Manufacturing Technology (ME461)

Instructor: Shantanu Bhattacharya

Review of last lecture

Loading of program in CNC systems. EIA and ASCII schemes of loading of program. Punching system (odd and even parity checks). Conventional numerical control. Direct Numerical Control. Distributed numerical control. Programmable logic controllers. Logic control (Attribute type questions and variable type questions)

Logical Control
The logical relationships can be expressed in a diagram form called a logic network diagram whose symbols are expressed below. The devices implementing the various logical relationships are what we refer to as logic devices. These logic devices are used in constructing PLC Although the logic network diagrams could be used to represent the logic in a PLC control program, another logic diagramming technique is known as ladder logic diagram.

These are more widely used in the industries and they were retained as PLCs got introduced from a convenience point of view of the technicians who were involved in wiring the various systems that were being controlled.

Ladder Logic Diagram

The ladder logic daigram makes use of representations similar to electrical circuits in which a series of connections represents a logical AND and a parallel connection represents a logical OR. A ladder logic diagram is made up of inputs and outputs connected accroding to appropriate logic. Each rung in the ladder represents a set of logical relationships between the inputs that lead to a particular output. The output from one rung of ladder could be used as an input in another rung of the same ladder. Except when special provisions are made it is considered that all rungs in a given ladder logic diagram are executed simultaneously, so the order of the rungs on the ladder in general does not matter.

Solved Example
A robot is to be used to unload finished parts from a machine onto an AGV and to load raw parts from the AGV to the machine. Assume that there are sensors at the AGVs docking station to indicate the arrival of the vehicle and onboard sensors on the vehicle to indicate whether the vehicle has actually brought some raw parts to be machined and whether the AGV has space to carry away a finished part. Also, assume that there are sensors on the machine to indicate whether the machine is loaded with a part and also a signal for the completion of part processing. The robot is required to unload a processed part from the machine onto the AGV, pick up a new part for processing from the AGV, and load it onto the machine. The AGV is to be dispatched after the completion of the cycle. Construct a ladder logic diagram.

Solution
I/O 01 02 03 04 20 21 22 Meaning/ Associated Action AGV has arrived AGV is carrying a new part to be processed AGV has space to store a processed part Machine has a finished part to be unloaded Unload old part from the machine onto the AGV Pick new part from the AGV and load onto the machine Dispatch the AGV

Solution

1. The first rung states that if inputs 01, 03, and 04 are all true, then output 20 is true. This is interpreted as meaning that if AGV has space to store a processed part, and the machine has a finished part to be unloaded, then the robot should unload the old part from the machine onto the AGV. 2. The second rung states that if (input 20 is true AND input 02 is true), OR (input 01 is true, and input 04 is not true, and input 02 is true), then output 21 is true. This rung thus illustrates the use of OR in a ladder logic diagram. The rung is interpreted as meaning that if the machine has been unloaded, and the AGV is carrying a new part to be processed, then the robot should load the new part from the AGV onto the machine. In this case there are two scenarios in which the same output may be obtained. Note in particular that output 20 from the previous rung is being used as an input on the current rung.

3. The third rung contains the logic for dispatching the AGV after it arrives at the docking station

Counters and Timers

Counters can be used in manufacturing to measure quantities such as production stock, inventory, and packaging. The counter accomplishes its task by counting voltage pulses, which can be generated by a sensor set to detect the event whose occurrence is to be noted. Every time a pulse is received the count is changed by one. For example the production stock can be counted with this technique. With the timers the main difference is that they are used specifically to count clock pulses. As a result, timers can be seen as clock driven whereas regular counters are event driven. A counter can be constructed to count up or down or both. Counters typically may have another input line to reset the counter to its initial value (usually zero). Dependent on the intended application, the counter may have more than one output. For example some counters may have CARRY (when the counter exceeds its maximum set limit) or BORROW (when the counter goes beyond its lower minimum set limit). Such counters can be connected in cascade fashion with a CARRY/BORROW from one counter connected to the input of the next counter, increasing the overall range of counting.

Example Problem
During the powder metallurgy process, a punch is used to press blended metal powder into a compact inside a die. A push button is used to start the process. When the start button is pressed, the die is filled with powder. The punch is then advanced and it applies pressure to the powder for a duration of 10s, after which it is retracted. The pressed compact is then ejected from the die and the cycle repeats itself. The cycle can be interrupted by pressing the stop button. If the stop button is pressed the punch is required to retract (if it had been advanced) before the process is stopped. We are required to construct a ladder logic diagram.

Solution
I/O 01 02 T1 30 31 32 34 35 Meaning Start Button Stop Button Timer (with a limit of 10s) Fill die Advance punch Retract punch Eject part (i.e., compact) Stop cycle

Solution
When the start button is pushed to initiate the process, or if a part has been ejected successfully from the die, and if the stop button has not been pushed, the die is filled with predetermined amount of powder. After the die is filled, the punch is advanced to start applying pressure on the powder. The pressing time is to last for 10s, after which the timer resets itself. After the 10s, or any time the stop button is pressed, the punch retracts. After the punch retracts and provided the stop button has not been pressed, the part is ejected. After the part is ejected, the cycle repeats from the beginning. When ever the stop button is pressed the punch gets retracted and the cycle is stopped.

Sample problem
This example illustrates the use of both the timing and counting functions. Consider a production line in which parts requiring processing are brought to a machine by a conveyor. A robot is used to load parts from the conveyor onto the machine and, after the part has been processed, unload the part from the machine and place it on the pallet. The cycle time for processing each part is 10mins. The robot is to palletize the parts by placing 125 parts on each pallet. The parts are to be arranged on the pallet in five layers of 25 parts each. Once the pallet is complete, it is dispatched and a new pallet is started. An allowance of 30 s is to be made for pallet dispatching and presentation of a new pallet. Construct a ladder logic diagram to effect the required control.

I/O 10 30

Meaning/ Associated Action Machine has a part to be unloaded Load machine with a new part

Solution

40
45 48 50 60

Unload a process part from the machine

The current pallet layer is full Increment layer being palletized by 1 The pallet is full-dispatch Present a new pallet

C100
C200 T250

Up counter with a limit set to 25

Up counter with a limit set to 5 Timer with limit set to 600s

Description of the various rungs

Notice that no identifying number for a counter or timer has been used more than once. This is a good practice as most of the PLCs use the same memory location for storing counter and timer data. Within the ladder logic diagram, the reader should note that a counter or timer function is set up on one rung and then references on another rung to trigger its function. Each of the counters and timers has two inputs and one output. One input triggers counting/ timing and the other input resets the device.

Description of various rungs

If the machine has a part to be unloaded and there is a pallet onto which to place it, the part is unloaded and placed on the pallet. After the part is unloaded or if there were no part in the machine to begin with a new part is loaded onto the machine. Timer T250 is used to time the processing operation, and after the 10min it takes to process the part, the robot is signaled that there is a part to be unloaded from the machine, T250 resets itself, and the cycle is repeated. Counter C100 is used to count parts as they are unloaded from the machine. When C100 counts 25 parts a signal is generated indicating that the current layer in the pallet is full and C100 is reset.

Description of various rungs

Counter C200 is used to count the number of full layers on the pallet. If the layer just completed is not the fifth layer, pallet loading is continued. When the no. of layers on a pallet reaches 5, a signal that the pallet is full is generated, the pallet is dispatched, and a signal is generated to present a new pallet. Timer T300 is used to time the dispatch and presentation of pallets, for which a time of 30 secs. is allowed. After the 30 secs, T300 resets itself and C200 also resets. The whole cycle can now be repeated with the newly presented pallet.

Generalized Process Control

We now see the concept of computer control of multiple manufacturing processes. By this we mean the use of a computer to monitor, control and coordinate the operations of various types of physical equipment on the sop floor in a concurrent manner. This type of control is an extension of the capabilities of the logical control associated with PLCs.
Specially, a control computer can be used to control several processes or pieces of equipment at the same time. This is in contrast with the PLC, which is dedicated to a single process, or the NC controller which is dedicated to a single machine. A control computer can be distinguished from the general purpose computer by its ability to communicate directly with the process or equipment being controlled. This capability for direct communication between the computer and process is called on-line-control. The main rationale for using a computer in manufacturing process is its response speed to the changing process parametres.