Lecture1_SV

Manufacturing Automation for Assembly and Inspection MM453
Manufacturing Automation for Assembly and

Inspection
MM453
Dr. Nigel Kent

Rm S366
nigel.kent@dcu.ie
Dublin City University
Sem 1 2021
Dr. Nigel Kent Manufacturing Automation for Assembly and Inspection, MM453 1/20
Lecture 1
Lecture 1
Lecture 1
Recommended Texts
• Robotics and Manufacturing Automation C.Ray Asfahl

670.427/ASF
• Assembly Automation and Product Design Boothroyd

Geoffrey 670.427/BOO
• Computer Automation in Manufacturing, An introduction.

Thomas O. Boucher 670.427/BOU
Lecture 1
Sample System
Click for Video 1 Click for Video 2
Lecture 1
Course Content
Content will be available on Loop as both an annotated lecture by

lecture basis and also compiled non annotated pdf for ease of
navigation.
The course can broadly be divided into three parts
1 Automation for Industrial Logic Control Systems
• Logic analysis
• Network diagrams
• Response diagrams
• Programmable logic controllers
• Ladder logic
• SCADA systems
Lecture 1
Course Content
2 Automated Assembly and Parts Feeding

• Transfer systems
• Part feeding devices
• Feed tracks
• Assembly line performance
• Cost Justification
3 Statistical Process Control (SPC)
• Process capability
• Control charts
• Sample averages
• Range
Lecture 1
Industrial Logic Control Systems
There are three types of control systems commonly used in

industry:
• Programmable logic
controllers (PLC’s)
• Digital electronics
• Logic control systems
Siemens S7-1200 PLC

These control systems are used to automate production processes
and to implement quality control (QC) systems.
Lecture 1
Automation decisions are taken based on inputs. There are two

categories:
Decision by attributes
– the measured input has a discrete value, i.e. high/low,
large/medium/small, round/square, black/white, 1/0, Yes/No.
Decision by variables
– the measured input can have a value anywhere within a range,
i.e. 25.4°C, 1004mbar, 100.2g etc.
Lecture 1
It is relatively easy to implement a control strategy when decisions

are based on attributes.
Decisions by variables can be converted to attributes, i.e.
• If t ≤ 100 then output = ON
• If t > 100 then output = OFF
Here a continuous range is converted to an attribute of being
below or not below a threshold value.
Lecture 1
Even apparently simple processes

can lead to relatively complex
control problems involving
multiple logical relationships
between variables.
The sort of process requiring

automation may be a furnace.
Furnace
Lecture 1
Here a furnace is used to preheat forged blanks.
Consider the following logic

• If the flame extinguishes it
must be reignited.
• If re-ignition fails the gas
must be turned off.
• A manual override or
On/Off switch is required.
Furnace
A more realistic automatic ignition would require a timer circuit so
that if the ignition fails after ′ x′ seconds the gas is turned off.
Lecture 1
In order to design the control logic for this problem a full analysis
must be performed so that whatever the state of the system, the
control signals are appropriately set.
For the purposes of this module we will start by using truth tables
to analyse problems with no time dependence.
Lecture 1
Logic Design
Truth Tables
A truth table, from an automation perspective, is a table showing
the state of one or more outputs for every possible combination of
inputs.
In1 In2 In3 Out1 Out2

0 0 0 1 0
0 0 1 0 1
.. .. .. .. ..
. . . . .
The values are typically 0 or 1 (decision by attributes). Note there

are ’dont care’ states we will get to.
Lecture 1
Logic Design - Panel Switch
Consider a simple control panel switch.

The on/off switch S controls a process P if the lock L is in the
unlock mode. The states are:
• Inputs
• S=0 Switch is off S - Switch
P - Process
• S=1 Switch is on
• L=0 Lock is on
• L=1 Lock is off L - Lock
• Outputs
• P = 0 Process is off
• P = 1 Process is on Switch/Lock
Lecture 1
P - Process
L
Account for all conditions by

counting up in binary. For
S L P
complex problems with multiple
0 0
inputs this can be a very
0 1
cumbersome task, therefore only
1 0
include inputs which have some
1 1
relevance.
Lecture 1
• Only when the lock is off

(L = 1) can S dictate the
state of P .
• When the lock is on (L = 0) S L P
then P remains unchanged, 0 0
therefore the state of P 0 1
determines the future state 1 0
of P . 1 1
• So to complete the truth
table we need to include the
output P as one of the
inputs to the table.
Lecture 1
• P ′ distinguishes the process as an output

from the process as an input P . S L P P′
• Each row of inputs is considered in terms 0 0 0
of their physical meaning and the output 0 0 1
is then assigned accordingly. 0 1 0
• Rows 4 and 7 seem to constitute a 0 1 1
paradox since P ′ ̸= P 1 0 0
• This may be interpreted as the input P 1 0 1
being considered as the status of the 1 1 0
output during the previous loop or scan 1 1 1
cycle of the program. Based on this
status value the ’new’ output state P ′ is
updated.
Note: When L = 0 then P ′ = P , but when L = 1 then P ′ = S
Lecture 1
Logic Design - Latching
P - Process
S
Inputs
• G = 0 Go button is not pressed
• G = 1 Go button is pressed
• S = 0 Stop button is not pressed
• S = 1 Stop button is pressed
Lecture 1
Logic Design - Latching
Operation G S P P′
• The Stop button takes 0 0 0
0 0 1
precedence over the Go
button when determining 0 1 0
the state of the process P . 0 1 1
1 0 0
• Once the Go button is
1 0 1
pressed the system latches
1 1 0
on until the Stop button is
1 1 1
pressed.
If S = 1 then P ′ = 0, if S = 0 then P ′ = P or G
Lecture 1
Basic Gates
To evaluate the truth table we use Boolean Algebra. As a recap

there are three basic operators.
AND
A B Y
0 0 0
0 1 0 Y = A AND B
1 0 0 Y = A.B
1 1 1
Lecture 1
Basic Gates
OR
A B Y
0 0 0
0 1 1 Y = A ORB
1 0 1 Y =A+B
1 1 1
NOT
A Y
0 1 Y = NOT A
1 0 Y =A

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Manufacturing Automation for Assembly and Inspection MM453

Manufacturing Automation for Assembly and

Dr. Nigel Kent

Dublin City University

• Robotics and Manufacturing Automation C.Ray Asfahl

• Assembly Automation and Product Design Boothroyd

• Computer Automation in Manufacturing, An introduction.

Click for Video 1 Click for Video 2

Content will be available on Loop as both an annotated lecture by

• Programmable logic controllers

2 Automated Assembly and Parts Feeding

• Part feeding devices

• Assembly line performance

There are three types of control systems commonly used in

Siemens S7-1200 PLC

Automation decisions are taken based on inputs. There are two

It is relatively easy to implement a control strategy when decisions

Even apparently simple processes

The sort of process requiring

Here a furnace is used to preheat forged blanks.

Consider the following logic

In1 In2 In3 Out1 Out2

The values are typically 0 or 1 (decision by attributes). Note there

Consider a simple control panel switch.

Account for all conditions by

• Only when the lock is off

• P ′ distinguishes the process as an output

To evaluate the truth table we use Boolean Algebra. As a recap

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