Lecture 3 (1)

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 2022
Dr. Nigel Kent Manufacturing Automation for Assembly and Inspection, MM453 1/24
Lecture 3
Lecture 3
Lecture 3
Lecture 2 Recap
Example
• An automatic work station cycles (Y = 1) when the power P
is on and the “cycle ready” indicator C is on.
• The machine is switched on with a spring return go switch G
and is switched off with a spring return stop switch S.
• The stop switch takes precedence over the go switch.
Inputs Outputs
Solenoid Cycle -Y
G Power P
Ready
S C
Lecture 3
Lecture 2 Recap
Inputs
List Inputs
Outputs
List Outputs
Lecture 3
Lecture 2 Recap
Inputs
• G = 0 when the go button is not pressed
• G = 1 when the go button is pressed
• S = 0 when the stop button is not pressed
• S = 1 when the stop button is pressed
• P = 0 when the power is off
• P = 1 when the power is on
• C = 0 when the cycle ready indicator is off
• C = 1 when the cycle ready indicator is on
Outputs
• P ′ = 0 when the power is off
• P ′ = 1 when the power is on
• Y = 0 station idles
• Y = 1 station cycles
Lecture 3
Lecture 2 Recap
G S P C P′ Y
0 0 0 0 0 0
0 0 0 1 X X State can’t exist
0 0 1 0 1 0
0 0 1 1 1 1
0 1 0 0 0 0
0 1 0 1 0 0 Would be X but S is on
0 1 1 0 0 0
0 1 1 1 0 0
1 0 0 0 1 0
1 0 0 1 X X State can’t exist
1 0 1 0 1 0
1 0 1 1 1 1
1 1 0 0 0 0
1 1 0 1 0 0 Would be X but S is on
1 1 1 0 0 0
1 1 1 1 0 0
Lecture 3
Lecture 2 Recap
Karnaugh map for P ′
PC
00 01 11 10
00 X 1 1
01 P ′ = G.S + P.S
GS
11
10 1 X 1 1
Lecture 3
Lecture 2 Recap
Karnaugh map for Y
PC
00 01 11 10
00 X 1
01 Y = C.S
GS
11
10 X 1
Lecture 3
Karnaugh Maps - Problem Breakdown
• A 2-Dimensional Karnaugh map can only be used for 4

variables.
• 3-dimensional Karnaugh maps exist and can be represented in
2 dimensions but these can be cumbersome and complicated
to use.
• If possible, break the system into sub systems to simplify the
analysis.
Lecture 3
Example:
G S1 S3 S1
L1
P
L2
Lecture 3
Given instructions
• The power (P ) to a press is turned on by a start button G and
is turned off by any one of three stop buttons, S1 , S2 or S3 .
• The press actuates (A = 1) when a limit switch L1 is
switched on.
• The press is deactivated when the limit switch L2 is switched
on and returns under spring action.
Lecture 3
Inputs
List Inputs
Outputs
List Outputs
Lecture 3
Inputs
• G = 0 when the go button is not pressed
• G = 1 when the go button is pressed
• S1→3 = 0 Stop buttons not pressed
• S1→3 = 1 Stop buttons pressed
• L1→2 = 0 Limit switches not activated
• L1→2 = 1 Limit switches activated
• P = 0 when the power is off
• P = 1 when the power is on
• A = 0 press is not actuated
• A = 1 press is actuated
Lecture 3
Outputs
• P ′ = 0 when the power is off
• P ′ = 1 when the power is on
• A′ = 0 press is not actuated
• A′ = 1 press is actuated
Lecture 3
• If the entire system is analysed there would be 8 inputs

• G, S1 , S2 , S3 , L1 , L2 , P , A
• Therefore 28 = 256 lines in the truth table!
• To analyse the system it is easier to break it up into
subsections.
• Look at the stop function.
• If any of the switches S1→3 are pressed the power is off,
therefore:
• Let S = S1 + S2 + S3
• Now a general stop function takes into account the three
individual switches appropriately.
Lecture 3
Truth table for Power P ′
G S P P′
0 0 0 0
0 0 1 1
0 1 0 0
0 1 1 0
1 0 0 1
1 0 1 1
1 1 0 0
1 1 1 0
Lecture 3
Karnaugh map for P ′
GS
00 01 11 10
P ′ = S.P + G.S
0 1
P ′ = S.(P + G)
P
1 1 1
Lecture 3
Truth Table for press actuation A′ - Using ”Don’t Care” states

P′ L1 L2 A A′ Comment
0 0 0 0 X X - Power off so no air supply
0 0 0 1 X ”
0 0 1 0 X ”
0 0 1 1 X ”
0 1 0 0 X ”
0 1 0 1 X ”
0 1 1 0 Xx x - L1 and L2 cant be both on
0 1 1 1 Xx ”
1 0 0 0 0
1 0 0 1 1
1 0 1 0 0
1 0 1 1 0
1 1 0 0 1
1 1 0 1 1
1 1 1 0 x x - L1 and L2 cant be both on
1 1 1 1 x ”
Lecture 3
Karnaugh map for press actuation A′ - Using ”Don’t Care” states
L2 A
00 01 11 10
00 X X X X
01 X X X X A′ = A.L2 + L1
P ′ L1
11 1 1 Xx Xx
10 1
Lecture 3
Potential issues with ”Dont’Care”
Always consider practicality of a ”Don’t Care” Assumption and

how to ’Fail Safe’
• X could be regarded as impossible don’t care states, but
considering safety they may be set to 0 since P ′ = 0 due to a
stop button being pressed. From a safety perspective a Stop
press could force all outputs to 0 as opposed to ”Don’t care”
• L1 = L2 = 1 should not occur, it would only happen if there
was a fault, therefore do not actuate.
• One or more switches stuck – set alarm perhaps.
Lecture 3
Truth table for press actuation A′ - Using fail safe approach

P′ L1 L2 A A′
0 0 0 0 0
0 0 0 1 0
0 0 1 0 0
0 0 1 1 0
0 1 0 0 0
0 1 0 1 0
0 1 1 0 0
0 1 1 1 0
1 0 0 0 0
1 0 0 1 1
1 0 1 0 0
1 0 1 1 0
1 1 0 0 1
1 1 0 1 1
1 1 1 0 0
1 1 1 1 0
Lecture 3
Karnaugh map for press actuation A′ - Using ”Don’t Care” states
L2 A
00 01 11 10 A′ = P.L2 .A + P ′ .L1 .L2

A′ = P ′ .L2 .(A + L1 )
00
01
P ′ L1
11 1 1
10 1
Lecture 3
Using the expression P ′ = S.(P + G)
A′ = S.(P + G).L2 .(A + L1 )
Substituting for S using the expression S = S1 + S2 + S3
A′ = S1 + S2 + S3 .(P + G).L2 .(A + L1 )
Lecture 3
Logic Diagramming
In most automated processes, timers, memories, counters and delays may
be used which cannot be expressed in terms of Boolean algebra. To
overcome this problem graphical means are employed.
Basic Logic Gates
A A
A.B A+B A A
B B
AND OR NOT
Logic Diagram - Panel switch with lock:
L S.L
L L.P + S.L
P L.P
S
P 0 = L.P + S.L
Lecture 3
Logic Diagramming
Cascaded Gates
It is possible to cascade AND gates and OR gates or have multiple
inputs, e.g.
A
A
= B = A.B.C
B C
C
Additional Operators
Other operators can be added in using a box with a title, i.e.,
A
B Delay
5s
Lecture 3
Logic Diagramming
Panel switch with lock

The panel switch with lock could be represented with a memory
function thus:
Memory
1
S
P
Here the output will follow the set command when the Enable
function is high. When the enable function is low, the output
remains unchanged.
Lecture 3
Logic Diagramming
Multiple Outputs
It is possible to have multiple outputs
A
X = A.B
B
Y =A+B
Z =A+B

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Manufacturing Automation for Assembly and Inspection MM453

Manufacturing Automation for Assembly and

Dr. Nigel Kent

Dublin City University

Karnaugh map for P ′

Karnaugh map for Y

• A 2-Dimensional Karnaugh map can only be used for 4

• If the entire system is analysed there would be 8 inputs

Truth table for Power P ′

Karnaugh map for P ′

Truth Table for press actuation A′ - Using ”Don’t Care” states

Karnaugh map for press actuation A′ - Using ”Don’t Care” states

Potential issues with ”Dont’Care”

Always consider practicality of a ”Don’t Care” Assumption and

Truth table for press actuation A′ - Using fail safe approach

Karnaugh map for press actuation A′ - Using ”Don’t Care” states

00 01 11 10 A′ = P.L2 .A + P ′ .L1 .L2

Using the expression P ′ = S.(P + G)

A′ = S.(P + G).L2 .(A + L1 )

Substituting for S using the expression S = S1 + S2 + S3

A′ = S1 + S2 + S3 .(P + G).L2 .(A + L1 )

Logic Diagram - Panel switch with lock:

Panel switch with lock

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