Module-2

Chapter-3 OBJECTIVES
CAD &Computer Afer studying this chápter
should be able to:
the reader

Graphics Appreciate the

Design process.
use
of Computers and

Software Understand graphic |syslem and its

configuratio.
Explain the functions f graphic system
Understand Geometry cornstruction in
graphic system
Appreciate the need fa transformations

3.1 MECHANICAL ENGINEERING DESIGN

Mechanical Engineering Design can be defined as
the use of sçientific principles,
technical information and imagination in the descriptíon of a machine or a mechanical
system to perform its speciic functions with maximum and
of a machine or mechanicat expcrienpe. The description
system mainly
is done in the form of drawings or blue prints.
3.2 CONVENTIONAL DESIGN PROCESS
The process of designing something consists
of six different steps or phases"Necessity
is the Mother of Invention". A>ways a design starts with a need.
Recognition of Need
It involves
identification by someone that a problem exists for
action
should be taken. which some corrective
The problem may ke the identifícation of some defect in the
need of new product in the carket existing machinery or
a

Definition of problem:
It involves through
speciication of the item to be designed. This specification inchudes
physical or functional characteristics, cost quality and operating
Synthesis
,

performance.
In this phase we dev-kop
of the problem, i.e.,
preliminary (basic) ideas regarding the topology and geometry
reyarding the shape and size and connectivity df various paYts in tne
product. In this phase a prototype model is created.
 Computer Integrated Manufacturing
112

Recognition
of Nced

Defination of
Problem

Synthesis

Analysis

Evaluation

Presentation
Analysis:
In this phase, a prototype model is analyzed bygiving different boundary conditons
and constraints, subjecting the model to diferent temperatures and loads to perform
feasibility study. If the product fails at this stage, once again the design is reverted back
to the synthesis phase.

Evaluation
The end products of the analysis phase is compared with the definition phase. If there
regquires any changes, then the design is one again reverted back to synthesis phase.
Presentation
This includes documentation of thedesignby
meansofdrawings, material specifications,
Bill of materials, Views, tolerances etc.

23COMPUTER AIDED DESIGN PROCESS

The varous design related tasks which are performed by a modern computer. Aided
design system can te grouped into four functional areas.
1Gdometrie Modeling
2. Enngineeine Analysis
3. Design review and evaluation
4. Automatcd drafting

to
Oeomerie modeling corresponds to synthesis phase. Engineering analysis corresponds
analysis, Desien review and evaluation corresponds to evaiuation phase.
uomated drafting corresponds to presentation phase
 CAD and Computer Graphics Software 121

d1oysuE
|Application Application Graphics
Database Program Package

i. Graphics Fackage:
Itis the software support between the userand the system. It consists of ip
and output subrovtines. Input subroutines accept data and commands from theuser and
forward them to the appiication program. Output subroutines controls the output devices.
Converts the application models into two- dimensionaBorthre dimensional graphical
images.
2. Application program
It Controls the storage of data and retrieves the data out of the application database.
The user works on the application program through graphics package.Aplication
programs develops the physical model of the graphical images. These physical models
are the mathematical representations of the geometry and are also called as application
models.
3. Application database:
Application database stores mathematical, umerical and logical definitions of
application models. Italso includes alphanumeic information such as bill ofmaterials,
mass properties and other data.
36 FUNCTIONS OF AGRAPHICS PACKAGE/SYSTEM
Some of the common functions of a graphics package are
1.Generation ofgraphic elements
2.Transformations
3. Display control and windwoing functions
4. Segmenting
User inputfunctions
1. Generation ofgraphic elements:
A graphic element in computer graphics is the basie image cntity such as dor , line ,
circle etc.
Graphical elements also include alphanumeric charactees, special symbols etc graphic
elements in 3-D are referred as primitives, such as sphere, cube cylinder. These prinitives
are used as building blocks to coastruct a3 dimensionai model.
118 Computer Integrated Manufacturing

2.Transformations:
Used to change (or) reposition the graphical entitics on the database. Translormations

includc enlargement and reductionofan entity by a process called as scaling, repositioning

the image or translation, rotation.
3. Display control and windwejng funetions:
These functions help the user to view the image from desired angle and at the desired
magniication. These function as are sometimes referred as windwoing, because the
graphics screen like a window used to observe the model.
Another aspect of display control is hidden line removal. Hidden line removal is the
concept in hich the image is divided into visible in visible lines.
In some software, users only will identity which lines are to be removed so that the
iagram is more understandable. Most of the other graphic packages are sophisticated
enough to remove these hidden lines.
4. Segmenting function
Provides capability to selectively replace, delete or modify the portions of the image.
Segment particular portion of the image.
Segmenting functions cannot be uscd in storage tubes, as there will be no0 selective
erase. If the image to be modified the entire screen must be
redrawn, with the changes
incorporated.
In case of refresh display, segments functions is
possible.
5. Uscr input functions:
These are the functions which help the user to enter commands. The
input functions
must be written for specific input devices. These
input functions are defined in such a way
that even the user without any programming experience can also work
eftectively.
3.9 CONSTRUCTING THE GEOMETRY
3.9.1 Graphic elements
The graphics system constructs the geometry out of
graphic ciemcnts. These elements
are called by the user duriug the construction prucess and added, one
by onc, to create the
model. During the process, each new clement specithed by its size, position and
orientation
is added to the model. These specifications are necessary to lorm the model to the
proper
shape and scale. For this purpose, the various transformations are used.
Boolean operations like addition, subtraction on intersection of
geometrie elemcnts
can be carried out on these elements. Figure 3.2 illustratcs this construction
feature for a
two-dimensional objct, C by subtracting circle B from rectangle A.
 08JECTIVES
Chapter-8 After studying this chapter the
beable to: reader should
ROBOT Know the historical
development of Robor,
Understand the different
TECHNOLOGY and their functions. parts of a
robot
Learn aboul various
Sensors.
types of robotic
ldetify the diferent bypes of
in robots. gipers used
Understand dijerent ypes of robot
programming methods.
Appreciate the
dijfjerent applications of
robots.
8.1 INTRODUCTION
Robot is an automatically controlled material handling unit
that is widely used in the
manufacturing industry. Robots are generally used for high volume production.
The term Robot was derived from Czech language in 1920 which
means forced labour.
The oficial definition for the robot given by Robot Institute of America (RIA).
was

Definition: "An industrial robot is are progranmable, multifunctional

manipulator
designed to move materials, parts, tools(ar)specialdevices through a variable programmed
motions for the performance of varietyoftasks"
A manipulator is a mechanical elemeat thaf consists of
series of joints and links as
shown in fig. 8.1.

Joint 3 Link 3
End of Arm

Link 2
Link

Jeint oint 2

Link0
Ba_e

Fig.3. Manipulator
Robot is an example of programmable automation. However robous can be useu n

Fixed and Flexible Aulomations.

Robot Technalogy

Disadvantages
.Initial investment
2. Cannot cost is high.
make decisions.
3. Cannot
adapt changes automatically.
4. Cannot
lean from
5. Experience.
Rxquires skilled programme.
6.
Requires proper maintenance.
7.
Leads to
Unemployment.
8.4 ROB0T ANATOMY
Link
Arm
Joints
Assembly ,Writst
End effcctor

Body

Base

Fig &.2 Components ofa Robo

Robot anatomy is concemed with the physical construction of the body, arm and wrist
of the machine. The various componentsofthe Robot are shown in figure 8.2.
Most of the Robots used in the industries are mounted on a base which is fastned
to the floor.
Body ofthe Robot is atached to the base
Arm assembly of the robot is attacbed to the body
Arm assembly consists of a series of links and joints.
The members of the robotic manipulator is called as links.
Joints are mainly responsible for the relative motion betweea two inks.
At the end of the a n assembly wrist is attachod.
The Body am and wrist assembly is calleud as Manipulator.
A Hand is attachod at the end ofthe wrist. and is called as end effector.
End effector is not considered as the part uf Rebot anatomy.
 C o m p u t e r I n t e g r a t e dM a n u f a c t u r i n g

146

4.15 INPUTS TO MRP SYSTEM

nies.
MRP must operate on the data contained in several
These files serves as input to MRP processors.
They are
1. Master Production schedule (MPS).
fnlc
2. Bill of Materials file (or) product structure
3. Inventory status file.

4.15.1 Master Production Schedule (MPS) and Wnen.

be produced
are to
The MPS specifies what end products
bex
into a specn
is converted
product line
production quantities of a major production
schedule.
he and is known as Master
SChedule of individual products capacliy.
and the company production
products
MPS IS based on the demand of
MPS is the key input which drives
the MRP
4.8
line is shown in fíig
.

The gencral format of MPS for a product called as

and these time periods are
uses weeks or months as
time periods
FS
"Time buckets".
Week
End Item 2 4

Product, P,|100 120 140 160

Product, P 80 90 100
40 60
Product,P
P2 and P3for one month (4 Weeks)
Fig 4.8 MPS ofproducts P1,
4.15.2. Bill of Materials file end
about the components needed to make an
.The MRP obtains information
product from
Bill-of-Materials (BOM) file.
file.
BOM file is also called as productstructure
.BOM file lists the raw materials and components for the end products listed in
Master Production schedule.
but also is structured to
ABill of material not only lists all the requred parts
the end
reflect the sequence of steps required
toproduce product.
each of Which represcntsa stage in the manufacture
The BOM has a series oflevels,
of the end product.
. The product structure for an assembled product is as shown in fig 6.9,
 Computerited Mannfacture Planning and Control
Systems

Final Aksemhly
LEnl'roduAssembly
Sub Assbmbly

SA SA SAB Level
Individeal parts
P
Matenal
Psvd
M M
MSLevel
Fig. 4.9 (a) Product Structure Chart
Parts Numbcr Parts Name
Quantity Description (Material Type, Cor
Dimensions, ctc)

The highest level (or) Zero-Level of the B.O.M

product. The next lorver level represents tbe final
make the final might.represent the sub assemblies assembly or emd
assembly. The next.lower
level might that
combined tare
the sub assemblies and
the bottom most level might represent the parts needed
to mae
which the parts are made. represent the taw materials ficom
4.15.3. Inventory status file
The inventory status file gives complete and upto-date
quantities. gross requirements, scheduled receipts and planedinformatjon on the
on-Hand
order releases for the item.
It also includes other
information such as lot sizes, Lead times, safety stock levels and
scrap allowances etc.
This file contains important information such as what
itenms shculd be ordered and
when the orders should be reieased.
The inventory status file keeps the data
about the projected use and receipts of each
item and determines the amount of
inventory that will be available in each time bucket
The inventory file must be kept upto date
taking into consideratiorj the daily inventory
transactions such as receipts, scrapped materials, Order releases and
planned orders
If the projected availab!e inventory is not sufficient to mcet
the requircment ina perioc,
the MRP program will recommend that the item be ordered.
4 Cempater Ietegrated Nerfacturing
l be thre dpes of data in a Inventory status file
tent master data: This data provides the information about individual parts. This
data includes Part Number, Manufacturing lead time. Quantity of parts.
)iaverdory stahus : This gives a time phased record about the current inventory level
s wedl as estimates any uture changes to the inventory
ie) Subsidiary data :This data provides the information about purchase orders, scrap(or)
rejects, Engineering design changes and so on
The MRP processor operates on the data contained in Master production Schedule
Bl-of-mstrials fle and Iaventory status fle.
The MPS speciñes period by period list ef fnal product require
Tae BOM file specihes what materials and coamponents are needed for each part
The Inventory status file specifes the data on current ánd future inventory stanus of
each prourt, component and material.

M60UTPUTS FROM MRP SYSTEM

The outputs provided by the MRP system are
1. Planned order release, which is a plan of the quantity of each material to be
ordered in each time period.
The order may be a purchase order wàich gives the authority to purchase raw
meterials (or) parts from outside vendons (or) Work orders which gives the
atthority to produce the parts in the factory.
2 Changes in the planned orders which represents the modiñcation of previous
planned orders.
3. Performance reports regarding how well the systetm is operating. Inventory
tumovers, costs, raw material usage and so on.
4. Planning reports such as inventory forecasts, purchase commitment repors, etc.
5. Cencellation reports

4.17 PROBLEMS IN USING MRP

1. Preparation of MPS must be realistic and must provide adequæte lead time
2. Maintaining accurate BOM fles.
3. Incorrect sock (Inventory) status.
4. Unrealistic lead times.
.Inti.pro per and untimely information flow among various related departm.ents.
6. Substantial education and training al ail levels.
.Continuous monitoring ofprogress gaimst schedule.
3. The entire
system is expens1ve
N