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8/12/2019 Lecture No 10 Automation of Machining
http://slidepdf.com/reader/full/lecture-no-10-automation-of-machining 1/62
Technology II.
Jan Tomíček
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Automation of machining
Is connected with the rising demands ofsociety and industry development.Is the way to intensification ofmanufacturing – increasing productivity,improving quality and lowering costsIs the way to improvements in
manufacturing technology, spreading thetechnological possibilities and way tomake the inovation cycle faster.
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What we need to automate?
Tool managementTool changeTool movementsSpindle start, devices startMaterial loading
Finished piece remove
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AUTOMATION OF MACHINING
Machine tools:general-purpose, manually operated(conventional);
- The leading power is the worker
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AUTOMATION OF MACHINING
Machine tools:automated:a) fixed automation – mechanisms: cams,
gear wheels, links, levers, arms; mechanicalstops, limit switches, etc. b) flexible automation – program control,
numerical control
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Fixed automation elements
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Cam
Is a disc or cylinder with a curve shaped path. A boss insupport is in the path and as the cam turns the supportmoves. Cam are connected together to provide complexmovement of support, feed, rotation and other.
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Cylindrical cam use – automatic lathe carriage
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Disc cam use – automatic lathe cross slide
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Fixed automation machine tools
automatic general-purpose machinee.g. a semiautomatic or an automatic lathe
single-purpose machine (usually unit-built)workpiece oriented function designtransfer line
integrated workpiece transport system
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Unit-built machine
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Feed drive unit - EV
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Drilling spindle unit - BO
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Slide unit - SE
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Circular indexing table unit - TA
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Modularunitsdesign
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Single purpose machine
Just one operation, of op. Step is done.Sometimes a batch of operation stepsSpecial machine designed to maximizethe production:
Multiple spindlesHigh feed drives
Multiple clamping Automatic part in feedSpecial tooling usage
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Single-purpose machineefficiency
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Transfer line – a concept
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Transfer line – a schema
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Transfer line – a design
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Block machining transfer line
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Transfer line station – an example
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2) Flexible automation
(soft, programable automation) is aimedat piece and small batch production dueto easy reprogramming.
Two basic formsProgram sequence controlNumerical control
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Program sequence control
The sequence of motions and switchingsis controlled by relays, timers, switches,perforated tape, programable cylinders,
plugboards and other controllers.
Easier reprogramming, limited program
options, almost no adjustments
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Perforated tapeEach line presents adifferent movementor switch. It has tobe printed correctly,no error control.
FYI:8 line perforated paper tape can contain one byte of information in one columnof holes. Normal pitch of columns is 2,54 mm. That means you need 2,6 m of
tape to store 1kB of data. A dual-layer DVD is then approx. 22100 km ofperforated tape.
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Numerical control
The most important type of automation. Almost all of new machines arenumerically controlled.
Priciple:Machine and all of its movements arecontrolled by a program. Program is a
list of instructions written is specificsyntax and having specific format.
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Mechanical vs. numerical
Limitations – speed, length of program,possible motions on cams.
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FLEXIBLE AUTOMATION1. Conventional machine tool
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FLEXIBLE AUTOMATION2. NC machine tool (stand-alone)
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FLEXIBLE AUTOMATION3. NC machine tool with tool magazine
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FLEXIBLE AUTOMATION4. CNC machine tool
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Mechanization vs. automation
Mechanization – human power is replacedby machines, drives, hydraulic or mechanicdevices
Automation – human control is replaced by
sequentional machine, cams, computer, PLCcontroller
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Automation degree
Semiautomatic run – tools are changedautomatically, blank or finished workpiece isrenowed by operator
Automatic run – both the tool and pieces are
placed and removed automatically by robot(line, tables)
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NC / CNC definition
Originaly only NC control was used.Program was stored on tape or disc andread one line after another.
Influence of rapid development ofcomputers resulted to CNC control(Computer numerical control). Now the
program is loaded into computers memoryand executed from here.
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CNC advantagesOption NC control CNC control
Program length Limited by data storagecapacity (tape)
Unlimited (limited bydata storage capacity – HDD drives over 1TB)
Program sequence One line after another Allows jump forward,backward, subprograms.
Jump to other programs N/A Yes
Canned cycles N/A Yes
Coordinates correction Manually only Yes, automatically
Tool lengthcompensation Manually only Yes, programable
Tool diametercompensation
N/A Yes, programable
Reading in advance N/A Yes, continual mode
Start after breakdown N/A Yes
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Program sequenceSubprograms
A link to another then thefollowing line is entered intomain programm. This subprogram isexecuted.
After finishing this programwe return to main programa we contiue until end ofmain program (M30)
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Basic principles of CNCmachines
NC/CNC machine consist of 3 basic elements.List of instructions – NC code – a mix of alphabecial
and numerical information. Contaion informationabout movements, feed, speed, tool change and
other machine functions (cooling, measuring)Control unit - control system – converts the programinto signal for machine and send them to machine(PLC controller)
Controlunit
(system)
MachineNCcode
Sensing
device
Drivemotor
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Basic principles of CNCmachines
NC/CNC machine consist of 3 basic elements.Machine tool – fitted with drive motor to operate
slides, support and spindle. Also with switchesto start/stop specific functions
Sensing device – optional(closed circuit)- sensingdevice control if a specific demand was fullfilled.Support feed, Table position etc.
Controlunit
(system)
MachineNCcode
Sensing
device
Drivemotor
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CNC machine tool
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Motions
Three types of motion1) point-to-point motion – tool is moved to
specific location, path or speed of move
between location is not controlled.(drilling)2) Linear control – movement along one of
the axes of the machine.3) Contouring control – movement can be
made in two or more axessimultaneously.
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MotionsPoint-to-point control Linear control Contouring control (continual)
drilling milling machines, lathes machining c.(milling, turning)
CNC hi i (MC)
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CNC machining centre(MC)MC combine a number of different
machining processes in one operation
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Modular tool set
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Modular tool set – toolingsystem All manufacturers around the worldBasic concept:1) Holder with standadized conecting part
– ISO, BSK cone, CAPTO system etc.2) Extension bar – active (vibration
elimination) adujstable and balanced3) Quick change tooltip/insert
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SECO - Combimaster
T l h
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Tool exchange
Tool exchange
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Tool exchange
Fl ibl ll
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Flexible cell – a concept
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Flexible manufacturing system
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Conveyors
Device used for transportation of blankand semiproduct in production
Types:Belt conveyorPulley(rolls) conveyorCradle conveyor
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Conveyors – Belt conveyor
Used for small parts and loose materialEndless belt made of rubber, plasticparticles, short boards (grids)
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Conveyors – pulley(roller) conveyor
For large solid parts and productsLow force needed (gravity slide ways)Use of pallets
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Pallet
Board used fortransportation
Equiped with jigs andother positioning
elements
Together with palletechanger is used
for automaticblank materialloading and partsunloading
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Pallet changer
aka Switch table2-4 pallets in one machine
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Loading of blank/semiproducts
- Manual- Accumulation conveyor
- Accumulating pieces to balance production
- Robot loading- For single standing, large production usage
(common machine tools)
- Line(conveyor) loading- For FMS and large batch production (special
machine tools)
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Loading
Flexible manufacturing system
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Flexible manufacturing systemFlexible manufacturing system for 4 types of automobile cylinder heads(GM 3801 – 3811)
BZ 400 BZ 500 Other Reserve
Flexible to suit various part variants
9 Flexible transfer machines (some incorporating BZ 400 machining centers),and 16 high-dynamic BZ 500 machining centers
Completely automated
Approximately 500,000 parts p.a.
Process automation and integration level
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Process automation and integration level
AUTOMATION OF MACHINING
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AUTOMATION OF MACHINING
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Effects of automation
- Cost reducing(per piece)
- Higher
investments- Speed
improvement- Productivity
improvement- Repeatability
improvement
C o n v e n
t i o n a
l t o o l s
C N
C t o o
l s
F M
S
C a
m ‘ s
M a c h
i n i n g c o s
t s
( K c / p c e
)
Productivity(pcs/hour)