K. V . M Sharma Partial Question Bank M -5C Advanced Mfg.

Systems

[Q01] Define ROBOT. What is an Industrial Robot?

Robot is a general-purpose programmable machine having some Anthropomorphic

characteristics.

An Industrial robot is robot built with an Intention of serving some of the industrial
purpose/end use like Human replaced operations, Material handling, Machine loading/Unloading,
Process operations, Inspections, Assembly operations etc

The word robot comes from the Slavic word robota, which means labour. A robot is a machine designed to
execute one or more tasks repeatedly, with speed and precision. A Robot responds to sensory input, runs
automatically without human intervention.

[Q02] What are the applications of ROBOTS in Material handling?

Followings are some of the Material-handling applications:

• Movement of material or parts from one location to another.
• It includes part placement,
• palletizing and/or depalletizing,
• machine loading and unloading.
• insertion operations

[Q03] What are the applications of ROBOTS in Inspection?

Followings are some of the Inspection applications:

 o Robotic vision: Video cameras are used to obtain an image of the area of interest, which
is digitized and compared to a similar image with required tolerance.

o Active Inspection: In active role robot is responsible for determining whether the part
is good or bad. Is done with the help of a sensor based closed loop system
o Passive Inspection: In this type of inspection robot does not directly involve in deciding.
Robot feeds a gauging station & the gauging station determines whether the part meets
the specification, the robot passively waits for the process to finish.

o Inspection by sensor Manipulation: Example - Optical mode of Inspection: By involving

the use of optics and light, usually a laser or infrared source is used to illustrate the
area of interest.

o Inspection by Parts Manipulation: Example - By using a feeler gauge or a linear

displacement transducer known as a linear variable differential transformer (LVDT),
the part being measured will come in physical contact with the instrument or by means
of air pressure, which will cause it to ride above the surface being measured.

[Q04] What are the applications of ROBOTS in Assembly?

Followings are some of the Assembly applications:

• Tool manipulations – Manipulations of a special tools like picking & movement of respective tools from the
magazine for part assembly.
• Part-handling manipulations - Automated positioning and orientation and firm gripping of respective parts
to be assembled.
• Material Manipulations - The applications involve the locating, moving and orienting of required materials
for the purpose of assembly.

[Q05] Explain the common ROBOTIC configurations.

Robotic configuration refers to the principle & mode of robotic arms movement. Followings are
the important robotic configurations:

1. Cartesian coordinate configuration – Combination of THREE linear - XYZ

2. Cylindrical coordinate configuration - Combination of TWO linear & ONE radial - RYZ
3. Spherical/Polar coordinate configuration - Combination of TWO circular & ONE linear
- ROZ
4. Articulate coordinate configuration
 • In cartesian coordinate configuration the arm movement happens through the
combination of THREE independent linear orthogonal movements like
X Freedom – Linear Arm movement left & right
Y Freedom – Linear Arm movement front & back
Z Freedom - Linear Arm movement up & down
Example : Overhead crane movement

• In cylindrical coordinate configuration the arm movements happen through the

combination of ONE rotational and TWO linear movements like
R Freedom – Radial Arm movement over the column
Y Freedom – Linear Arm movement front & back
Z Freedom - Linear Arm movement up & down
Example :

• In Spherical/Polar coordinate configuration the arm movements happen through the

combination of TWO rotational and ONE linear movement like
R Freedom – Radial movement of arm over the column
O Freedom – Circular Movement of arm over its axis.
Z Freedom - Linear Arm movement up & down
Example :

[Q06] Explain the anatomy of ROBOTIC, joints & links.

 Robot anatomy deals with the study of different joints and links and other aspects of the
manipulator's physical construction. A robotic joint provides relative motion between two links of the
robot. Each joint, or axis, provides a certain degree-of- freedom (dof) of motion.

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[Q07] What is CNC. Explain its components/Elements with a neat block diagram?

• CNC referrers to Computer Numerical Control. Here the functions and motions of a machine tool are
controlled by means of a prepared program containing coded alphanumeric data.

• CNC can control the motions of the work piece or tool, the input parameters such as feed, depth of cut,
speed, and the functions such as turning spindle on/of, turning coolant on/off.

Components/Elements OF A CNC

A CNC system consists of three basic 3 components:

Part Program, Machine Control Unit (MCU) and Machine tool

1 . Part program
• The part program is a detailed set of commands to be followed by the machine tool. Each command
specifies a position in the Cartesian coordinate system (x,y,z) or motion (work piece travel or cutting
tool travel), machining parameters and on/off function.

2 . Machine Control Unit (MCU)

• The machine control unit (MCU) is a microcomputer that stores the program and executes the
commands into actions by the machine tool

3 . Machine tool (lathe, drill press, milling machine etc)

• The machine tool could be one of the following: lathe, milling machine, laser, plasma, coordinate
measuring machine etc. Figure 3 shows that a right-hand coordinate system is used to describe the
motions of a machine tool

[Q08] what are the advantages and Disadvantages of CNC

Some of the advantages of CNC

• Increased productivity
• High accuracy and repeatability
 • Reduced production costs
• Reduced indirect operation costs
• Facilitation of complex machining operations
• Greater flexibility
• Improved production planning and control
• Lower operator skill requirement
• Facilitation of flexible automation
• high accuracy in manufacturing,
• short production time,
• greater manufacturing flexibility,
• simpler fixtures
• Reduced human error.

Disadvantages / Limitations
• high initial cost,
• high maintenance cost,
• Requirement of skilled part programmer.
• High downtime cost
• Need for continuous loading

[Q09] Explain with a schematic diagram open loop & Closed loop system.

[Q10] Write a short note on (a) CNC turning centers (b) CNC machining centers

(a) CNC turning centers

Is a versatile machine tool capable of multiple machining operations on a workpiece in a
single setup. Unlike the conventional lathe the instructions are given in the form of
coding and is executed, coordinated and controlled by a dedicated Controller unit.

Turning center is designed and build to perform variety of lathe operations (like plane turning ,
step turning ,Facing, Knurling, taper , thread cutting etc) on different surfaces simultaneously
and without operator’s intervention. Various required tools are organised in a TOOL MAGAZINE
and are coded. Respective tools become operational based on the CNC program written and
controlled by the controller unit.

Types of CNC turning centers : Some of the classifications are as under

▪ VMC, HMC & UMC Horizontal , Vertical & Universal turning centers : Based on spindle
orientation
▪ Classification based on degree of freedom: Ex – 2 Axis, 3 Axis, 2.5 Axis etc
▪ Based on number of spindles: Single, double etc
▪ Based on number of pallets : Single , double pallet etc

Typical features/advantages/need of CNC turning center

▪ Improve the productivity

▪ Reduce the lead time
▪ Reduces WIP – Work In Progress inventory
▪ Cost effective for jobs with divergent operations
▪ Reduction of floor space area
▪ Lesser number of skilled workers.
▪ Independent of worker’s fatigue
Disadvantages:
▪ High initial cost
▪ Need higher skill level
▪ Higher breakdown cost
▪ Higher maintenance cost

Schematic diagram of a CNC machining center

Some of the leading CNC turning center manufacturers in India

1. LMW ( Lakshmi Machine Works)

2. ACE Micromatic
3. BFW
4. COSMOS Impex
5. JYOTI CNC AUTOMATION LTD.
6. Lokesh Machine Tools
7. KTM Techno Solutions

(b) CNC machining centers :

Is a versatile machine tool capable of multiple machining operations on a workpiece in a

single setup. Unlike the conventional m/c tools the instructions are given in the form of
coding and is executed, coordinated and controlled by a dedicated Controller unit.

Machining center is designed and build to perform variety of operations (like milling , drilling
,reaming, boring, tapping etc) on different surfaces simultaneously and without operator’s
intervention. Various required tools are organised in a TOOL MAGAZINE and are coded.
Respective tools become operational based on the CNC program written and controlled by the
controller unit.

Types of CNC machining centers : Some of the classifications are as under

▪ VMC, HMC & UMC Horizontal , Vertical & Universal machining centers : Based on spindle
orientation
▪ Classification based on degree of freedom: Ex – 2 Axis, 3 Axis, 2.5 Axis etc
▪ Based on number of spindles: Single, double etc
▪ Based on number of pallets : Single , double pallet etc

Typical features/advantages/need of CNC machine

▪ Improve the productivity

▪ Reduce the lead time
▪ Reduces WIP – Work In Progress inventory
▪ Cost effective for jobs with divergent operations
▪ Reduction of floor space area
▪ Lesser number of skilled workers.
▪ Independent of worker’s fatigue
Disadvantages:
▪ High initial cost
▪ Need higher skill level
▪ Higher breakdown cost
▪ Higher maintenance cost

Schematic diagram of a CNC turning center

Some of the leading CNC machining center manufacturers in India

1. LMW ( Lakshmi Machine Works)

2. ACE Micromatic
3. BFW
4. COSMOS Impex
5. JYOTI CNC AUTOMATION LTD.
6. Lokesh Machine Tools
7. KTM Techno Solutions
Additional / Desirable/ Not essential

[QA1] What are the advantages and disadvantages of ROBOTs

[QA2] what is automation? What are the needs AND Applications of

automation?

[QA3] What are the advantages and limitations of automation?

[QA3] Explain the types of automation with examples