CNC AND AUTOMATION

CHAPTER-3

LVDT (Linear Variable Differential Transformer) - The LVDT full form is “Linear Variable
Differential Transformer” is LVDT. Generally, LVDT is a normal type of transducer. The main function
of this is to convert the rectangular movement of an object to the equivalent electrical signal. LVDT is
used to calculate displacement and works on the transformer principle.

The above LVDT sensor diagram comprises a core as well as a coil assembly. Here, the core is protected
by the thing whose location is being calculated, while the coil assembly is increased to a stationary
structure. The coil assembly includes three wire wound coils on the hollow shape. The inside coil is the
major, which is energized by an AC source. The magnetic flux generated by the main is attached to the
two minor coils, making an AC voltage in every coil.

Working Principle of LVDT

The working principle of the linear variable differential transformer or LVDT working theory is mutual
induction. The dislocation is a nonelectrical energy that is changed into an electrical energy. And, how the
energy is altered is discussed in detail in the working of an LVDT.
LVDT Applications

The applications of the LVDT transducer mainly include where dislocations to be calculated that are
ranging from a division of mm to only some cms.

 The LVDT sensor works as the main transducer, and that changes dislocation to electrical signal
straight.

 This transducer can also work as a secondary transducer.

 LVDT is used to measure the weight, force and also pressure

 Some of these transducers are used to calculate the pressure and load

 LVDT’s are mostly used in industries as well as servomechanisms.

 Other applications like power turbines, hydraulics, automation, aircraft, and satellites

Encoder:

Encoder Working Principle: Encoders are used to translate rotary or linear motion into a digital signal.
Usually this is for the purpose of monitoring or controlling motion parameters such as speed, rate,
direction, distance or position.

Encoder Working Principle

The Optical Encoders typically consist of a rotating and a stationary electronic circuit. The rotor is usually
a metal, glass, or a plastic disc mounted on the encoder shaft. The disc has some kind of optical pattern,
which is electronically decoded to generate position information.
The rotor disc in absolute optical encoder uses opaque and transparent segments arranged in a gray-code
pattern. The stator has corresponding pairs of LEDs and photo-transistors arranged so that the LED light
shines through the transparent sections of the rotor disc and received by photo-transistors on the other
side. After the electronic signals are amplified and converted, they are then available for the evaluation of
the position

What is a Sensor and Transducer?

The sensor is a device that senses a physical quantity and converts it into an analogue quantity which can
be measured electrically such as voltage, capacitance, inductance and ohmic resistance. The output needs
to be operated, interfaced & regulated by the system designer.

There are different kinds of sensors are available, that are used in various applications. The motion sensor
is a one type of sensor that is used in numerous systems like home security lights, automatic door fixtures
normally send out some kind of energy like ultrasonic waves, microwaves or light beams and sense when
the energy flow is interrupted by something entering its lane.

The transducer is a device that is connected to sensor to convert the measured quantity into a standard
electrical signal such as 0-10V DC, -10 to +10V DC, 4 to 20mA, 0 to 20mA, 0-25mA etc. The o/p of the
transducer can be directly used by the system designer.

Transducers are used in electronic communication systems to convert signals of different physical forms
to electronic signals. In the below figure, two transducers are used where the microphone is used as the
first transducer and as a second transducer speaker is used.

What is an Actuator?

Actuator are mechanical or electro-mechanical devices that provide controlled and sometimes limited
movements or positioning which are operated electrically, manually, or by various fluids such as air,
hydraulic, etc. Two basic motions are linear and rotary. Linear actuators convert energy into straight line
motions, typically for positioning applications, and usually have a push and pull function. Some linear
actuators are unpowered and manually operated by use of a rotating knob or hand wheel. Rotary actuators
convert energy to provide rotary motion. A typical use is the control of various valves such as a ball
valves or butterfly valves. Each actuator type has versions for various power configurations and come in
many styles and sizes depending on the application. Linear chain actuators provide push and pull motions
with rigid chains.
CHAPTER-5
Diagnostic study of common problems in CNC machines:

Ten common problems with CNC machine tool that can be diagnostic. That following problems is

1. Using the Wrong Cutting Tools / Settings.

2. Errors in Programming.
3. Poor Maintenance Of CNC Machine Tool.
4. Inadequate Worker Skill and Training.
5. Clamping/ Unclamping Problem Of Chucks And Fixtures.
6. Power Supply Problems.
7. Automatic Tool Changer Problems.
8. Machine Vibration/ Chatter.
9. Overheating Of Machine Tool.
10. Wrong CNC Machine Tool Partner.

Daily CNC machine tool preventive maintenance:

Things you can do between Preventive Maintenance visits to help extend the life of your machine and
keep it in smooth running condition:

1. Perform a visual check of the entire machine.

2. Get to know your machine by referring to the maintenance section of your operator’s manual.
3. Check the hydraulic unit and lubrication tank daily to see that the pressure and fluid levels are
correct.
4. Check the air regulator and make sure the air pressure is correct and that there is no moisture in
the lines.
5. Clean chips out of the machine daily, and check for areas where chips may collect and compact.
6. Check coolant daily and maintain the correct coolant level. Proper coolant mixture and
cleanliness improve the machining operation; clean chips from the coolant tank regularly.
7. Periodically check the hoses, belts, tool changer and way covers for signs of wear or malfunction.

Three common problems in CNC machines:

Three common problems are mechanically, electronically and pneumatically.

Electronically problems in CNC machines are:

(i) Dust falling on the electronics components.
(ii) Corrosive fumes ( coming from coolamts interacting with the hot chips)
(iii) Oil/ coolant dripping through cables.
(iv) Condensation of moisture.
(v) Insects.
(vi) Poor ventilation.
(vii) Improper power supply.
(viii) Improper earthing.
(ix) Loose connections and bare control wirings.
 Mechanically problems in CNC machines are:
1. Check machine level
2. Verify spindle sweep
3. Check gear shift operation*
4. Check spindle orientation alignment
5. Change gearbox oil
6. Inspect drive belt
7. Inspect and adjust tool changer system
8. Inspect spindle taper condition
9. Inspect way cover wipers
10. Check tool change operation
11. Clean/lubricate tool changer
12. Inspect counterbalance system
13. Check & adjust X, Y, Z backlash
14. Inspect lines, hoses and cables

Pneumatic problems in CNC machines are:

1. Oil level in the lubrication unit
2. Proper air pressure in the regulator
3. Proper air blast during tool changing
4. Moisture in pneumatic line
5. Air leakage

CHAPTER-6
Flexible manufacturing system (FMS)

Introduction

A flexible manufacturing system (FMS) is a manufacturing system in which there is some amount of
flexibility to react in the case of changes, whether predicted or unpredicted. This flexibility can be divided
into two categories:

1. Machine flexibility, covers the system's ability to be changed to produce new product types, and
ability to change the order of operations executed on a part, and
2. Routing flexibility, this consists of the ability to use multiple machines to perform the same
operation on a part, as well as the system’s ability to absorb large-scale changes, such as in
volume, capacity, or capability.

Most FMS systems consist of three main systems.

1. The work machines which are often using computerized machines,

2. Material handling system to optimize parts flow, and
3. The central control computer which controls material movements and machine flow.
An Industrial Flexible Manufacturing System (FMS) consists of robots, Computer-controlled Machines,
Numerical controlled machines (CNC), instrumentation devices, computers, sensors, and other stand-
alone systems such as inspection machines.

Advantages and disadvantages of FMSs implementation

Advantages

1. Faster, lower- cost changes from one part to another which will improve capital utilization
2. Lower direct labor cost, due to the reduction in number of workers
3. Reduced inventory, due to the planning and programming precision
4. Consistent and better quality, due to the automated control
5. Lower cost/unit of output, due to the greater productivity using the same number of workers
6. Savings from the indirect labor, from reduced errors, rework, repairs and rejects

Disadvantages

1. Limited ability to adapt to changes in product or product mix (ex. machines are of limited
capacity and the tooling necessary for products, even of the same family, is not always feasible in
a given FMS)
2. Substantial pre-planning activity
3. Expensive, costing millions of dollars
4. Technological problems of exact component positioning and precise timing necessary to process
a component
5. Sophisticated manufacturing systems

Group Technology

The basic approach enables all aspects of manufacturing, from design, through estimating and planning,
to production, to be rationalized. It forms the basis for the development of computer-aided procedures and
flexible automation. Group technology is a manufacturing philosophy or principle whose basic concept is
to identify and bring together related or similar parts and processes, to take advantage of the similarities
which exist, during all stages of design and manufacture.

If parts can be classified into families, and machines arranged into groups, then the handling of parts
during manufacture can be easily done by the robot. It must be understood that there exists a relationship
between finished products and the parts from which they are made. While assemblies may bear little
relation to each other, the sub-assemblies from which they are constructed will exhibit some like features.
By exploiting the similarities which exist among such a population of parts, group technology sets out to
reduce the time and cost of manufacture.

Define ‘Automation’. What are the various types of Automation?

The technique, method, or system of operating or controlling a process by highly automatic means, as by
electronic devices, reducing human intervention to a minimum. a mechanical device, operated
electronically, that functions automatically, without continuous input from an operator. Act or process
of automating.

Types of Automation System with examples

Automated production systems can be classified into three basic types:

1. Fixed automation,
2. Programmable automation, and.
3. Flexible automation.

Computer Integrated Manufacturing:

CIM is a manufacturing approach that provides a complete automation of a manufacturing facility. All the
operations are controlled by computers and have a common storage and distribution. The various
processes involved in a CIM are listed as follows:

1. Computer-aided design

2. Prototype manufacture

3. Determining the efficient method for manufacturing by calculating the costs and considering the
production methods, volume of products, storage and distribution

4. Ordering of the necessary materials needed for the manufacturing process

5. Computer-aided manufacturing of the products with the help of computer numerical controllers

6. Quality controls at each phase of the development.

7. Product assembly with the help of robots

8. Quality check and automated storage

9. Automatic distribution of products from the storage areas to awaiting lorries/trucks

10. Automatic updating of logs, financial data and bills in the computer system
CIM is a combination of different applications and technologies like CAD, CAM, computer-aided
engineering, robotics, manufacturing resource planning and enterprise management solutions. It can also
be considered as an integration of all enterprise operations that work with a common data repository.
The major components of CIM are as follows:

1. Data storage, retrieval, manipulation and presentation mechanisms

2. Real-time sensors for sensing the current state and for modifying processes
3. Data processing algorithms