module 4_product design and process technologies

7/27/2019 Module 4_Product Design and Process Technologies

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ISAT 211 CIM-1 1997-2000 M. Zarrugh

Computer-Integrated Manufacturing (CIM):

What It Is and Key Issues*

Definition:The use of computer control and information technology tointegrate and automate basic product development and

production activities in a manufacturing enterprise.

Key Issues:

Automation of product development activities

Planning and control (low-level) of manufacturing

processPlanning, scheduling and control (high-level) of

factory resources (materials, labor and machines)

Communications and data management capabilities

*Read: (CAD/CAM Module by M. Zarrugh, pp. 1-14)


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Computers in Manufacturing:

Key Systems

Computer system(Communications

Data Management

Control)

Design

Automation(CAD/CAE/

Tech. Pubs.)

MFG Process

Automation(CAM/CAPP/CAT/

Robotics)

MFG Resource

Planning

(MRP/MRPII)

Engineering Manufacturing

Management

CAD Computer Aided Design

CAE Computer Aided Engineering

CAM Computer Aided Manufacturing

CAPP Computer Aided Process Planning

CAT Computer Aided Testing

MRP Manufacturing Resource Planning


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CIM System: Basic Processes

Common Database,

Management,

Control System

Computer

Control & Communications

PDM(manage

product

data andconfigurations)

MRP

or

MRPII(manageMFG

resources)

Engineering

ManufacturingCAD

(design automation)Geometric modeling

Product structureAutomated draftingGroup technology

CAE(simulation)

StructuralThermal

Kinematic/DynamicLogic/Timing

Tech. Publishing(writing, multi-media)

Word-processingManuals

Documentation

CAM

(process automation)Process planning

NC/CNC

Industrial robots

FMS

CAT(automated test)Prototype testingIn-process testing

InspectionCMM

MRP(factory MGMNT)Production control

PurchasingReceiving/warehouse

Materials tracking

1997-2000 M. Zarrugh ISAT 211 CIM-3


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Design Automation:

CAD

What is it?CAD is an automated technology forelectroniccapture ofgeometry (form and fit) of parts and how the parts arearranged to form subassemblies and assemblies.

Its Benefits:

Electronic form permits easy modification, distribution

and reuse of the data

Removes drudgery from drawing process

No need to re-enter data in downstream applications

Electronic documents easier to track than paper

Can be done by engineers so development is faster


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CAD:

Geometric Modeling

Wireframes: 2D

3D

3D + surfaces

Solids:

B-rep (define boundary and fill it)

CSG (Boolean operations on conic primitives)

NURBS (analytical definition of surfaces and intersections)

Automated Drafting:

Generation of format detail and assembly drawings

through 2D projections and x-sections of 3D geometric

models


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Design Automation:

Computer-Aided Engineering(CAE)

CAE is the application of scientific lawsto physical systems to predict their

behavior under a variety of conditions

without ever building actual hardware.The geometry, captured in CAD as a

solids model, can be used in many

downstream simulations. Structuralanalysis uses finite elements

(FE) to predictsmalldeformations and

stresses for known geometry, boundary

conditions, loads and elastic properties.


7/18ISAT 211 CIM-7 1997-2000 M. Zarrugh

CAE:

More Types of Engineering Simulations

FE and finite difference models, used inthermalsimulations, determine temperature

changes and distributions resulting from

known heat loads and thermal properties.

Kinematic and dynamic simulations

consider large displacements of

interconnected rigid bodies (linkages or

mechanisms) in response to specificmotions and forces.

Electronic circuit designers use CAE tools

to verify the logic and timingof ICs, VLSI

devices and circuit boards. Show Ideas video clip



Design Automation:

Technical Publishing

Product definition requires many documents created ondesktop publishing systems.

The documents may specify

applicable standards, describe:special materials or processing conditions

summarize test results and test and inspection methods

use and repair methods.

Standards needed to simplify the storage and archivalof the documents.

Format translators and plug-ins required from

transferring documents across systems.



Manufacturing Automation:

Computer-Aided Manufacturing (CAM)

What is it?

Originally CAM referred to numerical control of machine

tools. Now CAM includes all automated processes in MFG.

Its benefits: Automation technology facilitates meeting customer's and

regulatory requirements.

CAM increases productivity which reduces processdevelopment and production cost.

Automation reduces errors, rework and promotes use of

existing solutions which shortens time-to-market.



CAM Processes:

Computer-Based Automation in Manufacturing

Numerical Control (NC) and Computer NumericalControl (CNC) of machine tools

Automated (or Computer-Aided) Process Planning

(CAPP) and tooling and fixturing design

Machine loading, machining, assembly and

inspection using industrial robots

Automated materials handling, storage and retrieval

Automated test and inspection

Flexible Manufacturing Systems (FMS)



Computer Automation in Manufacturing:

NC/CNC

Numerical Control (NC) is the control of machinetools by a series of numerical instructions encoded

in an NC part program.

Computer Numerical Control (CNC) is directcontrol of machine tools using a dedicated computer

on board. Part programs can be generated and

edited at the machine tool.CNC machine tools are often equipped with

automatic tool changers and part loader to minimize

waiting and setup times,



Computer Automation in Manufacturing:CNC Essential Features

CADSTATION

IdeasOld DesignsCreativity

Standards

PartGeometry CAM

STATION

NC Programming

NCPrograms

NC or CNCMachine Tool

Speeds/FeedsMaterial & SizeTooling

Parts

Show video clip




Automated Process Planning (CAPP)

Computer Aided Process Planning (CAPP)is acomputer assisted process of preparing instructions onhow to fabricate a part or build an assembly.

CAPP begins with interpreting design data (geometryand materials) into manufacturing processes.

The output of CAPP is a part routing or a "process plan"detailing specific processing sequence, machines, tools,

fixtures and cutting conditions (speeds and feeds).

The generation of process plans is not fully automatedyet since it requires human input to provide detailed

knowledge of current practices and capabilities.




Industrial Robots

Industrial robots are articulatedmachines that can move and

process materials under computercontrol in the factory.

Robots give consistentperformancein repetitive tasks: machineloading, inspection, monitoring,assembly, etc.

Robots can work in hazardous orunpleasant environments: spray

painting, arc welding, grinding,sanding, cleaning, handling

hazardous material




Industrial Robots

Robots can reduce cost since theywork at about the same rate as people,but cost about 1/2 as much as labor tooperate per hour.

Robots can increase productivity sincethey can work 24 hrs/day, do not needbreak or call in sick.

Robots can improve flexibility andsince tasks can be changed by a merechange of program, but people need tobe trained or retrained



Computers Automation in Manufacturing:

Automated Testing and Inspection

Testing and inspection close the loop around processesto insure that they are producing the desired results.

Prototype testing reduces the number of design

iterations and quickly checks conformance to designspecifications.

Automated test equipment is used in electronicmanufacturing to insure that devices and circuit boards

are manufactured and assembled correctly.

Vision, Coordinate Measuring Machines (CMM) androbotic inspection systems are used in discrete and

process manufacturing to inspect parts and products.



Computers Automation in Manufacturing:

Flexible Manufacturing Systems (FMS)

An FMS is a computer-based system in which machine tools andworkstations are arranged in groups orcells.

Cells produce a limited variety of part types obtained from

applying group technology (GT). The cell layout minimizes

waiting, part transfer and setup times.

An FMS can "randomly" produce a pre-determined variety of

parts having similar processing requirements.

Computers control schedules and track materials. The major benefit of an FMS isflexibility:

Producing a mix of different parts on-demand

Dynamic routing of parts to maintain work load balance

Accommodating changing production volumes


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Computers in Manufacturing:

Conclusions

Because of intensifying competition and acceleratingrate of change, CIM emerges as a strategic weapon withwhich business can adapt and survive in an everchanging and increasingly competitive businessclimate.

CIM brings automation and integration which results in:

shorter product development cycle

lower product development cost

lower production costs

responsiveness to changing markets and technologies

increased process and product quality

module 4_product design and process technologies

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