Automation

Automation can be defined as a technology concerned with the application of mechanical, electronic and
computer based systems to operate and control production.
The definition of automation is the use of machines and technology to make processes run on their own
without manpower.

AUTOMATED MANUFACTURING SYSTEMS

Automated manufacturing systems operate in the factory on the physical product. They perform operations such
as processing, assembly, inspection, or material handling in some cases accomplishing more than one of these
operations in the same system. They are called automated because they perform their operations with a reduced
level of human participation compared with the corresponding manual process. In some highly automated
systems, there is virtually no human participation.

Examples of automated manufacturing systems includes:

Automated machine tools that process machine parts
Transfer lines that perform a series of machining operations
Automated assembly systems
 Manufacturing systems that use industrial robots to perform
processing or assembly operations
Automatic material handling and storage systems to integrate
manufacturing operations
Automatic inspection system for quality control

Automated manufacturing systems can be classified into three basic types

1. Fixed automation
2. Programmable automation
3. Flexible automation

1. Fixed Automation
Fixed automation is a system in which the sequence of processing operations is fixed by the equipment
configuration. Each of the operations in the sequence is usually simple, involving perhaps a plain linear or
rotational motion or an uncomplicated combination of the two; for
example, the feeding of a rotating spindle. It is the integration and coordination of many such operations into one
piece of equipment that makes the system complex.
Typical features of fixed automation are:
High initial investment for custom-engineered equipment
High production rates
Relatively inflexible in accommodation product variety

The economic justification for fixed automation is found in products that are produced in very large quantities
and at high production rates. The high initial cost of the equipment can be spread over a very large number of
units, thus making unit cost attractive compared with alternative methods of production. Example of fixed
automation includes machining transfer lines and automated assembly machines.

2. Programmable Automation
In programmable automation, the production equipment is designed with the capability to change the sequence
of operations to accommodate different product configurations. The operation sequence is controlled by a
program which is a set of instructions coded so that they can be read and interpreted by the system. New
programs can be prepared and entered in to the equipment to produce new products.
Some of the features that characterize programmable automation include:
High investment in general purpose equipment
Lower production rates than fixed automation
Flexibility to deal with variations and changes in product configuration
Most suitable for batch production

Programmable automated systems are used in low and medium volume production. The parts or products are
typically made in batches. To produce each new batch of a different product, the system must be reprogrammed
with the set of machine instructions that correspond to the new product.

3. Flexible Automation
Flexible automation is an extension of programmable automation. A flexible automation system is capable of
producing a variety of parts with virtually no time lost for changeovers from one part style to the next.
There is no lost production time while reprogramming the system and altering the physical setup (tooling, fixture,
machine settings). It is a case of soft variety, so that the amount of changeover required between styles is minimal.

The features of flexible automation can be summarized as follows:

High investment for a custom engineered system
Continuous production of variable mixture of products
 Medium production rates
Flexibility to deal with product design variations
Examples of flexible automation are the flexible manufacturing systems for performing machining operations
that date back to the late 1960s.

AUTOMATIC TOOL CHANGER

An Automatic Tool Changer is equipment that reduces cycle times by automatically changing tools between cuts.
Automatic tool changers are differentiated by tool-to-tool time and the number of tools they can hold.
CNC tool changers allow a machine to perform more than one function without requiring an operator to change
the tooling. A CNC tool changer can quickly change the end effectors without the requirement of multiple robots.
Tool changers can be a manual tool changers or automatic tool changers. A CNC tool changer fulfills the
requirement of multiple tooling for a wide variety of machine tools.
Why Tool Changer is needed?
Tool changer is equipment which is used in CNC machines to reduce the cycle time. The term applies to a wide
variety of tooling, from indexable insert, single point tools to coded, preset tool holders for use in automatic tool
changers. It includes power-actuated, cross-slide tooling and turret tool holders for single spindle chuckers,
interchangeable-block boring tools.

A number of basic types of tool holders are available that accommodate most face mills, end mills, drills, reamers,
taps, boring tools, counterbores, countersinks, and spot facers. Arbor type cutters such as face mills and shell end
mills are held in an arbor type tool holders. Shank type mills are held in positive lock holder. Drills, reamers and
boring tools are held in a straight shank collet type holder. Taps are held in a tension and compression collet type
holders.

TYPES OF AUTOMATIC TOOL CHANGER

There are mainly three kinds of tool changers available in market according to the tool magazine arrangements
provided.

Tool change system with gripper arm

Tool change system with chain magazine

Tool change system with disc magazine

 A machining center
A machining center can be defined as a sophisticated CNC machine tool controlled by a computer running
programs driven by numerical data, which can perform multiple machining operations like milling, drilling,
tapping and boring operations at the same location control by making use of several area and a variety of tools
with Automatic Tool Changer (ATC) unit:

The CNC machining centers can be broadly categorized into two varieties.

a) Vertical machining centers (VMC)

b) Horizontal machining centers (HMC)

a) Vertical machining centers (VMC)

Vertical Machining centers are mainly used for flat type of work, such as plates, where the Majority of machining
is done on only one face of the part in a single setup. Most of the general VMC comes with 3 axes. However there
are some versions of vertical CNC machining center with an optional forth axis, usually a rotary head mounted
on the main table. The rotary head can be mounted either vertically or horizontally depending on the desired
results and the model type. This fourth axis can be used either for indexing or a pull rotary motion.
b. Horizontal Machining Centers (HMC)
Horizontal CNC machining centers are categorized as multi-tool and versatile machines, and are used for heavy
rectangular black Paris, where the majority of machining has to be done on more than one face in a single setup.
There are many applications in this area. Common examples are zarge Paris, such as Pump housing, gear cases,
manifolds, engine blocks and so on. Since there machines provides for heavier metal removal rates, the cutting
tools used are normally big. As a result, the tool magazine has to provide. For Zorger place for each tool. This
results in the tool magazines for HMC being heavier. Because of their Flexibility and Complexity, CNC HMCs
are priced significantly higher than VMCs.

Part Program

The set of instruction by which we can produce a part is known as part program.
It has 2 parts
Main Block
Sub Block
Main Program- It contains machine definition, tool definition & raw material definition. It doesnt deals with
tool movement.
Sub Program- It only contains of tool movement.
Steps to write a program
Read the drawing.
Think about all sequential operation.
Specify raw material size.
Tool definition.
Tool call.
Specify the tool position.
Specify the Z0 position.
Specify the depth of cut.
Specify co-ordinates for cutting operation.
Retract the tool at the end of the cut.
End of program.

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