Poly Mechanics

&
Automation
SAE-GOE
Hour 1 Topics - Poly Mechanics & Automation
• What is Poly Mechanics & Automation
• Duties in Poly Mechanics & Automation
• Skills of Poly Mechanics & Automation
• Modern Automotive Industry
• Career in Poly Mechanics & Automation
 India’s Ranking
Year wise Country Position
in Professional Skills
Total Medal Points Received at Competitions
2011 2013 2015 2017
0
16
5 14
14 1 Silver Medal
10 1 Bronze Medal
12
9 Medallion of
15 19 Excellence
10
20
8
56 8
8 Medallion of Excellence
25 29
30 33 6
45
35 39 4 3 3 Medallion of Excellence
47
40 2
48 0
45
0
Country Position No. of Countries 2011 2013 2015 2017
Total Medal Points
Job roles in Manufacturing Industry
• Level 1 Job – Assemblers and fabricators put together pieces of products, and
assemble finished products. They use their hands, as well as tools and machines.
• Level 2 Job – Welders, solderers, cutters, and brazers use equipment to cut or
join metal parts. These positions require some technical education
• Level 3 Job – Machinists and operators use tools and die makers to set up,
maintain, and operate computer and mechanically-operated machines that are
used to create parts for the manufacturing process
• Level 4 Job – Production managers oversee the day-to-day production
operations. They ensure that production stays on schedule, they hire and manage
workers, and they fix production issues.
• Level 5 Job – Quality control inspectors examine raw materials and finished
products for any hazards, defects, or deviations by using technical equipment and
computer programs.
Who is a PM & A technician
• Level 3 Job – Maintenance Engineers/ Machinst /Operators
• Technicians belonging to electrical and mechanical engineering,
• Produce parts for production machinery and install those parts,
• Mechanical & Maintenance Fitters adept at hydraulics, pneumatic &
mechanical components.
• Carry out technical work in production plants and advice on issue
resolving procedures.
Duties of a PM & A technician
Duties of a Poly Mechanics and Automation technician
1. Work organization and management
2. Engineering Manufacturing process
3. Manufacturing Assembly principles
4. Electrical principles and automation control systems
Skills of Poly Mechanics & Automation
• skills in machining tools, logic, automation control, basic electrical
circuitry
• skills to diagnose and troubleshooting problems
• keen awareness of the implications, both financial and business
reputation, of delays in production as a result of reliability issues on
the production line.
• Meet time constraints to provide innovative and cost-effective
solutions to production issues.
• proactively promote health and safety best practices and legislation
1. Work organization and management duties
• The technician must know and understand:
• Health and safety legislation and best practice
• The range and uses of trade related machinery
• How to use and operate machine tools safely
• Specific safety issues relating to working with air and fluids
• Specific safety issues relating to work involving electricity
• Specific safety issues relating to work involving cutting tools
• The importance of working logically and in a well-organized manner
• The financial and business implications of faulty engineering equipment or
plant
• The importance of listening as part of effective communications
1. Work organization and management skills
• Consistently apply and promote health and safety legislation and best
practice and work in a safe manner on a worksite
• Operate trade machinery effectively, safely, and in accordance with
manufacturers’ instructions
• Select and use appropriate machine tools safely and effectively
• Select and use appropriate trade related cutting tools including air and
fluids
• Work within regulations and best practice when working with electricity
• Plan and prioritize own work and work of others to maximize efficiency and
to meet prescribed timescales
• Demonstrate strong listening and questioning skills to deepen
understanding of complex situations
2. Engineering manufacturing process duties
• The technician must know and understand:
• How to interpret engineering drawings (ISO standards)
• Terminology and symbols used in engineering drawings and
specifications
• How parts are produced using engineering machine tools such as
milling, turning, and grinding
• Feeds and speeds to operate machinery
• Types and characteristics of materials used in the manufacturing
industry • Ferrous • Non-ferrous • Composites
• Principles of pneumatics in automation projects
 2. Engineering manufacturing process skills
• Understand, interpret, and analyse engineering drawings supplied on both ISO E or ISO A
standard formats
• Explain content and implications of engineering drawings to others
• Manufacture parts in regard to supplied drawings using the most appropriate methods,
materials, and tools to specified tolerances
• Manufacture engineering parts by using processes of milling, grinding, and turning
• Select appropriate materials for manufacturing parts from materials used in the
manufacturing industry – ferrous, non-ferrous and composite materials
• Manufacture parts to specific tolerances by effectively use precision engineering
measuring tools
• Demonstrate the use feeds and speeds effectively while operating engineering machinery
• Produce systems using pneumatics
3. Manufacturing assembly duties
• The technician needs to know and understand:
• Mechanical systems principles and operations in order to support
fault finding and diagnosis.
• Principles of pneumatics in manufacturing plant in order to support
fault finding and diagnosis
• Procedures and order for assembly of engineering parts, either
supplied or self-manufactured
• • Interpretation and understanding manufacturers’ instructions for
supplied parts and engineering plant
3. Manufacturing assembly skills
• Assemble self-manufactured and supplied engineering components
• Read, interpret and follow manufacturer’s instructions for supplied
engineering parts and plant
• Locate and diagnose faults in engineering machinery and plant
Engineering manufacturing process
• Explain faults to other professionals, describing the cause, implication, and
remedy
• Using specialist technical knowledge and expertise, remove, or repair faults
• Following appropriate investigation and consideration, find, and apply
innovative solutions to difficult challenges
• Provide Expert advice and guidance on ongoing use and maintenance of
engineering plant and machinery to avoid or minimize future faults
4. Electrical and automation control systems duties
• The technician needs to know and understand:
• Principles of electricity and its use in a manufacturing setting
• Principles behind electrical wiring circuits in automation and PLC control
systems
• Electrical and programme logic controller (PLC) systems and their use in
automation and the manufacturing process
• Programming of PLC systems
• Commissioning an automation project
• Fault finding and faults remedy in both mechanical and electrical systems
• Common faults and weaknesses found in electrical and PLC systems
4. Electrical & automation control systems
skills
• Wire automation and functions of a project (low voltage)
• Produce and initialize PLC programmes for sequence relay control,
motion control, process control, distributed control systems and
networking
• Commission an automation report
• Interpret and analyse an automation report and recommend and
initialize remedial action required
• Remove or repair any electrical faults
• Test equipment or plant to ensure that it is operating properly
Modern Automotive Industry requirements
• Automotive=Automated
• Electric vehicles
• IOT
• Green Power
• Driverless
• Modern Materials
• 3D printing
• Grid Hire
• Safety
• Multi mode transport
Automotive=Automated
• Computerised Wheel Alignment
• Automated Service centres
• In vehicle Diagnostics
• In vehicle Networking – CAN, LIN,
• Cognitive security
• Intelligent Dash Boards
• Rear Cameras
• Map assistant
• Voice Assistant
• Entertainment Assistant(In vehicle Infotainment)
Electric vehicles
• Electric Automobiles- planes, trains, bus, car, bikes, hover board,
skates
• 10 minutes to change entire engine
• Seconds to diagnose vehicle issues
• Hours to charge
• Paisa/Units per kilometre
• 5 main parts of an electric motor – Stator, Commutator, Rotor,
Brushes, Coil
IOT
• Automation using Internet communication technology
• Things – sensors, devices, modules, actuators,
• Real time monitoring
• Automated travelling Protocols
• Driving assistance
• Energy assistance
• Predictive maintenance assistance
• Emergency assistance
Green Power
• Eco friendly Hybrid designing
• Solar power
• Hydel power
• Steam power
• Gas power
• Manual power
• Electric
• Biodiesel
• Hydrogen Fuel cell
• bioGas
Driverless
• Autonomous, Automated, Co-operative
• Hyderabad Metro
• Lufthansa Airways
• Voyager Spaceship
• Google Waymo, Uber Vehicle
• Driverless Automobiles- Citizen Bus
• Technologies – IoT, Robotics, poly Mechanics, Automation
• Protocols – autonomous vehicle, safe, Autosar, traffic
Modern Materials
• Material Selection Charts – Ashby charts
• Plastic
• Carbon Alloys
• Glass, Ceramic
• AL, MG, CU, Steel alloys
• Nano technology
• Tensile Strength vs Density
• Strength vs Cost
• Strength vs Energy
• Performance - Thermal, Chemical and Mechanical properties
3D printing
• Complex geometries
• Fast prototyping
• Lab Testing
• Nano technology
• Design Testing
• Nylon, Resin, Wax, Steel, Photopolymer,
Hire
• Grid Hire
• Car Pooling
• Multi destinations
• Self Drive
• Ola & Uber
Safety
• Passenger safety airbags, central lock, biometric, RFiD, BT,
• IoT Medic Aid
• Water bags
• Crash bags
• Child safety
• Real time Navigation assistance
• Real time vehicle maintenance
• Anti puncture solution / wheel change solution
Multi mode travel
• Metro to Bus, Car, Bicycle
• Boat to Train, bus, bicycle
• Bicycle
• Train to Plane, Ship,
• DLF, Blue Dart, Delta, AWS,
Demand for PM & A technicians
• Level 3 job role
• Automated manufacture technology – machining, assembling
• Automated repair technology – diagnostics, maintenance
• Cross industry sector demand
• Safe career prospects
• No recession damage
Hour 2 Topics - Automation
• Industrial Automation
• PLC
• SCADA
Industrial Automation
• Automation - the delegation of human control functions to technical
equipment.
• Programming device for sequence based or logic based functioning
routines
• Perform automatic operations by means of different kinds of
machines and Information technology
• No human intervention is needed
• No human supervision is needed
Advantages of Automation
• Higher productivity.
• Lower running cost.
• Superior quality of end product.
• Efficient usage of energy and raw materials.
• Improved safety in working conditions etc
Types of Automation
• Home/Building automation Example: lifts, smoke detectors
• Office automation Example: printers, cctv cameras
• Scientific automation Example: rocket launching,
• Light automation Example: street solar lightening
• Industrial automation Example: automated bottle filling stations ,
steel factories etc productivity.
Basic Structure of Automatic Control System

PLC Microprocessor Computers

Communication network

Network Interface

Analog controls
A/D D/A
converter converter Digital Signals
Analog
Signals

Sensors and Actuators

Physical Process
INDUSTRIAL AUTOMATION-MANUFACTURING
Industrial Automation - The use of Computerized or robotic
devices to complete manufacturing tasks.
CONTROL SYSTEM

PLANT FIELD
INSTRUMENT

HARDWARE SOFTWARE
CONTROL CONTROL
PLC
• PLC is a industrial grade digital computer designed for multiple inputs
and multiple output arrangements (MIMO), designed to withstand
high temperature ranges, electrical noise, vibration and impact.
• PLC was introduced in late 1960’s
Components of a PLC system

Pushbuttons, contacts, limit switches, etc. Solenoids, contactors, alarms etc.

 What are Inputs?
• Switches and Pushbuttons
• Sensing Devices
• Limit Switches
• Photoelectric Sensors
• Proximity Sensors
• Condition Sensors
• Pressure Switches
• Level Switches
• Temperature Switches
• Vacuum Switches
• Float Switches
• Encoders
What are Outputs?

• Valves
• Motor Starters
• Solenoids
• Actuators
• Control Relays
• Horns & Alarms
• Stack Lights
• Fans
• Counter
• Pumps
• Printers
Chassis and Backplane

All PLCs need some method of communicating between the

controller, I/O and communications modules. Here are three

ways used to accomplish this communications between the

various components that make up the PLC system.

Power Supply
A power supply is needed to provide power to the PLC and any other
modules. Power supplies come in various forms:
• Power supply modules that fit into one of the slots in a chassis
•External power supplies that mount to the outside of a chassis
Stand alone power supplies that connect to the PLC or I/O through a power cable
•Embedded power supplies that come as part of the PLC block.
 Programming Software
Software that runs on a PC is required to configure and program PLCs

Different products may require different programming software. Software allows programs to be

written in several different languages.

Types of Programme Memory

Program memory

Programmable Non-programmable
(Read-write memory)

Non-alterable
Alterable
ROM / PROM

UV erasable Electrically erasable

EPROM / REPROM EEPROM / EAPROM

Semiconductor RAM Semiconductor

EEPROM / EAPROM
Components of a PLC system
• POWER SUPPLY - provides the voltage needed to run the primary PLC
components
• I/O MODULES - provides signal conversion and isolation between the
internal logic level signals inside the PLC and the field’s high level
signal.
• PROCESSOR Provides processing power to command and govern the
activities of the entire PLC system.
• PROGRAMMING DEVICE - To enter the desired program that will
determine the sequence of operations and to control the process
equipment or driven machine
PLC operation sequence
1)Self test: Testing its own hardware and
software for faults.
2) Input scan: Copy all the inputs and their Self test

values into memory.

3)Logic solve/scan: Using the input values, Input scan

the ladder logic program is solved once and

outputs are updated. Logic scan

4) Output scan: Output values will be

updated with temporary values in memory Output
scan
PLC programming languages
1) Ladder Logic
2) Functional Block Diagram
3) Sequential Function Chart
4) Boolean mnemonics
 Ladder Logic
 The ladder logic is the oldest programming language
for PLC.
 It is well suited to express Combinational logic.
The main ladder logic symbols represent the elements :

make contact

break contact

relay coil
 AND Gate OR Gate
A B Logic(Y) A B Logic(Y)
OFF OFF OFF
OFF OFF OFF
OFF ON ON
OFF ON OFF
ON OFF ON
ON OFF OFF
ON ON ON
ON ON ON

Y
A B Y
B
 NOR Gate NAND Gate
A B Logic(Y) A B Logic(Y)
OFF OFF ON OFF OFF ON
OFF ON OFF OFF ON ON
ON OFF OFF ON OFF ON
ON ON OFF ON ON OFF

A B Y Y

B
Block diagram of aPLC
Outputs
LEDs

Inputs
Ladder Logic Program for Start/Stop of Motor :

X1 X2 Y1

Y1
Programming PLC:
Starting of Motor:
Continuous Running of motor when Start Buttonis
released:
To Stop the Motor :
1. Reliability.
2. Flexibility in programming and reprogramming.
3. Cost effective for controlling complexsystems.
4. Small physical size, shorter project time.
5. High speed of operation.
6. Ability to communicate with computer systems inthe plant.
7. Ease of maintenance /troubleshooting.
8. Reduced space.
9. Energy saving.
10. Industry Grade tolerances
 Disadvantages of PLCs
 PLC devices are proprietary it means that part or software of one
manufacturer can’t be used in combination with parts of another
manufacturer.
 Limited design and cost option
 Fixed Circuit Operations.
 PLCs manufacturers offer only closed architectures.
Whereverautomation is desired the PLCs are best suited to meet the task.

Few examples of industries where PLCs are used :

1)Robotic manufacturing and control
2) Car park control
3) Train control station system
4) Food processing
5)Materials handling
6)Machine tools
7)Conveyer System etc.
Supervisory Control & Data Acquisition - SCADA
• SCADA or Supervisory Control and Data Acquisition is an real time industrial process control
systems used to centrally monitor and control remote or local industrial equipment such as
motors, valves, pumps, relays, etc
• Supervisory
 Operator/s, engineer/s, supervisor/s, etc
• Control
 Monitoring
 Limited
 Telemetry
 Remote/Local
• Data acquisition
 Access and acquire information or data from the equipment
 Sends it to different sites through telemetry
 Analog / Digital
 Ethernet External Instruments
PC links
and Control Devices

Direct serial
link

fieldbus

Modem

Radio
Advantages of SCADA
The primary purpose of SCADA is supervisory control of remote
systems - to monitor, control, alert, Visually represent Data and
continuous Data acquisition
• Saves Time and Money
• Less traveling for workers between components
• Reduces man-power needs
• Increases production efficiency of a company
• Cost effective for power systems
• Saves energy
• Reliable
Hour 3 Topics - Automation
• DCS
• HMI
• Pneumatics
• Hydraulics
DCS – Distributed Control system
• A distributed control system (DCS) refers to a control system usually
of a manufacturing company in which the controller elements are not
central in location but are distributed throughout the system with
each component sub-system controlled by one or more controllers
• The entire system of controllers is connected by networks for
controlling, communication and monitoring
Components of Distributed Control system
1. CPU
2. Analog Input Module
3. Digital Input Module
4. Analog Output Module
5. Digital Output Module
6. Communication System
7. Communication network bus
8. Human Interface system (HIS)
9. Field device
10. MES – Manufacturing equipment Systems
Uses of Distributed Control system
Architecture of Distributed Control system
Levels of Distributed Control system
Human Machine Interface (HMI)
• A human machine interface (HMI) is an interface which permits
interaction between a human being and a machine.
• Human machine interfaces vary widely, from control panels for
nuclear power plants to the screen and input buttons on a cell
phone.
Human Machine Interface (HMI)
• Two components are needed in a human machine interface. The
first is an input. A human user needs some way to tell the
machine what to do, to make requests of the machine, or to
adjust the machine. Examples of input devices include
keyboards, toggles, switches, touch screens
Variable Frequency Drive (VFD)
• Variable Frequency Drives are used to run the motors of single phase or
three phase supply.
• VFD is used to accelerate and deaccelerate the speed of motor
with in a particular time.

• Drives commands: -
• Start/Stop
• Speed reference
• Acceleration/ de-acceleration
Features of Variable Frequency Drive (VFD)
• Dynamic braking : -Dynamic braking stops the system more quickly than
coasting
• Highly efficient
• Low power consumption
• Small space consumption
• Low cost
• Easy to use
• Highly specific
Pneumatic systems
• A pneumatic system is a system that uses compressed air to transmit
and control energy
• Pneumatic systems rely on a constant supply of compressed air to
make them work. Compressed air is provided by an air compressor.
• The compressor sucks in air from the atmosphere and stores it in a
high pressure tank called a receiver. This compressed air is then
supplied to the system through a series of pipes and valves.
• Compressed air is mainly used to do work by acting on a piston or
vane. Pneumatic energy is used in steel industry.
Uses of Pneumatic systems
1. Pneumatic presses,
2. Pneumatic drills
3. pneumatic rammers
4. Spray painting
5. Chemical spraying
6. Riveting
7. Machining tools
8. Unloading of hoppers and bins,
9. Lifting and moving of objects
10. Operating system valves for air, water or chemicals
Hydraulic systems

• A Hydraulic system is a system that uses compressed liquid to

perform tasks. They work on Pascal’s Law.
• The pressurized fluid in an Hydraulic systems acts upon every part of
the section of a containing vessel and creates force or power.
• By the use of this force, operators can lift heavy loads, and precise
repetitive tasks can be easily done.
• Hydraulic systems are mainly used to do work by acting on a piston or
vane. They are mostly used in Automotive and Aeronautical industry.
Uses of Hydraulic systems
1. Jack Hammer
2. Breaker
3. Vehicle lifter
4. Splitter
5. Wrench
6. Pressure Sensor
7. Pressure Switch
8. Riveters
9. Lifting and moving of objects
10. Nail and Staple machines
Hour 4 Topics – Engineering Drawing
• Introduction
• Types
• Symbols In Automotive Industry
• Advanced symbols
• Project discussion – Driver less car with OpenCV & Python
Introduction to Engineering Drawing
• A type of technical drawing, that is used to clearly define the shape
and dimensional requirements for engineered item
• It is also a graphical language that communicates designing ideas and
manufacturing information.
• Since the advent of computer-aided design (CAD), engineering
drawing are mostly done in the electronic medium using computers
and electronic graphic tools.
• Some of the tools of manual drafting include pencils, pens and their
ink, straightedges, T-squares, French curves, triangles, rulers,
protractors, dividers, compasses, scales, erasers, and tacks or push
pins.
Introduction to Engineering Drawing
• Engineering drawing is used to transfers information from design into manufacture.
• In Model-Based Definition (MBD) or Digital Product Definition (DPD) the information
captured by the CAD software is fed automatically into a CAM (computer-aided
manufacturing) program, which creates code in machine understandable languages
such as G-code. This code can be executed by a CNC machine tool (computer
numerical control), 3D printer, or a hybrid machine tool that uses both.
• In MBD, the dataset, is not a drawing but a legal instrument.
• The term "technical data package" (TDP) is used to refer to the complete package of
information that communicates information from design to production
• Engineering drawing is used by CAD/CAM programmers, CNC setup workers, and
CNC operators to do manufacturing, as well as quality assurance staff (inspectors)
and logistics staff (for materials handling, shipping-and-receiving, and front
office functions).
Engineering Drawing
Engineering Drawings convey the following critical information:
• Geometry – the shape of the object; represented as viewed from
various angles, such as front, top, side, etc.
• Dimensions – the size of the object is captured in accepted units.
• Tolerances – the allowable variations for each dimension.
• Material – represents what the item is made of.
• Finish – specifies the surface quality of the item, functional or
cosmetic.
 Engineering Drawing – line styles
A variety of line styles graphically represent physical objects:
• visible – continuous lines used to depict edges directly visible from a particular angle.
• hidden – short-dashed lines that may be used to represent edges that are not directly
visible.
• center – alternately long- and short-dashed lines, used to represent the axes of circular
features.
• cutting plane – thin, medium-dashed lines, or thick alternately long- and double short-
dashed used to define sections for section views.
• section – are thin lines in a pattern used to indicate surfaces in section views resulting
from "cutting". Section lines are commonly referred to as "cross-hatching".
• phantom –alternately long- and double short-dashed thin lines used to represent a
feature or component that is not part of the specified part or assembly.
Engineering Drawing – Projections
• Multi view Projection is a orthographic projection that shows the object as
it looks from the front, right, left, top, bottom, or back and is typically
positioned relative to each other according to the rules of either first-angle
or third-angle projection. The origin and vector direction of the projectors
(also called projection lines) differ.
• Auxiliary view is an orthographic view that is projected into any plane other
than one of the six primary view’s. These views are typically used when an
object contains some sort of inclined plane.
• An isometric projection shows the object from angles corresponding to
rotation of the object by ± 45° about the vertical axis, followed by rotation
of approximately ± 35.264° [= arcsin(tan(30°))] about the horizontal axis
starting from an orthographic projection view.
Engineering Drawing – Projections
 Engineering Drawing - Symbols
• Engineering drawing abbreviations and symbols are used to
communicate and detail the characteristics of an engineering drawing.
• Technical standards exist to provide abbreviations, acronyms, and
symbols that may be found on engineering drawings.
• Many corporations have such standards, which define some terms and
symbols specific to them.
• At International level, ASME standard Y14.38 is one of the widely used
standards.
Machining Tools and process
• Drilling
• Turning
• Milling
• Grinding
• Chipping
Q & A session
Project Description – Driverless Car using
OPenCV and Python