MODULE IV

Flexible Manufacturing System(FMS)

A flexible manufacturing system (FMS) is a highly automated

GT machine cell, consisting of a group of processing
workstations (usually CNC machine tools), interconnected by an
automated material handling and storage system, and controlled
by a distributed computer system.

The reason the FMS is called flexible

it is capable of processing a variety of different part styles
simultaneously at the various workstations, and the mix of part
styles and quantities of production can be adjusted in response to
changing demand patterns.
 Benefits of FMS

 Increased machine utilization

 Fewer machines required
 Reduction in factory floor space required
 Greater responsiveness to change
 Reduced inventory requirements
 Lower manufacturing lead times
 Reduced direct labour requirements and higher labour productivity
 Opportunity for unattended production
 What Makes It Flexible?

Three capabilities that a manufacturing system must possess

to be flexible:
1) The ability to identify and distinguish among the different
part or product styles processed by the system.
2) Quick changeover of operating instructions
3) quick changeover of physical setup
 Tests of Flexibility

Four reasonable tests of flexibility in an automated manufacturing system:

1. Part variety test. Can the system process different part styles in a
nonbatch mode?
2. Schedule change test. Can the system readily accept changes in production
schedule, and changes in either part mix or production quantities?
3. Error recovery test. Can the system recover gracefully from equipment
malfunctions and breakdowns, so that production is not completely disrupted?
4. New part test. Can new part designs be introduced into the existing product
mix with relative ease ?
 Types of Flexibility in Manufacturing

Flexibility Type Definition

Machine Flexibility Capability to adapt a given machine (workstation) in the

system to a wide range of production operation and part styles

Production Flexibility The range of part styles that can be produced on the system

Mix Flexibility The ability to change the product mix, while manufacturing
the same total production quantity

Routing Flexibility Capacity to produce parts through alternative work stations

Volume Flexibility Produce parts in high and low total quantities of production

Expansion Flexibility Ease with which the system can be expanded

 Types of FMS

Flexible manufacturing systems can be distinguished according to

the kinds of operations they perform:
1) Processing operations
2) Assembly operations

Two other ways to classify FMSs are by:

1) Number of machines
2) Level of flexibility
 Types of FMS

Flexible manufacturing systems can be distinguished according

to the number of machines in the system.
The following are typical categories:
1) Single Machine Cell (SMC)
2) Flexible Manufacturing Cell (FMC)
3) Flexible Manufacturing System (FMS)
Single Machine Cell (SMC)
 Single Machine Cell (SMC)

 A single machine cell (SMC) consists of one CNC machining

centre combined with a parts storage system for unattended
operation.
 Completed parts are periodically unloaded from the parts
storage unit, and raw work parts are loaded into it
 The cell can be designed to operate in either a batch mode or a
flexible mode or in combinations of the two
 Single Machine Cell (SMC)

 When operated in a flexible mode, the system satisfies three of the

four f1exibili1y tests
 It is capable of (1) processing different part styles, (2) responding to
changes in production schedule, and (4) accepting new part
introductions.
 (3),error recovery, cannot be satisfied because if the single machine
breaks down, production stops.
Flexible Manufacturing Cell (FMC)
 Flexible Manufacturing Cell (FMC)

 A flexible manufacturing cell (FMC) consists of two or three

processing workstations(typically CNC machining centres or
turning centres) plus a part handling system.
 The part handling system is connected to a load/unload
station.
 In addition, the handling system usually includes a limited
parts storage capacity.
 A flexible manufacturing cell satisfies the four flexibility tests
 Flexible Manufacturing System (FMS)

 A flexible manufacturing system (FMS) has four or more processing

workstations connected mechanically by a common part handling system
and electronically by a distributed computer system.
 An important distinction between an FMS and an FMC is the number
of machines
 Second difference is that the FMS generally includes nonprocessing
workstations that support production but do not directly participate in
it(Other stations include part/pallet washing stations, coordinate
measuring machines, and so on)
 Third difference is that the computer control system of an FMS is
generally larger and more sophisticated, often including functions not
always found in a cell, such as diagnostics and tool monitoring.
Features of the three categories of flexible cells and systems
 Types of FMS

FMS classified according to the level of flexibility designed

into the system.
Two categories are distinguished
1) Dedicated FMS
2)Random-Order FMS
 Dedicated FMS

 A dedicated FMS is designed to produce a limited variety of

part styles, and the complete universe of parts to be made on
the system is known in advance.
 The term special manufacturing system has also been used in
reference to this FMS type.
 The part family is likely to be based on product commonality
rather than geometric similarity.
 The product design is considered stable, and so the system can
be designed with a certain amount of process specialization to
make the operations more efficient.
 Dedicated FMS

 Instead of using general purpose machines, the machines can

be designed for the specific processes required to make the
limited part family, thus increasing the production rate of the
system.
 Machine sequence may be identical or nearly identical for all
parts processed and so a transfer line may be appropriate.
 In which the workstations possess the necessary flexibility to
process the different parts in the mix
 Random-Order FMS

 A random-order EMS is more appropriate when the part

family is large, there are substantial variations in part
configurations, there will be new part designs introduced into
the system and engineering changes in parts currently
produced, and the production schedule is subject to change
from day-to-day.
 To accommodate these variations, the random-order FMS
must be more flexible than the dedicated
Comparison of dedicated and random-order FMS types.
 FMS Components

Basic components of FMS

1) Workstations
2) Material Handling and Storage System
3) Computer Control System
4) People required to manage and operate the system.
 Workstations

Workstations typically found in an FMS

Load/Unload Stations
The load/unload station is the physical interface between the
FMS and the rest of the factory.
Raw work parts enter the system at this point, and finished
parts exit the system.
Loading and unloading can be accomplished either manually or
by automated handling systems
 Workstations

Machining Stations.
The most common applications of FMS are machining operations
The workstations used in these systems are therefore
predominantly CNC machine tools.
CNC machining centres possess features that make them
compatible with the FMS, including automatic tool changing and
tool storage, use of palletized work parts, CNC, and capacity for
distributed numerical control (DNC)
 Workstations

Other Processing Stations

The processing workstations consist of press working
operations, such as punching, shearing, and certain bending
and forming processes.
Assembly
Some FMSs are designed to perform assembly operations.
Flexible automated assembly systems are being developed to
replace manual labour in the assembly of products typically
made in batches.
Material Handling and Storage System

Functions of the Handling System

 Random, independent movement of work parts between
stations.
 Handle a variety of work part configurations.
 Temporary storage.
 Convenient access for loading and unloading work part
 Compatible with computer control.
 Material Handling Equipment

The types of material handling systems used to transfer parts

between stations in an FMS include a variety of conventional
material transport equipment d industrial robots.
The material handling function in an FMS is often shared between
two systems:
1) Primary handling system
2) Secondary handling system
 Material Handling Equipment

Primary handling system is responsible for moving work parts

between stations in the system.

Secondary handling system is to transfer work from the

primary system to the machine tool or other processing station
and to position the parts with sufficient accuracy and
repeatability to perform the processing or assembly operation.
 FMS Layout Configurations

The material handling system establishes the FMS layout.

Layout configurations can he divided into five categories:
1) In-line layout
2) Loop layout
3) Ladder layout
4) Open field layout
5) Robot-centred cell
In-line layout
 In-line layout

 In the in-line layout, the machines and handling system are

arranged in a straight line.
 Its simplest form. the parts progress from one workstation to
the next in a well-defined sequence, with work always moving
in one direction and no back flow
Loop layout
 Loop layout

 In the loop layout, the workstations are organized in a loop

that is served by a part handling system.
 Parts usually flow in one direction around the loop, with the
capability to stop and be transferred to any station.
 A secondary handling system is shown at each workstation to
permit parts to move without obstruction around the loop.
 The load/unload stations) arc typically located at one end of
the loop.
Ladder layout
 Ladder layout

 The ladder layout consists of a loop with rungs between the

straight sections of the loop, on which workstations are
located.
 The rungs increase the possible ways of getting from one
machine to the next, and obviate the need for a secondary
handling system.
 This reduces average travel distance and minimizes
congestion in the handling system, thereby reducing transport
time between workstations.
Open field layout
 Open field layout

 The open field layout consists of multiple loops and ladders

and may include sidings as well
 This layout type is generally appropriate for processing a large
family of parts
 The number of different machine types may be limited, and
parts are routed to different workstations depending on which
one becomes available first.
 Robot-centred cell

 The robot-centred cell uses one or more robots as the material

handling system.
 Industrial robots can be equipped with grippers that make
them well suited for the handling of rotational parts, and
robot-centred FMS layouts are often used to process
cylindrical or disk-shaped parts
 Computer Control System

 The FMS includes a distributed computer system that is

interfaced to the workstations, material handling system, and
other hardware components.
 A typical FMS computer system consists of a central
computer and microcomputers controlling the individual
machines and other components.
 The central computer coordinates the activities of the
components to achieve smooth overall operation of the system
 Computer Control System

Functions performed by the FMS computer control system

1)Workstation control
2)Distribution of control instructions to workstations
3)Production control
4)Traffic control(management of the primary material handling
system that moves work parts between stations)
5)Shuttle control(This control function is concerned with the
operation and control of the secondary handling system at
each workstation)
 Computer Control System

6)Work piece monitoring

7) Tool control
a)Tool location. This involves keeping track of the cutting tools
at each workstation
b) Tool life monitoring
8)Performance monitoring and reporting
9)Diagnostics
 Human Resources

Functions typically performed by humans include:

1) loading raw work parts into the system
2) unloading finished parts (or assemblies) from the system
3) changing and setting tools
4) equipment maintenance and repair
5) NC part programming in a machining system
6) programming and operating the computer system
7) overall management of the system
 FMS Applications

 Flexible automation is applicable to a variety of

manufacturing operations.
 FMS technology is most widely applied in machining
operations.
 Other applications include sheet metal press working, forging,
and assembly.
 Industrial Robotics

 An industrial robot is a general-purpose, programmable

machine possessing certain anthropomorphic characteristics.

 Anthropomorphic characteristic of an industrial robot

 Mechanical arm
 Capability to respond to sensory inputs
 Communicate with other machines
 Make decisions.
 Importance of Industrial Robots

 Robots can be substituted for humans in hazardous or

uncomfortable work environments.
 A robot performs its work cycle with a consistency and
repeatability that cannot be attained by humans.
 Robots can be reprogrammed.
 Robots are controlled by computers and can therefore be
connected to other computer systems to achieve computer
integrated manufacturing.
Robot Anatomy
 Robot Anatomy

 The manipulator of an industrial robot is constructed of a series

of joints and links.
 Robot anatomy is concerned with the types and sizes of these
joints and links and other aspects of the manipulator's physical
construction.
Joints and Links
 A joint of an industrial robot is similar to a joint in the human
body: It provides relative motion between two parts of the body.
 Each joint provides the robot with degree-of-freedom (dof) of
motion.
 Robot Anatomy

 Connected to each joint are two links, an input link and an

output link.
 Links are the rigid components of the robot manipulator.
 The purpose of the joint is to provide controlled relative
movement between the input link and the output link
Types of Joints
 Types of Joints

The five joint types are:

a. Linear joint(type L joint) : The relative movement between
the input link and the output link is a translational sliding
motion, with the axes of the two links being parallel.
b. Orthogonal Joint (type U joint) : This is also a translational
sliding motion, but the input and output links are
perpendicular to each other during the move.
c. Rotational Joint (type R joint) : This type provides rotational
relative motion, with the axis of rotation perpendicular to the
axes of the input and output links.
 Types of Joints

d. Twisting joint (type T joint) : This joint also involves rotary

motion, but the axis or rotation is parallel to the axes of the
two links.
e. Revolving joint (type V joint) : In this joint type, the axis of
the input link is parallel to the axis of rotation of the joint. and
the axis of the Output link is perpendicular to the axis of
rotation.
 Common Robot Configurations

 A robot manipulator can he divided into two sections: a body-

and-arm assembly and a wrist assembly.
 There are three degrees-of-freedom associated with the body-
and arm, and either two or three degrees-of-freedom
associated with the wrist.
 At the end of the manipulator's wrist is a device related to the
task that must be accomplished by the robot. The device,
called an end effector.
 Body-and -Arm Configurations.

[Link] configuration
2. Cylindrical configuration
3. Cartesian coordinate robot
4. Jointed-arm robot.
5. SCARA (Selective Compliance Assembly Robot Arm)
 Polar configuration.

This configuration consists

of a sliding arm (L joint)
actuated relative to the
body, that can rotate about
both a vertical axis (T
joint) and a horizontal axis
(R joint).
 Cylindrical configuration

 This robot configuration consists

of a vertical column, relative to
which an arm assembly is moved
up or down.
 The arm can be moved in and
out relative to the axis of the
column.
 T joint to rotate the column
about its axis , a L joint is used
to move the arm assembly
vertically along the column,
while an O joint is used to
achieve radial movement of the
arm
 Cartesian Coordinate Robot

Other names for this

configuration include
rectilinear robot and x-y-z
robot.
It is composed of three
sliding joints, two of which
are orthogonal.
 Jointed-Arm Robot

This robot manipulator has the

general configuration of a human
arm.
The jointed arm consists of a
vertical column that swivels
about the base using a T joint.
At the top of the column is a
shoulder joint (R joint), whose
output link connects to an elbow
joint ( R joint)
 SCARA (Selective Compliance Assembly Robot Arm)

This configuration is similar to the

jointed arm robot except that the
shoulder and elbow rotational
axes are vertical.
The arm is very rigid in the
vertical direction, but compliant in
the horizontal direction.
Wrist Configurations
 Wrist Configurations

 The robot's wrist is used to establish the orientation of the end effector.
 Robot wrists usually consist of two or three degrees-of-freedom.
 One possible configuration for a three-degree-of-freedom wrist
assembly.
The three joints are defined
a) Roll using a T joint to accomplish rotation about the robot's arm axis.
b) Pitch, which involves up-and-down rotation, typically using a R joint.
c) Yaw, which involves right-and-left rotation, also accomplished
by means of a R joint.
 Joint Drive Systems

Robot joints are actuated using any of three possible types of

drive systems:
1. Electric drive systems use electric motors as joint actuators
(e.g., servomotors or stepping motors).
[Link] and [Link] drive systems use devices such
as linear pistons and rotary vane actuators to accomplish the
motion of the joint.
 Joint Drive Systems

 Pneumatic drive is typically limited to smaller robots used in

simple material transfer applications.
 Electric drive and hydraulic drive are used on more sophisticated
industrial robot.
 Electric drive robots are relatively accurate compared with
hydraulically powered robots.
 Hydraulic drive have greater speed and strength.
 The drive system, position sensors (and speed sensors if used),
and feedback control systems for the joints determine the
dynamic response characteristics of the manipulator.
 Robot Control Systems

Hierarchical control structure of a robot microcomputer controller

 Robot Control Systems

Microprocessor-based controllers are commonly used in

robotics as the control system hardware.
Robot controllers can be classified into four categories
(1) Limited Sequence Control
(2) Playback with point-to-point control
(3) Playback with continuous path control
(4) Intelligent control.
 Limited Sequence Control

 This is the most elementary control type.

 It can be utilized only for simple motion cycles, such as pick-
and-place operations.
 It is usually implemented by setting limits or mechanical stops
for each joint and sequencing the actuation of the joints to
accomplish the cycle.
 Playback With Point-to-point Control

 Playback control means that the controller has a memory to

record the sequence of motions in a given work cycle as well
as the locations and other parameters (such as speed)
associated with each motion and then to subsequently play
back the work cycle during execution of the program.
 In Point-to-point (PTP) control, individual positions of the
robot arm are recorded into memory.
 Each position in the robot program consists of a set of values
representing locations in the range of each joint of the
manipulator.
 Playback With Continuous Path Control

 Continuous path robots have the same playback capability as

the PTP type.
 The difference between continuous path and PTP is the same
in robotics as it is in NC
 A playback robot with continuous path control is capable of
one or both of the following:
[Link] storage capacity: the number of locations that can
be recorded into memory is far greater than for point-to-point.
2. Interpolation calculations: the controller calculates the
path between the starting point and the ending point of each
move using interpolation routines
 Intelligent control

 An intelligent robot is one that exhibits behaviour that makes it

seem intelligent.
 Some of the characteristics that make a robot appear intelligent
include the capacity to:
 interact with its environment

 make decisions when things go wrong during the work cycle

 communicate with humans

 make computations during the motion cycle

 respond to advanced sensor inputs such as machine vision

 End Effectors

 End effector is usually attached to the robot's wrist.

 The end effector enables the robot to accomplish a specific
task.
 The two categories of end effectors are grippers and tools.
Grippers
 Grippers are end effectors used to grasp and manipulate
objects during the work cycle.
 The objects are usually work parts that are moved from one
location to another in the cell.
 Gripper

Robot mechanical gripper

 Types of Grippers

1. Mechanical Grippers, consisting of two or more fingers that

can be actuated by the robot controller to open and dose to
grasp the work part.
2. Vacuum Grippers, in which suction cups are used to hold
flat objects.
3. Magnetized Devices, for holding ferrous parts.
4. Adhesive Devices, where an adhesive substance is used to
hold a flexible material such as a fabrics.
5. simple mechanical devices such as hooks and scoops.
 Tools

 Tools are used in applications where the robot must perform some
processing operation on the work part.
 Examples of the tools used as end effectors by robots to perform
processing applications include:
• spot welding gun
• arc welding tool
• spray painting gun
• rotating spindle for drilling, routing. grinding, and so forth
• assembly tool (e.g., automatic screwdriver)
• heating torch
• water jet cutting tool
 Sensors in Robots

Sensors used in industrial robots can be classified into two

categories:
1) Internal sensors are those used for controlling position and
velocity of the various joints of the robot.
These sensors form a feedback control loop with the robot
controller.
2) External sensors are used to coordinate the operation of the
robot with other equipment in the cell.
 External sensors

1. Tactile sensors. Used to determine whether contact is made

between the sensor and another object.
Tactile sensors can be divided into two types in robot
applications: (a) touch sensors and (b) force sensors
(a) touch sensors : those that indicate simply that contact
has been made with the object.
(b) force sensors : used to indicate the magnitude of the force
with the object.
 External sensors

2. Proximity sensors. Indicate when an object is close to the sensor,

When this type of sensor is used to indicate the actual distance of
the object, it is called a range sensor.
3. Optical sensors. Photocells and other photometric devices can be
utilized to detect the presence or absence of objects and are often
used for proximity detection.
4. Machine vision. Used in robotics for inspection, parts
identification, guidance, and other uses.
5. Other sensors. this miscellaneous category includes other types of
sensors that might be used in robotics, including devices for
measuring temperature, fluid pressure, fluid flow, electrical voltage,
current, and various other physical properties.
 Industrial Robot Applications

1. Hazardous work environment for humans. When the work

environment is unsafe, unhealthful, hazardous, uncomfortable,
or otherwise unpleasant for humans.
2. Repetitive work cycle. capable of performing the work cycle
with greater consistency and repeatability.
3. Difficult handling for humans. task involves the handling of
parts or tools that are heavy or otherwise difficult to manipulate.
4. Multi Shift Operation. the robot replaces two or three workers
5. Infrequent changeovers.
6. Part position and orientation are established in the work
cell.
 Robot Programming

 A robot program can be defined as a path in space to be followed by the

manipulator, combined with peripheral actions( peripheral actions include
opening and closing the gripper, performing logical decision making, and
communicating with other equipment in the robot cell) that support the
work cycle.
 A robot is programmed by entering the programming commands into its
controller memory.

 For robots, three programming methods can be distinguished

a) Lead Through Programming
b) Computer-like Robot programming
c) Off-line Programming
 Lead Through Programming

In lead through programming, the task is taught to the robot

by moving the manipulator through required motion cycle,
simultaneously entering the program into the controller
memory for subsequent play black
There are two methods of performing the lead through teach
procedure:
(1) Powered lead through
(2) Manual lead through
Powered lead through

Robot Teach Pendant

 Powered lead through

 Powered lead through is commonly used as the programming

method for playback robots with point-to-point control.
 It involves the use of teach pendant (hand-held control box)
that has toggle switches and/or contact buttons for controlling
the movement of the manipulator joints.
 Using the toggle switches or buttons , the programmer power
drives the robot arm to the desired positions, in sequence, and
records the positions into memory
 Manual lead through

 Manual lead through is convenient for programming playback

robots with continuous path control where the continuous path
is an irregular motion pattern such as in spray painting.
 This programming method requires the operator to physically
grasp the end-of-arm or tool attached to the arm and manually
move it through the motion sequence ,recording the path into
memory.
 Robot Programming Languages

The use of textual programming languages became an appropriate

programming method as digital computers took over the control
function in robotics.
Textual programming languages for robots provide the opportunity to
perform the following function that lead through programming
cannot readily accomplish:
 Enhanced sensor capabilities. including the use of analogue as well
as digital inputs and outputs
 Improved output capabilities for controlling external equipment
 Program logic that is beyond the capabilities of lead through methods
 Computations and data processing similar to computer programming
languages
 Communications with other computer systems
 Motion Programming

 Motion programming with robot languages usually requires a

combination of textual statements and lead through
techniques.
 This method of programming is sometimes referred to as
on-line/offline programming.
The basic motion statement is
MOVE P1
which commands the robot to move from its current position
to a position and orientation defined by the variable name Pl
 Motion Programming

HERE P1 or LEARN P1
These are used in the lead through procedure to indicate the
variable name for the point
What is recorded into the robot's control memory is the set of
joint positions or coordinates used by the controller to define
the point.
MOVES P1
denotes a move that is to be made using straight line
interpolation. The suffix on MOVE designates straight line
motion.
 Motion Programming

APPROACH P1,40 MM
APPROACH command moves the gripper to a safe distance (40 mm)
above the point.
DEFINE PATH l23 = PATH(Pl,P2,P3)
This is a path that consists of points P1, P2, and P3
MOVE PATH 123
This statement is used to drive the robot through the path.
SPEED 75
The speed of the robot is controlled by defining either a relative
velocity or an absolute velocity
 Simulation and Off-line Programming

 The trouble with lead through methods and textual

programming techniques is that the robot must be taken out of
production for a certain length of time to accomplish the
programming.
 Off-line programming permits the robot program to be
prepared at a remote computer terminal and downloaded to the
robot controller for execution.
 In true off-line programming there is no need to physically
locate the positions in the work space for the robot as
required with present textual programming languages
 Simulation and Off-line Programming

 Some form of graphical computer simulation is required to

validate the programs developed off-line, similar to offline
procedures used in NC part programming.
 The advantage of true off-line programming is that new
programs can be prepared and downloaded to the robot
without interrupting production
 The off-line programming procedures being developed and
commercially offered use graphical simulation to construct a
three-dimensional model of a robot cell for evaluation and off-
line programming
 Simulation and Off-line Programming

 The cell might consist of the robot, machine tools, conveyors,

and other hardware.
 The simulator permits these cell components to be displayed
on the graphic, monitor and for the robot to perform its work
cycle in animated computer graphics.
 After the program has been developed using the simulation
procedure, it is then converted into the textual language
corresponding to the particular robot employed in the cell.