8 - semester me 408 theory course plan

7/24/2019 8 - Semester ME 408 Theory Course Plan

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Kasegaon Education Society (KES)

Rajarambapu Institute of Technology (RIT)

DEPARTMENT OF MECHANICAL ENGINEERING

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FMTH0301/Rev.5.1

Course Plan

Semester: 8 - Semester Year:

Course Title: Automation and Robotics Course Code: ME 408

Total Contact Hours: 4 Duration of SEE Hours: 3

SEE Marks: 50 ISE + MSE Marks: (20+30=50)

Lesson Plan Author: Prof. Mukund Kavade Date: 19-01-2016

Checked By: Prof. Chandan Waghmare Date: 20-01-2016

Prerequisites:

1. Knowledge of Advanced Production Systems.

2. CNC Machine tools

3. Knowledge of CNC part programming etc.

Course Outcomes (COs):

At the end of the course the student should be able to:

1. Recognize manufacturing automation and Advanced Automation Functions

2. Explain process and discrete manufacturing industries and its processes.

3. Explain and evaluate Transfer Lines and Assembly Automation.

4. Recognize and explain need, meaning and classification of robotics, its control systems and end

effectors.

5. Write simple robot programs in VAL II language.

6. Explain robot applications


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Course Articulation Matrix: Mapping of Course Outcomes (CO) with Program

Outcomes

Course Title: Automation and Robotics Semester: 8 - Semester

Course Code: ME 408 Year:

Course Outcomes (CO) / Program Outcomes

(PO)

a b c d e f g h i j k l m

1. Recognize manufacturing automation and

Advanced Automation Functions

H

2. Explain process and discrete manufacturing

industries and its processes.

L

3. Explain and evaluate Transfer Lines and

Assembly Automation.

L H

4. Recognize and explain need, meaning and

classification of robotics, its control systems and

end effectors.

H

5. Write simple robot programs in VAL II

language.

H

6. Explain robot applications L

Degree of compliance L: Low M: Medium H: High


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Course Content

Course Code: ME 408 Course Title: Automation and Robotics

L-T-P-SS: 3-1-0-0 Credits: 4 Contact Hrs: 4

CIE Marks: 50 SEE Marks: 50 Total Marks: 100

Teaching Hrs: 4 Exam Duration: 3 hrs

Content Hrs

Unit - 1

Chapter No. 1. Manufacturing automation

Automated manufacturing systems, fixed /programmable /flexible automation, Need of

automation, Automation principles and strategies. Basic elements of automated

systemspower, program and control, Advanced automation functions: Safety monitoring,

Maintenance and Repair diagnostics, Error detection and recovery, Levels of automation.

8 hrs

Chapter No. 2. Industrial Control Systems

Industrial control systems in process and discrete manufacturing industries, Continuous and

discrete control, Computer process control, forms of computer process control

4 hrs

Chapter No. 3. Transfer Lines

Fundamentals, Configurations, Transfer mechanisms, storage buffers, control, applications;

Analysis of transfer lines with and without storage buffers.

6 hrs

Chapter No. 4. Automated Assembly Lines

Assembly Automation: Types and configurations, Parts delivery at workstations- Various

vibratory and non-vibratory devices for feeding and orientation, Product design for

automated assembly, Quantitative analysis of assembly systems.

6 hrs

Chapter No. 5. Fundamentals of Industrial Robots

Robot anatomy, Robot motions, Robot specifications, Robot drive systems, Robot control

systems, End effectors, Robot sensors

6 hrs

Chapter No. 6. Robot programming

Robot Programming: Lead through method, Robot program as a path in space, Methods of

defining positions in space, Motion interpolation, branching; Textual robot programming

languages-VAL II. Constants variables and other data objects, Motion commands, End

effectors and sensor commands.

6 hrs


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Chapter wise Plan

Course Code and Title: ME 408 / Automation and Robotics

Chapter Number and Title: 1. Manufacturing automation Planned Hours: 8 hrs

Learning Outcomes:

At the end of the topic the student should be able to:

TLOs COs BL

1. Define and classify manufacturing automation CO1 L2

2. Recognize the need of manufacturing automation. CO1 L2

3. Explain the automation principles and trategies CO1 L2

4. Explain advanced automation functions CO1 L2

5. Discuss automation levels CO1 L2

Lesson Schedule

Class No. - Portion covered per hour

Date

planned

Date

Conducted

1. Introduction to syllabus, COs, POs mapped with the course, teaching,

assessment and evaluation techniques.

11/01/16

2. Automated manufacturing systems, fixed /programmable /flexible

automation

12/01/16

3. Need of automation 14/01/16

4. Automation principles and strategies. 18/01/16

5. Basic elements of automated systems: power, program and control 19/01/16

6. Advanced automation functions: Safety monitoring, Maintenance and

Repair diagnostics

21/01/16

7. Error detection and recovery 25/01/16

8. Levels of automation. 28/01/16

Review Questions

Sr. No. - Questions TLOs BL

1. What are the Course Outcomes (COs) of this course (Automation and

Robotics)

TLO1 L1

2. What is manufacturing automation? What are its types? TLO1 L2

3. How flexible automation reduces production down time? TLO1 L2


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4. Discuss the reasons for manufacturing automation? TLO2 L25. Disvuss the manufacturing principles and strategies TLO3 L2

6. Explain the advanced automation functions TLO4 L2

7. What are the levels of manufacturing automation TLO5 L2

8. What is manufacturing automation? Why companies implement

automation?

TLO1 L2

9. What are the basic elements of automation? Discuss program of

instructions in detail.

TLO1 L2


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Course Code and Title: ME 408 / Automation and RoboticsChapter Number and Title: 2. Industrial Control Systems Planned Hours: 4 hrs

Learning Outcomes:


TLOs's CO's BL PI Code

1. Summarize Industrial Control systems in process and discrete item

manufacturing industries

CO2 L2

2. To define and differentiate Continuous and discrete control CO2 L43. To explain process control and forms. CO2 L2

Lesson Schedule


Date

planned

Date

Conducted

1. Industrial control systems in process and discrete manufacturing

industries

01/02/16

2. Continuous and discrete control 02/02/16

3. Computer process control 04/02/16

4. forms of computer process controls 08/02/16

Review Questions

Sr. No. - Questions TLOs BL PI Code

1. Compare continuous control with discrete control TLO2 L4

2. Explain with flow chart feed forward control system TLO3 L2

3. What is adaptive control system? TLO3 L2

4. Explain with suitable examples event driven changes and time driven

changes in discrete control system.

TLO3 L2


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Course Code and Title: ME 408 / Automation and RoboticsChapter Number and Title: 3. Transfer Lines Planned Hours: 6 hrs

Learning Outcomes:


TLOs's CO's BL PI Code

1. Explain fundamentals and configuration of transfer lines CO3 L2

2. Describe transfer mechanism with sketches. CO3 L1

3. Recognize the need of storage buffers and interpreting the benefits ofthe same.

CO3 L4

4. Describe the control of the production lines. CO3 L2

5. Summarize the applications of production lines. CO3 L2

6. Analyze efficiency of transfer lines with and without storage buffers. CO3 L4

Lesson Schedule


Date

planned

Date

Conducted

1. Fundamentals and Configurations of transfer lines 09/02/162. Workpart transfer mechanism 11/02/16

3. storage buffers, control, applications 15/02/16

4. Control of the automated production lines 16/02/16

5. Analysis of transfer lines without storage buffers. 18/02/16

6. Analysis of transfer lines with storage buffers. 22/02/16

Review Questions

Sr.No. - Questions TLOs BL PI Code

1. Explain with sketch varous configurations of transfer lines. TLO1 L2

2. Explain with sketch linear work transfer mechanism TLO2 L1

3. What is storage buffer? Why it is used on transfer lines? TLO3 L4

4. What are the applications of automated production lines? TLO5 L2

5. A ten station transfer machine has an ideal cycle time of 30 sec. The

frequency of line stops F = 0.075 stops/cycle. When a line stop occurs, the

average downtime is 4.0 min. Raw workpart cost is Rs.0.55/pc, line

operating cost = Rs.42/hr, and the cost of disposable tooling = Rs.0.27/pc.

Determine: i) Average production rate in pc/hr. ii) Line efficiency iii)

TLO6 L4


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Proportion downtime and Average cost of a component produced.6. A 30 station transfer line has an ideal cycle time Tc = 0.75 min, average

downtime Td = 6.0 min. per line stop occurrence and a station failure

frequency p = 0.01 for all stations. A storage buffer of capacity of 20 parts

is located in between stations 15 and 16 to improve line efficiency. Using

the upper bound approach Determine: i) Line efficiency ii) Production rate

of the line. Assume that the downtime (Td = 6.0 min) is constant bsp; Line

efficiency iii) Proportion downtime and Average cost of a component

produced.

TLO6 L4

7. In the operation of a 15 station transfer line, the ideal cycle time = 0.58

min. Breakdowns occurs at a rate of every 20 cycles, and the average

downtime per breakdown is 9.2 min. Transfer line is located in a plant thatworks an 8 hrs/day and 5 days/ week. Determine: i) Line efficiency. How

many parts the transfer line will produce in a week. ht:150%;mso-list:l0

level1 lfo1'>ii) Production rate of the line. Assume that the downtime (Td =

6.0 min) is constant bsp; Line efficiency iii) Proportion downtime and

Average cost of a component produced.

TLO6 L4


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Course Code and Title: ME 408 / Automation and RoboticsChapter Number and Title: 4. Automated Assembly Lines Planned Hours: 6 hrs

Learning Outcomes:


TLOs's CO's BL

1. Define, classify and explain configuration of assembly automation CO3 L2

2. Explain various methods used to deliver parts at workstations CO3 L2

3. Recognize the design of product for automated assembly CO3 L3

4. To perform quantitative analysis of automated assembly systems. CO3 L5

Lesson Schedule


Date

planned

Date

Conducted

1. Assembly Automation: Types and configurations 23/02/16

2. Parts delivery at workstations- Various vibratory and non-vibratory

devices for feeding and orientation

25/02/16

3. Product design for automated assembly 08/03/164. Quantitative analysis of assembly systems 10/03/16

5. Quantitative analysis of assembly systems 2 14/03/16

6. Quantitative analysis of assembly systems 3 15/03/16

Review Questions


1. Discuss with sketches Automated assembly system configurations.

Write in tabular format possible work transfer methods for these

configurations.

TLO1 L2

2. Discuss the principles of design for automated assembly TLO3 L3

3. A six station automatic assembly machine has an ideal cycle time of 12

sec. Downtime occurs for two reasons. First mechanical and electrical

failures of the workheads occur with the frequency of once per 50 cycles.

Average downtime for these causes is 3 min. Second defective

components also result in downtime. The fraction defect rate of each of the

six components added to the base part at six stations is q = 2%. The

probability that a defective component will cause a station jam is m = 0.5

for all stations. Downtime per occurrence for defective part is 2 min.

determine: i) Yield of assemblies that are free of defective components ii)

TLO4 L5


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Proportion of assemblies that contain at least one defective component.Average production rate of good assemblies.

4. 1. Discuss with sketches Automated assembly system configurations.

Write in tabular format possible work transfer methods for these

configurations.

TLO1 L2

5. 2. Discuss the principles of design for automated assembly TLO3 L3

6. 3. A six station automatic assembly machine has an ideal cycle time of

12 sec. Downtime occurs for two reasons. First mechanical and electrical

failures of the workheads occur with the frequency of once per 50 cycles.

Average downtime for these causes is 3 min. Second defective

components also result in downtime. The fraction defect rate of each of the

six components added to the base part at six stations is q = 2%. The

probability that a defective component will cause a station jam is m = 0.5

for all stations. Downtime per occurrence for defective part is 2 min.

determine: i) Yield of assemblies that are free of defective components ii)

Proportion of assemblies that contain at least one defective component.

Average production rate of good assemblies.

TLO4 L5


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Course Code and Title: ME 408 / Automation and RoboticsChapter Number and Title: 5. Fundamentals of Industrial Robots Planned Hours: 6 hrs

Learning Outcomes:


TLOs's CO's BL

1. To recognize the need of robot CO4 L2

2. To define robot and robotic system CO4 L2

3. To explain robot anatomy and physical configurations CO4 L1

4. To explain robot degrees of freedom CO4 L2

5. To explain robot motions CO4 L2

6. To explain robot technical features such as axes of motions, speed,

acceleration, work envelope, accuracy, repeatability, precision, payload

and reliability.

CO4 L2

7. To compare robot drive systems viz. electric, hydraulic and pneumatic. CO4 L4

Lesson ScheduleClass No. - Portion covered per hour

Dateplanned

DateConducted

1. Introduction to robotics, Need of using robot 17/03/16

2. Robot anatomy, Robot motions 21/03/16

3. Robot specifications 22/03/16

4. Robot drive systems 28/03/16

5. Robot control systems 29/03/16

6. End effectors, Robot sensors 31/03/16

Review Questions


1. Define robot. What are the basic elements of robotic system TLO2 L2

2. What is the need of using robot. What are the basic elements of robotic

system

TLO1 L2

3. Explain the basic configurations of the robots and their work volumes f

robotic system

TLO3 L1

4. Discuss the following robot specifications: i) Work volume ii) Speed of

movement iii) Robot motions iv) Payload capacity

TLO6 L2


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Course Code and Title: ME 408 / Automation and RoboticsChapter Number and Title: 6. Robot programming Planned Hours: 6 hrs

Learning Outcomes:


TLOs's CO's BL

1. To list robot programming methods CO5 L1

2. To write robot program using lead through methods CO5 L3

3. To explain robot program as path in a space. CO5 L4

4. To explain joint interpolation CO5 L2

5. To explain methods of defining positions in space CO5 L2

6. To explain and use motion interpolation in robot programming CO5 L3

7. To explain and use branching in robot programs. CO5 L3

8. To explain the methodology of writing robot programs using textual

programming language.

CO5 L2

9. To recognize the use of constants, variables, motion commands, end

effector and sensor commands in robot programs.

CO5 L3

To write the robot programs using VAL II programming language. CO5 L3

10To explain robot applications CO6 L2

Lesson Schedule


Date

planned

Date

Conducted

1. Robot Programming: Lead through method, 04/04/16

2. Robot program as a path in space 05/04/16

3. Methods of defining positions in space, Motion interpolation 07/04/16

4. Textual robot programming languages-VAL II 11/04/16

5. Constants variables and other data objects, Motion commands, 12/04/16

6. End effectors and sensor commands. 19/04/16

Review Questions

Sr.No. - Questions TLOs BL

1. Discuss any three monitor commands used in VAL II programming language. TLO9 L3

2. Discuss lead through programming methods TLO1 L1


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3. Write a program in VAL II for palletizing application. Pallet capacity is 20 (5 rowsand 4 columns). Incoming conveyor brings the workpiece at fixed position. Robot

picks it up and places into the pallet. When pallet is full it is taken away from the

work cell and empty pallet is brought in and then cycle repeats. Make suitable

assumptions and state them clearly.

TLO9 L3

4. Write a leadthrough robot program using branching to perform a palletizing

operation. Suppose that the operation required the robot to pick up parts from an

input chute, and place them on a pallet with 24 positions as depicted in figure given

below. When a start signal is given, the robot must begin picking up parts and

loading them into the pallet, continuing until all 24 positions on the pallet are filled.

The robot must then generate a signal to indicate that pallet is full, and wait for the

start signal to begin the next cycle. height:8.1pt'> Write a leadthrough robot programusing branching to perform a palletizing operation. Suppose that the operation

required the robot to pick up parts from an input chute, and place them on a pallet

with 24 positions as depicted in figure given below. When a start signal is given, the

robot must begin picking up parts and loading them into the pallet, continuing until

all 24 positions on the pallet are filled. The robot must then generate a signal to

indicate that pallet is full, and wait for the start signal to begin the next cycle.

TLO9 L3

5. What are the main categories of robot applications? List the processing

applications of robot..

TLO10 L2

Prof. Mukund V. Kavade Prof. Dr. S. S. Gawade

Course Faculty Head of Department (Mech. Engg.)

8 - semester me 408 theory course plan

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