8 - Semester ME 408 Theory Course Plan

Kasegaon Education Society (KES)
Rajarambapu Institute of Technology (RIT)

DEPARTMENT OF MECHANICAL ENGINEERING
FMTH0301/Rev.5.1
Course Plan
Semester: 8 - Semester
Year:
Course Title: Automation and Robotics
Course Code: ME 408
Total Contact Hours: 4
Duration of SEE Hours: 3
SEE Marks: 50
ISE + MSE Marks: (20+30=50)
Lesson Plan Author: Prof. Mukund Kavade
Date: 19-01-2016
Checked By: Prof. Chandan Waghmare
Date: 20-01-2016
Prerequisites:
1. Knowledge of Advanced Production Systems.
2. CNC Machine tools
3. Knowledge of CNC part programming etc.
Course Outcomes (COs):

At the end of the course the student should be able to:
1.
Recognize manufacturing automation and Advanced Automation Functions

Explain process and discrete manufacturing industries and its processes.
3. Explain and evaluate Transfer Lines and Assembly Automation.
4. Recognize and explain need, meaning and classification of robotics, its control systems and end
effectors.
5. Write simple robot programs in VAL II language.
6. Explain robot applications
2.
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Page 1 of 13.

Course Articulation Matrix: Mapping of Course Outcomes (CO) with Program

Outcomes
Semester: 8 - Semester
Course Code: ME 408
Year:
Course Outcomes (CO) / Program Outcomes

(PO)
1. Recognize manufacturing automation and

Advanced Automation Functions
2. Explain process and discrete manufacturing

industries and its processes.
3. Explain and evaluate Transfer Lines and
Assembly Automation.
4. Recognize and explain need, meaning and

classification of robotics, its control systems and
end effectors.
H
H
5. Write simple robot programs in VAL II

language.
L
6. Explain robot applications
Degree of compliance L: Low M: Medium H: High
Page 2 of 13.

Course Content
Course Code: ME 408
L-T-P-SS: 3-1-0-0
Credits: 4
Contact Hrs: 4
CIE Marks: 50
SEE Marks: 50
Total Marks: 100
Teaching Hrs: 4
Exam Duration: 3 hrs
Content
Hrs
Unit - 1
Chapter No. 1. Manufacturing automation
8 hrs
Automated manufacturing systems, fixed /programmable /flexible automation, Need of

automation, Automation principles and strategies. Basic elements of automated
systemspower, program and control, Advanced automation functions: Safety monitoring,
Maintenance and Repair diagnostics, Error detection and recovery, Levels of automation.
Chapter No. 2. Industrial Control Systems
4 hrs
Industrial control systems in process and discrete manufacturing industries, Continuous and
discrete control, Computer process control, forms of computer process control
Chapter No. 3. Transfer Lines
6 hrs
Fundamentals, Configurations, Transfer mechanisms, storage buffers, control, applications;

Analysis of transfer lines with and without storage buffers.
Chapter No. 4. Automated Assembly Lines
6 hrs
Assembly Automation: Types and configurations, Parts delivery at workstations- Various

vibratory and non-vibratory devices for feeding and orientation, Product design for
automated assembly, Quantitative analysis of assembly systems.
Chapter No. 5. Fundamentals of Industrial Robots
6 hrs
Robot anatomy, Robot motions, Robot specifications, Robot drive systems, Robot control
systems, End effectors, Robot sensors
Chapter No. 6. Robot programming
6 hrs
Robot Programming: Lead through method, Robot program as a path in space, Methods of
defining positions in space, Motion interpolation, branching; Textual robot programming
languages-VAL II. Constants variables and other data objects, Motion commands, End
effectors and sensor commands.
Page 3 of 13.

Chapter wise Plan

Course Code and Title: ME 408 / Automation and Robotics
Chapter Number and Title: 1. Manufacturing automation
Planned Hours: 8 hrs
Learning Outcomes:
At the end of the topic the student should be able to:
TLOs
COs
BL
1. Define and classify manufacturing automation
CO1
L2
2. Recognize the need of manufacturing automation.
CO1
L2
3. Explain the automation principles and trategies
CO1
L2
4. Explain advanced automation functions
CO1
L2
5. Discuss automation levels
CO1
L2
Lesson Schedule
Class No. - Portion covered per hour
Date
planned
1. Introduction to syllabus, COs, POs mapped with the course, teaching,

assessment and evaluation techniques.
11/01/16
2. Automated manufacturing systems, fixed /programmable /flexible

automation
12/01/16
3. Need of automation
14/01/16
4. Automation principles and strategies.
18/01/16
5. Basic elements of automated systems: power, program and control
19/01/16
6. Advanced automation functions: Safety monitoring, Maintenance and

Repair diagnostics
21/01/16
7. Error detection and recovery
25/01/16
8. Levels of automation.
28/01/16
Date
Conducted
Review Questions
Sr. No. - Questions
TLOs
BL
1. What are the Course Outcomes (COs) of this course (Automation and
Robotics)
TLO1
L1
2. What is manufacturing automation? What are its types?
TLO1
L2
3. How flexible automation reduces production down time?
TLO1
L2
Page 4 of 13.

4. Discuss the reasons for manufacturing automation?
TLO2
L2
5. Disvuss the manufacturing principles and strategies
TLO3
L2
6. Explain the advanced automation functions
TLO4
L2
7. What are the levels of manufacturing automation
TLO5
L2
8. What is manufacturing automation? Why companies implement TLO1

automation?
L2
9. What are the basic elements of automation? Discuss program of

instructions in detail.
L2
TLO1
Page 5 of 13.


Chapter Number and Title: 2. Industrial Control Systems
Learning Outcomes:
TLOs's
CO's
BL
1. Summarize Industrial Control systems in process and discrete item

manufacturing industries
CO2
L2
2. To define and differentiate Continuous and discrete control
CO2
L4
3. To explain process control and forms.
CO2
L2
Lesson Schedule
Date
planned
1. Industrial control systems in process and discrete manufacturing

industries
01/02/16
2. Continuous and discrete control
02/02/16
3. Computer process control
04/02/16
4. forms of computer process controls
08/02/16
PI Code
Date
Conducted
Review Questions
Sr. No. - Questions
TLOs
BL
1. Compare continuous control with discrete control
TLO2
L4
2. Explain with flow chart feed forward control system
TLO3
L2
3. What is adaptive control system?
TLO3
L2
4. Explain with suitable examples event driven changes and time driven
changes in discrete control system.
TLO3
L2
PI Code
Page 6 of 13.


Chapter Number and Title: 3. Transfer Lines
Learning Outcomes:
TLOs's
CO's
BL
1. Explain fundamentals and configuration of transfer lines
CO3
L2
2. Describe transfer mechanism with sketches.
CO3
L1
3. Recognize the need of storage buffers and interpreting the benefits of

the same.
CO3
L4
4. Describe the control of the production lines.
CO3
L2
5. Summarize the applications of production lines.
CO3
L2
6. Analyze efficiency of transfer lines with and without storage buffers.
CO3
L4
Lesson Schedule
Date
planned
1. Fundamentals and Configurations of transfer lines
09/02/16
2. Workpart transfer mechanism
11/02/16
3. storage buffers, control, applications
15/02/16
4. Control of the automated production lines
16/02/16
5. Analysis of transfer lines without storage buffers.
18/02/16
6. Analysis of transfer lines with storage buffers.
22/02/16
PI Code
Date
Conducted
Review Questions
Sr.No. - Questions
TLOs
BL
1. Explain with sketch varous configurations of transfer lines.
TLO1
L2
2. Explain with sketch linear work transfer mechanism
TLO2
L1
3. What is storage buffer? Why it is used on transfer lines?
TLO3
L4
4. What are the applications of automated production lines?
TLO5
L2
5. A ten station transfer machine has an ideal cycle time of 30 sec. The
frequency of line stops F = 0.075 stops/cycle. When a line stop occurs, the
average downtime is 4.0 min. Raw workpart cost is Rs.0.55/pc, line
operating cost = Rs.42/hr, and the cost of disposable tooling = Rs.0.27/pc.
Determine: i) Average production rate in pc/hr. ii) Line efficiency iii)
TLO6
L4
PI Code
Page 7 of 13.

Proportion downtime and Average cost of a component produced.

6. A 30 station transfer line has an ideal cycle time Tc = 0.75 min, average
downtime Td = 6.0 min. per line stop occurrence and a station failure
frequency p = 0.01 for all stations. A storage buffer of capacity of 20 parts
is located in between stations 15 and 16 to improve line efficiency. Using
the upper bound approach Determine: i) Line efficiency ii) Production rate
of the line. Assume that the downtime (Td = 6.0 min) is constant bsp; Line
efficiency iii) Proportion downtime and Average cost of a component
produced.
TLO6
L4
7. In the operation of a 15 station transfer line, the ideal cycle time = 0.58 TLO6
min. Breakdowns occurs at a rate of every 20 cycles, and the average
downtime per breakdown is 9.2 min. Transfer line is located in a plant that
works an 8 hrs/day and 5 days/ week. Determine: i) Line efficiency. How
many parts the transfer line will produce in a week. ht:150%;mso-list:l0
level1 lfo1'>ii) Production rate of the line. Assume that the downtime (Td =
6.0 min) is constant bsp; Line efficiency iii) Proportion downtime and
Average cost of a component produced.
L4
Page 8 of 13.


Chapter Number and Title: 4. Automated Assembly Lines
Learning Outcomes:
TLOs's
CO's
BL
1. Define, classify and explain configuration of assembly automation
CO3
L2
2. Explain various methods used to deliver parts at workstations
CO3
L2
3. Recognize the design of product for automated assembly
CO3
L3
4. To perform quantitative analysis of automated assembly systems.
CO3
L5
Lesson Schedule
Date
planned
1. Assembly Automation: Types and configurations
23/02/16
2. Parts delivery at workstations- Various vibratory and non-vibratory

devices for feeding and orientation
25/02/16
3. Product design for automated assembly
08/03/16
4. Quantitative analysis of assembly systems
10/03/16
5. Quantitative analysis of assembly systems 2
14/03/16
6. Quantitative analysis of assembly systems 3
15/03/16
Date
Conducted
Review Questions
Sr. No. - Questions
TLOs
BL
1. Discuss with sketches Automated assembly system configurations.

Write in tabular format possible work transfer methods for these
configurations.
TLO1
L2
2. Discuss the principles of design for automated assembly
TLO3
L3
3. A six station automatic assembly machine has an ideal cycle time of 12 TLO4
sec. Downtime occurs for two reasons. First mechanical and electrical
failures of the workheads occur with the frequency of once per 50 cycles.
Average downtime for these causes is 3 min. Second defective
components also result in downtime. The fraction defect rate of each of the
six components added to the base part at six stations is q = 2%. The
probability that a defective component will cause a station jam is m = 0.5
for all stations. Downtime per occurrence for defective part is 2 min.
determine: i) Yield of assemblies that are free of defective components ii)
L5
Page 9 of 13.

Proportion of assemblies that contain at least one defective component.

Average production rate of good assemblies.
4. 1. Discuss with sketches Automated assembly system configurations. TLO1
Write in tabular format possible work transfer methods for these
configurations.
L2
5. 2. Discuss the principles of design for automated assembly
TLO3
L3
6. 3. A six station automatic assembly machine has an ideal cycle time of TLO4
12 sec. Downtime occurs for two reasons. First mechanical and electrical
failures of the workheads occur with the frequency of once per 50 cycles.
Average downtime for these causes is 3 min. Second defective
components also result in downtime. The fraction defect rate of each of the
six components added to the base part at six stations is q = 2%. The
probability that a defective component will cause a station jam is m = 0.5
for all stations. Downtime per occurrence for defective part is 2 min.
determine: i) Yield of assemblies that are free of defective components ii)
Proportion of assemblies that contain at least one defective component.
Average production rate of good assemblies.
L5
Page 10 of 13.


Chapter Number and Title: 5. Fundamentals of Industrial Robots
Learning Outcomes:
TLOs's
CO's
BL
1. To recognize the need of robot
CO4
L2
2. To define robot and robotic system
CO4
L2
3. To explain robot anatomy and physical configurations
CO4
L1
4. To explain robot degrees of freedom
CO4
L2
5. To explain robot motions
CO4
L2
6. To explain robot technical features such as axes of motions, speed,

acceleration, work envelope, accuracy, repeatability, precision, payload
and reliability.
CO4
L2
7. To compare robot drive systems viz. electric, hydraulic and pneumatic.
CO4
L4
Lesson Schedule
Date
planned
1. Introduction to robotics, Need of using robot
17/03/16
2. Robot anatomy, Robot motions
21/03/16
3. Robot specifications
22/03/16
4. Robot drive systems
28/03/16
5. Robot control systems
29/03/16
6. End effectors, Robot sensors
31/03/16
Date
Conducted
Review Questions
Sr. No. - Questions
TLOs
BL
1. Define robot. What are the basic elements of robotic system
TLO2
L2
2. What is the need of using robot. What are the basic elements of robotic
system
TLO1
L2
3. Explain the basic configurations of the robots and their work volumes f
robotic system
TLO3
L1
4. Discuss the following robot specifications: i) Work volume ii) Speed of TLO6
movement iii) Robot motions iv) Payload capacity
L2
Page 11 of 13.


Chapter Number and Title: 6. Robot programming
Learning Outcomes:
TLOs's
CO's
BL
1. To list robot programming methods
CO5
L1
2. To write robot program using lead through methods
CO5
L3
3. To explain robot program as path in a space.
CO5
L4
4. To explain joint interpolation
CO5
L2
5. To explain methods of defining positions in space
CO5
L2
6. To explain and use motion interpolation in robot programming
CO5
L3
7. To explain and use branching in robot programs.
CO5
L3
8. To explain the methodology of writing robot programs using textual

programming language.
CO5
L2
9. To recognize the use of constants, variables, motion commands, end

effector and sensor commands in robot programs.
CO5
L3
To write the robot programs using VAL II programming language.
CO5
L3
10To explain robot applications
CO6
L2
Lesson Schedule
Date
planned
1. Robot Programming: Lead through method,
04/04/16
2. Robot program as a path in space
05/04/16
3. Methods of defining positions in space, Motion interpolation
07/04/16
4. Textual robot programming languages-VAL II
11/04/16
5. Constants variables and other data objects, Motion commands,
12/04/16
6. End effectors and sensor commands.
19/04/16
Date
Conducted
Review Questions
Sr.No. - Questions
TLOs
BL
1. Discuss any three monitor commands used in VAL II programming language.
TLO9
L3
2. Discuss lead through programming methods
TLO1
L1
Page 12 of 13.

3. Write a program in VAL II for palletizing application. Pallet capacity is 20 (5 rows

and 4 columns). Incoming conveyor brings the workpiece at fixed position. Robot
picks it up and places into the pallet. When pallet is full it is taken away from the
work cell and empty pallet is brought in and then cycle repeats. Make suitable
assumptions and state them clearly.
TLO9
L3
4. Write a leadthrough robot program using branching to perform a palletizing

operation. Suppose that the operation required the robot to pick up parts from an
input chute, and place them on a pallet with 24 positions as depicted in figure given
below. When a start signal is given, the robot must begin picking up parts and
loading them into the pallet, continuing until all 24 positions on the pallet are filled.
The robot must then generate a signal to indicate that pallet is full, and wait for the
start signal to begin the next cycle. height:8.1pt'> Write a leadthrough robot program
using branching to perform a palletizing operation. Suppose that the operation
required the robot to pick up parts from an input chute, and place them on a pallet
with 24 positions as depicted in figure given below. When a start signal is given, the
robot must begin picking up parts and loading them into the pallet, continuing until
all 24 positions on the pallet are filled. The robot must then generate a signal to
indicate that pallet is full, and wait for the start signal to begin the next cycle.
TLO9
L3
5. What are the main categories of robot applications? List the processing TLO10
applications of robot..
L2
Prof. Mukund V. Kavade
Prof. Dr. S. S. Gawade
Course Faculty
Head of Department (Mech. Engg.)
Page 13 of 13.

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8 - Semester ME 408 Theory Course Plan

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Kasegaon Education Society (KES)

Rajarambapu Institute of Technology (RIT)

Course Title: Automation and Robotics

Course Code: ME 408

Total Contact Hours: 4

Duration of SEE Hours: 3

ISE + MSE Marks: (20+30=50)

Lesson Plan Author: Prof. Mukund Kavade

Checked By: Prof. Chandan Waghmare

Course Outcomes (COs):

Recognize manufacturing automation and Advanced Automation Functions

Kasegaon Education Society (KES)

Course Articulation Matrix: Mapping of Course Outcomes (CO) with Program

Course Code: ME 408

Course Outcomes (CO) / Program Outcomes

1. Recognize manufacturing automation and

2. Explain process and discrete manufacturing

4. Recognize and explain need, meaning and

5. Write simple robot programs in VAL II

6. Explain robot applications

Degree of compliance L: Low M: Medium H: High

Kasegaon Education Society (KES)

Course Title: Automation and Robotics

Total Marks: 100

Exam Duration: 3 hrs

Automated manufacturing systems, fixed /programmable /flexible automation, Need of

Chapter No. 2. Industrial Control Systems

Chapter No. 3. Transfer Lines

Fundamentals, Configurations, Transfer mechanisms, storage buffers, control, applications;

Chapter No. 4. Automated Assembly Lines

Assembly Automation: Types and configurations, Parts delivery at workstations- Various

Chapter No. 5. Fundamentals of Industrial Robots

Chapter No. 6. Robot programming

Kasegaon Education Society (KES)

Chapter wise Plan

Planned Hours: 8 hrs

1. Define and classify manufacturing automation

2. Recognize the need of manufacturing automation.

3. Explain the automation principles and trategies

4. Explain advanced automation functions

5. Discuss automation levels

1. Introduction to syllabus, COs, POs mapped with the course, teaching,

2. Automated manufacturing systems, fixed /programmable /flexible

4. Automation principles and strategies.

5. Basic elements of automated systems: power, program and control

6. Advanced automation functions: Safety monitoring, Maintenance and

7. Error detection and recovery

2. What is manufacturing automation? What are its types?

3. How flexible automation reduces production down time?

Kasegaon Education Society (KES)

4. Discuss the reasons for manufacturing automation?

5. Disvuss the manufacturing principles and strategies

6. Explain the advanced automation functions

7. What are the levels of manufacturing automation

8. What is manufacturing automation? Why companies implement TLO1

9. What are the basic elements of automation? Discuss program of

Kasegaon Education Society (KES)

Course Code and Title: ME 408 / Automation and Robotics

Planned Hours: 4 hrs

1. Summarize Industrial Control systems in process and discrete item

2. To define and differentiate Continuous and discrete control

3. To explain process control and forms.

1. Industrial control systems in process and discrete manufacturing

2. Continuous and discrete control