Code No: 07A80307

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Set No. 2

IV B.Tech II Semester Examinations,APRIL 2011 AUTOMATION IN MANUFACUTRING Common to Mechanical Engineering, Mechatronics, Automobile Engineering Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. (a) Explain how the information is transferred in various levels of automation. (b) Discuss the advantages of automated system. What are the dierent types automation? Discuss them briey. Draw the simple block diagram of pneumatic circuit and discuss it briey. [8+8] 2. (a) With the help of neat sketches, explain the following linear transfer mechanisms: i. Walking Beam Transfer System. ii. Chain Drive Conveyor System. (b) Enumerate the dierences between synchronous and asynchronous transfer mechanisms. [10+6] 3. (a) What is Upper-bound approach used in the analysis of transfer lines? Explain with a suitable example. (b) Discuss briey about the following terms used in automated ow lines: i. Buer stock eectiveness. ii. Starving and Blocking of stations. 4. Briey describe the following AS/RS units: (a) Unit load AS/RS. (b) Mini load AS/RS. (c) Man-on-board AS/RS. (d) Automated item retrieval system. 5. (a) Discuss the following Rapid Prototyping techniques: i. Fused Deposition Modelling. ii. Droplet Deposition Manufacturing. (b) Discuss the reasons for implementation of Business Process Reengineering concepts in various companies. [8+8] 6. What is the objective of Adaptive Control with Constraints? Draw the block diagram of a typical computerized Adaptive Control with Constraints system for grinding process and explain in detail. [16] 7. (a) Briey discuss the following terms used in line balancing: 1 [44] [8+8]

Code No: 07A80307 i. Cycle Time. ii. Precedence Constraints. iii. Balance Delay.

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Set No. 2

(b) A manual assembly line is to be designed with a production rate of 100 completed assemblies per hour. The line will have eight stations and the length of each station is 1.0 m. The minimum allowable tolerance time is to be 2.0 min. If the line is gured to have an uptime eciency of 97% (estimated from previous similar lines), determine the following parameters for the line: i. ii. iii. iv. Ideal cycle time. Conveyor speed. Feed rate. Part spacing along the belt.

[8+8]

8. (a) Discuss the importance of vehicle management and safety in Automated Guided Vehicle System. (b) Describe the following cranes: i. Bridge crane. ii. Gantry crane. [8+8]

Code No: 07A80307

R07

Set No. 4

IV B.Tech II Semester Examinations,APRIL 2011 AUTOMATION IN MANUFACUTRING Common to Mechanical Engineering, Mechatronics, Automobile Engineering Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. (a) Discuss the powder based Rapid Prototyping system with the help of neat sketch. (b) Dene Concurrent Engineering and discuss the goals of Concurrent Engineering. [8+8] 2. (a) Dene Fixed Automation and Flexible Automation. Enumerate the dierences between them. (b) What are the important pneumatic components used in automated system? Describe briey. [8+8] 3. (a) Discuss the general methods of transporting work pieces on ow lines. (b) Discuss the advantages and limitations of the continuous transfer mechanisms. [10+6] 4. (a) Enumerate the dierences between lower bound approach and upper bound approach. (b) In the operation of a certain 15-station transfer line, the ideal cycle time is 0.58 min. Breakdowns occur at a rate of once every 10 cycles and the average downtime per breakdown ranges between 2 and 9 min, with an average of 4.2 min. The plant in which the transfer line is located works an 8-hour, 5 days per week. How many parts will the line be capable of producing during an average week? [6+10] 5. (a) What is manual single station assembly and manual assembly line ? Enumerate the dierences between them. (b) A manual production ow line is arranged with six stations and a conveyor system is used to move parts along the line. The belt speed is 1.8 m/min and the spacing of raw workparts along the line is one every 1.35 m. The total line length is 13.5 m, hence each station length equals 2.25 m. Determine the following: i. Feed rate. ii. Tolerance time. iii. Theoretical cycle time.

[6+10]

6. (a) Discuss the important features and applications of various non-powered industrial trucks and various powered industrial trucks. (b) Explain the following conveyor systems: 3

Code No: 07A80307 i. Cart-on-track conveyor. ii. Screw conveyor.

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Set No. 4
[8+8]

7. (a) Explain the conguration and control features of carousel storage systems. (b) Discuss the important applications of carousal storage systems. [8+8]

8. (a) Explain the various operation parameters that can be measured in turning operation to use them in adaptive control systems. (b) Briey discuss the application of Adaptive Control in turning operation.[8+8]

Code No: 07A80307

R07

Set No. 1

IV B.Tech II Semester Examinations,APRIL 2011 AUTOMATION IN MANUFACUTRING Common to Mechanical Engineering, Mechatronics, Automobile Engineering Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. (a) Discuss the following factors in material handling equipment: i. Flow rate of materials. ii. Routing factors. (b) When are the cranes used in manufacturing industries? Describe the dierent types of cranes used for material handling. [8+8] 2. (a) With the help of neat sketches, explain the following linear transfer mechanisms: i. Powered Roller Conveyor System. ii. Walking Beam Transfer System. (b) Explain the advantages and limitations of synchronous transfer mechanisms. [10+6] 3. (a) What is Rapid Prototyping? Explain what type of materials can be processed by Rapid Prototyping techniques. (b) Discuss the advantages and limitations of Rapid Prototyping Techniques.[8+8] 4. (a) Explain how the eciency of manufacturing plant can be improved by employing the following automation strategies: i. ii. iii. iv. Integrated Operations. Process Control Optimization. Increased Flexibility. Computer Integrated Manufacturing.

(b) Discuss the following automated machine tools: i. Rotary Indexing Machine ii. Transfer Machine. [8+8]

5. What is Adaptive Control with Optimization? Draw the block diagram of Adaptive Control with Optimization for turning process and explain the various parameters measured. [16] 6. (a) Discuss the objectives for installing an automated storage system in a factory. (b) What are the reasons that justify the installation of an automated storage system for work-in-process? [8+8]

Code No: 07A80307

R07

Set No. 1

7. (a) The following data apply to a 12-station in-line transfer machine: P = 0.01 (all stations have an equal probability of failure) Tc = 0.3 min Td = 3.0 min Using the lower-bound approach, compute the following for the transfer machine: i. The frequency of line stops. ii. The average production rate. iii. The line eciency. (b) The following data apply to a 12-station in-line transfer machine: P = 0.01 (all stations have an equal probability of failure) Tc = 0.3 min Td = 3.0 min Using the upper-bound approach, compute the following for the transfer machine: i. The frequency of line stops. ii. The average production rate. iii. The line eciency. 8. (a) Explain the following terms in line balancing: i. Manual rational work element. ii. Total work content. iii. Work Station Process Time. (b) The total work content time of a certain assembly job is 7.8 min. The estimated downtime of the line is D = 5% and the required production rate is Rp = 80 units/hr. i. Determine the theoretical minimum number of workstations required to optimize the balance delay. ii. For the number of stations determined in part (i), compute the balance delay d. iii. What feed rate should be specied if a moving belt line is to be used? [6+10]

[8+8]

Code No: 07A80307

R07

Set No. 3

IV B.Tech II Semester Examinations,APRIL 2011 AUTOMATION IN MANUFACUTRING Common to Mechanical Engineering, Mechatronics, Automobile Engineering Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. (a) What is adaptive control? Under what conditions adaptive machining and non-adaptive machining. (b) Discuss the comparisons between adaptive machining and non-adaptive machining. [8+8] 2. (a) Dene Lower bound approach used in the analysis of transfer lines without storage buer and explain with suitable example. (b) Briey discuss the following related to the eciency of an automated ow lines: i. Eciency of line with storage buer. ii. Eciency of line without storage buer. [8+8]

3. What are the dierent types of Non-powered industrial trucks and powered industrial trucks? Discuss them with the help of simple sketches. [16] 4. (a) Briey discuss the following assembly processes: i. Mechanical fastening ii. Joining methods (b) What are the various techniques for solving large scale line balancing problems based on the use of the computer? Describe any one technique. [8+8] 5. (a) Discuss the following automation strategies: i. ii. iii. iv. Combined Operations On-line inspection Plant Operation Control Process Control and Optimization.

(b) List out the various hydraulic components that can be used in automated manufacturing systems. Explain them briey. [8+8] 6. (a) Explain the various special features of AS/RS components. (b) Discuss the following interfacing problems in AS/RS systems: i. Mechanical interface. ii. Information interface. [8+8]

7. (a) Draw the neat sketch of Rachet and Pawl mechanism for rotary indexing table and discuss briey. 7

Code No: 07A80307

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Set No. 3

(b) A Geneva with six slots is used to operate the worktable of a dia indexing machine. The slowest workstation on the dial indexing machine has an operation time of 3 seconds, so the table must be in a dwell position for this length of time: i. At what rotational speed must the driven member of the Geneva mechanism be turned to provide this dwell time? ii. What is the indexing time each cycle? [6+10] 8. (a) Discuss the importance of Concurrent Engineering approach. (b) What are the dierent methodologies available in Business Process Reengineering? Discuss them briey. [8+8]