory bowl feeder, pictured in Figure 17.2, is a very common
example of the hopper-feeder combination.

3.​ Selector and/or orientor. These elements of the delivery system establish the proper
orientation of the components for the assembly work head. A selector is a device that acts as a
filter, permitting only parts in the correct orientation to pass through. Incorrectly oriented parts
are rejected back into the hopper. An orientor is a device that allows properly oriented parts to
pass through, and reorients parts that are not properly oriented initially. Several selector and
orientor schemes are illustrated in Figure 17.3. Selector and orientor devices are often combined
and incorporated into one hopper-feeder system.

4.​ Feed track. The preceding elements of the delivery system are usually separated from the
assembly work head by a certain distance. A feed track moves the components from the hopper
and parts feeder to the location of the assembly work head, maintaining proper orientation of the
parts during the transfer. There are two general categories of feed tracks: gravity and powered.
Gravity feed tracks are most common. In this type, the hopper and parts feeder are located at an
elevation above that of the work head. Gravity is used to deliver the components to the work
head. The powered feed track uses vibratory action, air pressure, or other means to force the
parts to travel along the feed track toward the assembly work head.

5.​ Escapement and placement device. The escapement removes components from the feed
track at time intervals that are consistent with the cycle time of the assembly work head. The
placement device physically places the component in the correct location at the workstation for
the assembly operation. These elements are sometimes combined into a single operating
mechanism. In other cases, they are two separate devices. Several types of escapement and
placement devices are pictured in Figure 17.4
Q10)

i.​Automated Assembly Systems – Applications:

1.​ Electronics Industry

o​ Assembling smartphones, tablets, computers

o​ PCB (Printed Circuit Board) component placement

2.​ Automobile Industry

o​ Assembly of car parts like doors, engines, dashboards

o​ Fastening, welding, and riveting operations

3.​ Medical Device Manufacturing

o​ Assembly of syringes, inhalers, and test kits

4.​ Consumer Goods

o​ Assembling toys, home appliances, and packaging products

5.​ Aerospace Industry

o​ Precision assembly of components in aircraft manufacturing

6.​ Watch and Instrument Manufacturing

o​ Micro-assembly of precision parts

ii.​Automated Production Systems – Applications:

1.​ Automobile Manufacturing

o​ Machining of engine blocks, body painting, welding, and assembly

2.​ Food and Beverage Industry

o​ Automated packaging, bottling, mixing, and labeling

3.​ Pharmaceutical Industry

o​ Tablet pressing, capsule filling, and packing

4.​ Textile Industry

o​ Dyeing, weaving, and cutting fabric with automation

5.​ Chemical Industry

o​ Continuous production of chemicals and petrochemicals

6.​ Electronics Manufacturing

o​ SMT (Surface Mount Technology) line for automated PCB production

7.​ Metal Industry

o​ CNC machining, laser cutting, forging, and stamping