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Showing posts with label Fundamentals of Design and Manufacturing. Show all posts

industrial robots and components of robots

on January 17, 2019

industrial robots and components of robots

industrial robots and components of robots

An industrial robot is a reprogrammable, multifunctional manipulator designed to move material, parts, tools or specialized devices through variable programmed motions to accomplish a variety to adapt to many different kinds of jobs in many different industries and perform these jobs with some degree of dexterity and flexibility in motions. In contrast, fixed or special purpose automation is less universal and includes machiners designed to do one particular job in one specific industry.

 industrial robots and components of robots
  • Basic elements of robot are:
  • Manipulator
  • Controller
  • End effectors
  • Sensors
  • Energy source
industrial robots and components of robots
industrial robots and components of robots
Controllers:-Controllers or (programmable controller) is an industrially hardened microprocessor that can be programmed relay ladder logic. It is a device that controls the various aspects of motion of a machine over a pre-determined program to accomplish a repetitive cycle. 
The programmable controller consists of central processing unit (C.P.U.), memory (RAM or core type) and input/output modules. There is a complete flexibility to change relays and wiring.
industrial robots and components of robots

Sensors:-Sensors are typically hardware components of adaptive control system. Sensor, together with the decision making power makes a robot quantitatively different from a NC machine tool or any hard automation machine. It allows robot to accomplish far more complex and difficult task by enabling it to react intelligently to changing conditions.
industrial robots and components of robots
Types of sensors:-
Sensors useful in manufacturing can be classified as:
  • Mechanical sensors:-These measure quantities such as position shape, velocity force, torque, pressure, vibration, strain and mass.
  • Electrical sensors:-These sensors measure voltage, current, charge and conductivity.
  • Thermal sensors:-These sensors measure temperature, flex, conductivity and specific heat.
industrial robots and components of robots
Benefits of employing robots are:-
  1. Working in hostile environments
  2. Performing dull or monotonous jobs.
  3. Lifting and moving heavy objects.
  4. Working during unfavorable hours.
  5. Providing repeatability and consistency.

computer simulation

on January 16, 2019

computer simulation 

In computer simulation a system analyst is interested in optimizing the system that is in finding ways which make the component of a system work together in best possible ways.
So we can say that simulation is a tool for analyzing and designing systems. There are many steps in analyzing a system. One of the major steps is to find a solution from the model. 
A computer simulation model is a set of a mathematical functions, profanity distributions and decision rules and is aped to imitate the way a system behaves under some specified conditions. It is a descriptive   model and differ from optimization model a s optimization model compute the best values for variables so as to optimize some measure of the system. 
On the other hand simulation models provide alternative system designs and operating procedures when optimization models are not practical.

 Advantages of computer simulation:-
Simulation helps in understanding of complex problems/systems.
  1. It applies to the problems that defy mathematical solutions.
  2. It permits study of alternatives under controlled conditions.
  3. It avoids risk and disruptive experiments with actual system.
  4. It compresses time to reveal long-range effects.
  5. It is less costly than other experiments of real world system.

7 steps of brainstorming

on January 14, 2019
7 steps of brainstorming

7 steps of brainstorming

brainstorming is defined as a method to practice a conference techniques by which a group attempts to find diffrent concepts for a specific need by gathering or collecting all the ideas spontaneously contributed by its members.

7 steps of brainstorming are:
Step 1: On a piece of paper, each person makes a list of his or her ideas.
Step 2: Sitting in a circle to lessen dominance by any individual each person takes a turn reading one idea at a time, starting at the top of his or her list.
Step 3: As the ideas are read , the are displayed so that everyone can see them.
Step 4: Participants skip ideas that have been read by someone else proceeding to the next original idea on the list.
Step 5: When all of the lists have been read, the leader asks the participants ,in turn ,if any new idea have occured to then .It is very likely that upon seeing other people's ideas , group members will think or more ideas.
Step 6: The leader continues asking each person , in turn ,if there any more ideas until the group runs out of suggestions.
Step 7: Participants refelect on alll of the ideas generated.

The new ideas developed at step 5 are the main reason for emphasizing that brainstorming is a group technique.Ideally brainstorming has a synergistic effect ;group members generate more ideas as group than the would merely by aggregating their individual lists.

Brainstorming can be viewed as having two phases , the idea - generation phase and idea - evaluation  phase.Step 7 is the evaluation phase.If brainstorming is to be successful as possible ,evaluation or criticism of any idea should not be allowed during the idiea - generation phase(steps 1 - 5).

 Also Learn...

 morphology of design
brainstorming techniques
robust design
group technology
engineering design ,design by innovation design by evolution
explain the design for manufacturablity
economic feasiblity,recyoblity

brainstorming technique advantages disadvantages

on January 14, 2019

brainstorming technique
brainstorming technique

Brainstorming is an idea-generating approach that is used to find problems, cause of problems of variation, ways to prevent problems, solutions to problems, or ways to implement these solutions. It can be viewed as a meeting in which those in attendance are encouraged to think of as many ideas as possible. Brainstorming is defined as a method to practice to conference technique by which a group attempts to find deferent concepts for a specific need by gathering or collecting all the ideas spontaneously contributed by its member.

brainstorming technique
The more ideas, the higher the quantity of the desired product.
Brainstorming has many applications but its uses for product development and process management are listed below:

brainstorming technique
i. New product development- obtaining ideas for new products and improving existing products.
ii. Advertising- developing ideas for advertising campaigns.
iii. Problem-solving- issues, root causes, alternative solutions, impact analysis, and evaluation.
iv. Process management- finding ways of improving business and production processes.
v.Project management- identifying client objectives, risks, deliverables, work packages, resources, roles and responsibilities, tasks, and issues.
vi. Team building- generates sharing and discussion of ideas while simulating participants to think and create ideas.
vii. Business planning- develop and improve the product idea.

brainstorming technique
The following are the member of the brainstorming session:
1)Designer
2)Engineers
3)Executives
4)Marketing Experts
5)Psychology experts etc.

Techniques in use for brainstorming are:
  • Creative techniques
  • Osborn's Brainstorming technique
  • Philips 66 Buzz session technique
  • Crawford slip writing technique
  • brainstorming technique

Advantages of brainstorming technique are:
1.It is possible to refine the ideas of different people for a better solution to the problem.
2.It allows people to use maximum creativity to find solutions.
3.It increase harmony among people in reaching to a feasible solution.
4.The person participating may not be highly qualified or a consultant but may find a solution.
5.This method is easy to understand and not a complicated technique.
6.Generated ideas and solutions may be used elsewhere also.

Disadvantages of brainstorming technique are:
1.Some dump ideas may also be accepted for evaluation.
2.Overlapping of ideas is possible.
3.Some emotional and environmental mental blocks are possible e.g. unease with chaos, fear of criticism, and perpetuation of incorrect assumptions.

Some points to keep in mind during brainstorming technique session are:
1.No criticism of ideas during the session: One way to prevent the criticism is to disallow discussion during the session, present the ideas in brief and in short format.
2.Wild, Silly and Crazy ideas are welcome. Such ideas may help others to generate solid ideas or help for a fun and humorous environment.
3.Generate as many ideas as possible. One way to do so is to appoint a facilitator who will keep rotating the turns without allowing break time. Keep the competitive spirit alive. Some people produce more ideas when competing with others in a group.

Also, Learn...
morphology of design
7 steps of brainstorming
robust design
group technology
engineering design,design by innovation design by evolution
explain the design for manufacturablity
economic feasiblity,recyoblity

Robust Design and Primary Tools for used for development of robust desing

on January 11, 2019

Robust Design

Robust Design is the systematic approach to finding optimum values of design factors that lead to economic designs with low variability .Taguchi methods achieve this goal by first performing parametric design and then ,if the outcomes are still not optimumby performing tolerance design.

In product design , Robust Design robustness means that the product can maintain consistent performance with minimal disturbance due to variations in uncontrollable factors in its operating enviroment.

In Process design ,Robust Design robustness means that the process continues to produce good and efficient  product with minimal effect from uncontrollable variations in its operating enviroment.

The Robust Design Robustness Stratergy uses five primary tools:-
1. P-Diagram is used to classify the variables associated with the product into noise control ,signal (input ),and response (output) factors Robust Design.

2. Ideal function is used to mathematically specify the ideal form of the signal response relationship as embodied bby the design concept for making the higher level system work perfectly Robust Design.

3. Quadratic Loss Function (also known as Quality  Loss Function) is used to quantify the loss incurred by the user due to deviation from target performance Robust Design.

4.Signal to Noise Ratio is used for gathering dependable information about control factors (design parameters) with a small number of experiments Robust Design.

5.Orthogonal Arrays are used for gathering dependable information about control factors (design parameters) with a small number of experiments Robust Design.

Robust Design- Parameter Design: Setting optimal parameters for the product and process(e.g speed , temperature e.t.c ).

What do you understand by ‘Group Technology’? Enumerate the advantages and disadvantages of group technology?

on January 11, 2019

Group Technology

Group technology is a manufacturing philosophy  approach in which similar parts are indentified and grouped together in order to take advantage of their similarities in design and production. Similarities among parts permit them to be classified into part families.
Similiar parts are arranged into part families ,where each part family possesses similiar design and.or manufacturing characterstics.

Advantages of group technology:-

The advantage of Group technology can be divided into three groups:
  • Engineering
  • Manufacturing
  • Process planning
Group Technology in Engineering:- The major advantage of GT for engineering come in cost avoidance, because engineers can now quickly and easily search the database for components that either presently exist or can be used with slight modification, rather than issuing new part numbers. Another engineering advantage is the standardization of design. By recalling a family of parts and comparing productivity costs, the designer can design to least-cost methods. This means the entire engineering department can standardize on corner radii, tolerances, chamfers, counter bores, surface finishes and so on.

Group Technology in Manufacturing:-Studies have shown that a part on a machine tool 5% of the total time it is in the shop during the remaining 95% of the time, it is being moved from one department to another or merely waiting in a warehouse, bin, pallet or some familiar site. Furthermore, of the 5% of the time that it is on a machine tool, it is in contact with the cutting tool only 30% of that time. The remaining 70% of the 5% is spent in tool changing clamping, unclamping, measuring and so on. In short, the part contact time with the cutter is only 1.5% (5% X 30%) of its time in the shop. Higher production rates have usually meant higher r.p.m. , better inserts, or higher feeds, but that is attacking only 1.5% of the problem. The real problem is with the part out in the shop on a pallet. It is called work-in-progress (WIP) inventory. 

Group technology (GT) is concerned more with the 95% of the time the part is waiting than the 5% of the part is on a machine tool. GT attacks this problem by grouping machine tools into work cells, rather than in the traditional shop layout of locating all lathes in one department, the mills in another, drill presses in another and so on.


Process planning:- There is much interest by manufacturing firms in automating the task of process planning using computer-aided process planning systems. The shop trained people who are familiar with the details of machining and other processes are gradually retiring, and these people will be unavailable in the future to do process planning. An alternative way of accomplishing this function is needed, and CAPP systems are providing this alternative. CAPP is usually considered to be part of computer aided manufacturing (CAM). However, this tends imply that CAM is a standalone system. In fact, a synergy results when CAM is combined with CAD to create a CAD/CAM system. In such a system, CAPP becomes the direct connection between design and manufacturing.

 Advantages:
  1. Better lead times gives a fast response and more reliable delivery.
  2. Work in progress and finished stock level are reduced.
  3. Output is improved because of improved resource utilisation.
  4. Less materials handling is needed.
  5. Better space utilisation
Disadvantages of group technology:-

Although in Group Technology ,some variation is there os is absolutely essential for the automated factories of the future ,most companies are reluctant to incorporate the concept into their organisation.
The reasons advanced are that the implementaion is expensive ,slow and tedious ;a difficult learning curve is involved and people are complacent and satisfied with the status.

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What are the Objectives of engineering desin?Explain the following design concepts : Design by evolution and Design by Innovation?

on January 10, 2019

Objectives of Engineering Design Process

Engineering desing is the systematic , intelligent generation and evaluation of specifications for artifacts to have form and function to achieve stated objectives and satisfy specified constraints.

A successful design must consider the following important factor and objectives to maintain long lasting satisfactory sales appeal.

(i)     Satisfied customer needs.
(ii)    Sound and functional product.
(iii)   Good appearance and aesthetic appear.
(iv)   Better Quality both in material andn workman.
(v)    Safety is use and Operation.
(vi)   Adaptability under various conditions.
(vii)  Ease of maintenance.
(viii) Beneficial o society at large scale.
(ix)   Competitive prices.

The design of a device or a system can be done in any one of the two way.
  1. Design by evolution
  2. Design by Innovation
1. Engineering Design by Evolution: A product is allowed to evolve over a period of time with only slight improvement (Where no competition is met and capability of designer are limited).

 Engineering Design by evolution has disadvantage like it is unsuitable for mass production and enable to tap new technologies.

2.Engineering Design by Innovation: This is achieved by rapid scientific growth and technological discoveries as well as competition among companies.
Innovation leads to new design ideas to satisfy growing needs of society.
Invention of computer and electricity are typical examples.


Explain the term ‘ Design for manufacturability’ . State the guidelines to implement it?

on January 10, 2019

Design for manufacturability 

Design for manufacturability is based on minimizing the cost of production including minimizing the time to market while maintaining a high standard of quality for the product. It provides guidelines in the selection of materials, processes and generates piece part and tooling cost estimates at any stage of product design. In order to meet the above objectives the following care is to be taken for Design for manufacturability  :

i.Complete drawings must be produced with all the detailed specifications like shape, form, fit, finish, function and interchangeability requirements.

 ii. The design prepared should be conductive to the application of economic processing.
 iii. Avoid over designing.
 iv.Adequate attention is required to measurement of problems.
 v. Selection of the material and process should be optimum.
 vi.Preparation of material list for all components of the product for buying the raw materials.
 vii. Prepare a list of the parts which are to be fabricated and parts to be bought from the market, i.e., make or buy decision.
viii. Sequence of operations on each component is a particular process and should be decided.
Selection of machine tools required for performing operations at the desired accuracies, and prepares complete specifications of such machine tools.

Describe the term ‘economic feasibility’, ‘recycobility’ and ‘evaluation of design’?

on January 10, 2019

Economic feasibility:-

Economic feasibility: The design term, often with the support of a financial analyst, build an economic model for the new product. This model is used to justify continuation of the overall development program and to resolve specific trade-offs among, for example, development costs and manufacturing costs. While economic analysis is shown as one of the later activities in the concept development phase, an early economic analysis will almost always be performed before the project even begins.

Recyclability: Pollution control and resource conservation can both be achieved by recycling, i.e., making usable goods out of things that would otherwise become garbage or waste. The level and extent of recycling are determined by economic factors. As the quality of ores dwindles and the cost of land filling increases, recycling is likely to increase and become the ultimate solution. Other factors include tax credits, consumer attitude, cost of pollution control, cost of collection and transportation. Paper wastes may be used as fuel for power generation or as raw material for recycled paper; the scraps from metal stamping are remelted; the chips from lumber processing are made into reconstituted materials; the sprues and runners of thermoplastic parts are usually ground and mixed with virgin materials; old ships can be converted into steel bars for use in reinforced concrete.

 Design for recycling encompasses several ideas:
1)     Recycling by repair
2)     Recycling by conversion
3)     Design for easy separation
4)     Allowing for contamination

 Products can be recycled as a whole or as a functional subassemblies.Many products can be recycled by conversion. At the end of their intended functions, they are used for another purpose.
Use of biotechnology in recent times has made possible to convert many waste products into useful products. So design engineer can consider the same during the work.

 Evaluation of design: After a prototypes is made, it should be studied carefully to make sure that it can be manufactured. Economic considerations at this stage become critical to the future success of the product. The most pertinent economic considerations are those concerned with the realities of the market which regulates the production and distribution of goods. Thus a designer must keep the following constraints in mind.
  
i. The total market for the product.
ii.That portion of the total market which might demand a product like the one being designed.
iii.That portion of the total market which might demand the particular design developed (market penetration).
iv.The price at which competitive products are being sold.
v.The basic price/sales relation of the product.

 Also Learn...

morphology of design
brainstorming techniques
7 steps of brainstorming
robust design
group technology
engineering design ,design by innovation design by evolution
explain the design for manufacturablity

What do you understand by ‘morphology of design’? Discuss the phases of feasibility study, preliminary design and detailed design?

on January 10, 2019

   Morphology of design 

   Morphology of design refers to the study of the chronological structure of design projects. The following phases are usually involved in any design project:
a.      Feasibility study
b.      Preliminary design
c.      Detailed design
d.     Production planning
e.      Distribution planning
f.        Consumption planning
g.     Retirement planning

Various steps involved in each phase of Morphology of design  are discussed below:

a. Feasibility study: Provides a set of useful solutions to a problem. 
Various steps are;
i. To demonstrate that the original need has current existence.
ii.To explore the design problem and identify elements
like parameters,constraints, major design criteria etc.
iii. To conceive a number of possible solutions.
 iv. To sort out potentially useful solutions on the basis of physical 
reliability, economic worthwillness, and financial feasibility.

b. Preliminary design: Establishes which the best design concept is. Various 
steps involved Preliminary design are;
      
i.To subject each alternative solution to order of magnitude 
analysis until one is proved to be the best.
ii.To initiate synthesis studies for establishing the fineness of the 
range within which the major design parameters must be controlled.
iii.To study how the design will meet consumer’s taste, how it will match 
with products of competitors, whether scarce and critical raw materials will 
continue to be available, rate of obsolescence.
iv.The rate of deterioration of performance with corrosion, wear fatigue, etc.
v. To test the critical aspects of the design in order to validate the design 
concept and provide information for subsequent phases.

c. Detailed design: Furnishes the engineering description of a feasible design.
Various steps fo Detailed design are;

 i.To develop an overall, provisional synthesis as a master layout.
ii.To prepare specifications of components.
iii.To initiate experimental design by constructing models to check out untried ideas.
iv.To test prototypes and using information obtained as basis of redesign 
and refinement.

morphology of design
Also Learn...
morphology of design
brainstorming techniques
7 steps of brainstorming
robust design
group technology
engineering design ,design by innovation design by evolution
explain the design for manufacturablity
economic feasiblity,recyoblity
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