flexible manufacturing systems - my liuc
TRANSCRIPT
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LIUC - Ingegneria Gestionale 1
Flexible
manufacturing
systems
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Components of a
FMS
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Computer Numerical Control
Computer Numerical Control (CNC) means that a local
computer directly controls machine functioning.
Numerical control allows the transmission of information
to the machine tool, and thus all the subsequent actions
implemented by the machine itself.
Numerical control means exploiting information
technology and electronics in order to improve machine
tools performances and flexibility
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LIUC - Ingegneria Gestionale 4
Computer Numerical Control
Compared to traditional machines, CNC machines
require totally different manpower operations.
First CNC machines were built in the mid-’50s but their
large-scale diffusion started in the ‘70s.
The very first CNC machine was built in 1947 in USA for
the aeronautic industry, in order to meet the need to
provide complex surfaces in reasonable times.
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Technological evolution
Traditional Machine
Considerable passive
times (air cutting and
machine stoppage)
Higher error possibility
Productivity also depends
on operator skills
CNC Machine
Strongly reduced passive
times, also related to
machine equipment
Error possibility only during
the programming phase
Production results do not
depend on operator skills
Productivity strongly
depends on the
technological level of the
machine
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Human-machine interface
Traditional Machine
Design analysis
Mnemonic activities to
identify operations
sequences
Parts fixing
Tools fixing
Working parameters
settings
Operations execution
CNC Machine
Off-line computer
programming
Transferring of the
program to the machine
Parts fixing
Tools loading
Operations starting
Operations supervision
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Opportunities and Problems
Opportunities
High automation
High flexibility
Passive time reduction
Productivity increase
Quality improvement
Waste reduction
Manpower reduction
Versatility increase
Problems
High costs related to:
Acquisition investment
Maintenance
Assistance
Programming of
processing cycles
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CNC machines characteristics
One engine for each controlled axis (synchronized and simultaneous movements)
Moving elements provided with transductors that continuously recognize axis positions
High installed power
High speed of positioning movements
Mechanisms to quickly change tools
Tools to hold and move pallets, for the rapid replacement of finished products with WIP products
Conveyors facilitating the gathering and disposal of shavings
Sliding barriers delimiting working areas in order to ensure operators security
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LIUC - Ingegneria Gestionale 9
A schematic representation of a CNC lathe
MM: spindle engine
TRN: transductor angular
speed
MZ: engine Z axis
TRSDZ: transductor Z axis
MX: engine X axis
TRASDX: transductor X axis
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Machining centre
It is a machine with multiple scope of work, highly
flexible where it is possible to make a high number of
operations (drilling, milling, ….)
Main technical characteristics:
Operating field (workable volume)
Orientation of the rotational axis of the spindle (p.e.:
horizontal)
Number of controlled axes
Max rotational speed of the spindle
Max translation speed of the axes (passive move)
Installed power / avaiilable power
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3,4 and 5-axis machining
centers
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Warehouse for tools
Tools required for producing a part and/or a set of parts
need to be located in a warehouse for tools dedicated to
the machine tool before the start of the machining phase
Before their positioning, tools undergo a off-line
presetting (they are dimensioned considering a fixed
point of reference). Presetting-data need to be
memorized within the governing units so that ensuring
the correct execution of the machining.
Warehouse for tools can hold up to hundreds tools
simultaneously
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LIUC - Ingegneria Gestionale 15
Wareohouse for tools of a machine
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Automatic change of the tool
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Wareohouse for tools of the system
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System for changing tools with AGV
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Systems for changing parts
Changing the part should be as quick as possible so
that avoiding wasting time during the machining
phase.
In order to hold and handle parts (or pallets) a table is
exploited, its movements are allowed by an automatic
system.
Different CNC centers can be linked with each others
and presuppose the presence of systems moving
pallets from one center to another
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Pallet exchangers: rotating with two
compartments
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T, holding-pallet table
F, pallet with finished product
P, pallet with the part to be processed
S, system for pallet exchange
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Rotating table Pallet carousel
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Mobile head Commuting table
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Shuttle
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System buffers and inter-
operational buffers
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Roller conveyor
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Rail transport
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Automated Guided Vehicle (AGV)
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Guiding system of an AGV (1)
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Guiding system of an AGV (2)
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Guiding system of an AGV (3)
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Speed profile of an AGV
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LIUC - Ingegneria Gestionale 32
Dimension check
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Multi-headed tester
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Gantry system for the dimension check
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Automated Storage/Retrieval System - ASRS - (Ingersol-
Rand)
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Automated Storage/Retrieval System - ASRS - (Caterpillar)
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Focus on CNC
machines
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Programming elements
The part program provides all information required to execute the machining phases: Regarding the tool trajectory from the part, both
related to the geometry and to the moving modes (of advancement, cutting, positioning, …)
Regarding the chosen technological parameters (speed, advancement, …)
Regarding other auxiliary information, such as: Tool selection
Use of cutting fluids
Load/unload of pallets
…
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An easy program in the
language of CNC
machines
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Machining
The machining program is loaded in the memory of the governing unit
The machining program is selected at the moment the parts need to be processed
Before starting each machining phase, the «zero machine» has to be identified, it is the reference for all handling instructions
A setup programming cycle (complete or partial) has to be executed in order to verify the presence of any programming error
Parts have to be positioned
The program is launched
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CAM systems – Computer Aided
Manufacturing
CAD systems can be integrated with the related CAM package. They allow to create, starting from the design, the part program. The part program provides all paths of tools to be given directly to the CNC machine to execute machining operations
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Numerical Control:
conclusions The two fundamental and characterizing parameters of a
production system are (they are in a trade-off
relationship):
Productivity: the capacity to process a high quantity of parts in a
given time, given defined levels of quality and cost
Flexibility: the capacity to quickly adapt to process an high
number of parts that have different and changeable
characteristics
CNC machines optimally provide both the
aforementioned characteristics, indeed they ensure:
Reduced execution times (productivity)
Minimal passive times (flexibility)
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Numerical Control: conclusions It is particularly advantageous for the machining of:
Parts with complex shape
Parts requiring an high number of tools
Continuous control of the cutting speed
Exploitation of not highly skilled operators
Further applications of CNC (in addition to the shaving removal) can be: Robots
Measuring machines
Centers for the machining of sheet metal
Centraper la lavorazione della lamiera
Laser cutting systems, water jet, …. flat parts systems
The set of CNC machines constitute a FMS – Flexible Manufacturing System,based on the electronic link of single units with a central PC, which manages the allocation of processing activities required on the different machines
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Robot
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Rossum universal robots (K. Capek), 1920
In this theatrical drama, for the first time the term robota = forced or heavy labor was used
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Robotics laws (I. Asimov), 1942
A robot may not injure a human being or, through inaction, allow a human being to come to harm
A robot must obey any orders given to it by human beings, except where such orders will conflict with the First Law
A robot must protect ist own existence as long as suchprotection does not conflict with the First or Second Law
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Main typologies of robots
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Cartesian
Anthropomorphic
SCARA
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Constituent elements of robots: the
hand
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The hand can execute gripper functions or end effector functions
Standard hand Hand with high opening
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Constituent elements of robots: the
hand
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Hand with aligned fingers Self-centering hand
The hand can execute gripper functions or end effector functions
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Constituent elements of robots: the
hand
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Hand with camsHand with cams with internal
and external jaws
The hand can execute gripper functions or end effector functions
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Constituent elements of robots: the
hand
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Hand for parts with different sizesSpecial hand for glass tubes
The hand can execute gripper functions or end effector functions
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Constituent elements of robots: the
hand
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Flashlight for arc welding Hand with ladle
The hand can execute gripper functions or end effector functions
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Constituent elements of robots: the
hand
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Gun for points welding Pneumatic iron
The hand can execute gripper functions or end effector functions
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FMS – Conceptual
schema and
examples
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LOGIC SYSTEM OF A FMS
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MAX MAKINO SYSTEM
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SHORT-TERM PROGRAMMING
ACTIVITY
PROGRAMMAZIONE
OPERATIVA STP: fase 1
(dettaglio settimanale)
LAN DI FABBRICA
R T C S
PIANO DISTAFFAGGIPIANO ESECUTIVOPIANO CARICAMENTO
GREZZI
PIANO STAFFAGGI
Piano congelato 15g Piano previsionale 15g
PROGRAMMAZIONE
AZIENDALE
PIANO MENSILE
PROGRAMMAZIONE
OPERATIVA STP : fase 2
(dettaglio turno di lavoro)
PIANO PREPARAZIONE
ATTREZZATURE
PIANO PREPARAZIONE
UTENSILI
Production Planning
System che effettua
l'attività di Short
Term Planning del FMS
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PLANNED TEMPORAL
HORIZONT
Piano Caricamento Pezzi
Piano staffaggioPIANO ESECUTIVO CONGELATO
Piano
rilasciato
14hx orex ore
istante correntePPS - FASE 1
PPS - FASE 2
RTCS
Turno Turno Turno
previsionalecongelatocongelato
Settimana x Settimana x+1congelata congelata
PIANI DI TURNO CONGELATO
Turno
previsionale
15ggprevisionali
PIANI
CONGELATI
SETTIMANALIin esecuzione
Turnopronto a
partire
Turnopronto a
partire
tempo
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Architecture of the management
system
Tempo fisico diinterazione tra i diversilivelli gerarchici
FMS / FAS Hardware System
(PPS = Production PlanningSystem del sistema automatico)
livello 3 - livello di area orizzontetemporale breve (15 gg)Short Term Planning
Work Center Plan
Medium Term Planning (tipicamente costituito dalle fasi MRP - Material Requirement Planning eCRP - Capacity Requirement Planning)
livello 2 - livello di impiantoorizzonte temporale medio ( 3 - 12mesi )
livello 1 - livello di fabbricaorizzonte temporale lungo (12-24 mesi)Master Production Schedule
min / ore
ore / giorni
nsettimane
FMS / FAS
R T C S
FMS / FASPPS
C R P
M R P
M P S
livello 4 - tempo realeorizzonte temporale correnteReal Time Scheduling
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SCAMP system
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SCAMP system
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AN EXAMPLE OF
MANUFACTURING CELL
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Badger Meter CELL
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Badger Meter CELL
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FANUC FMS