This document discusses different types of manufacturing systems. It describes manufacturing systems as consisting of production machines, material handling systems, computer control systems, and human resources. The document outlines different types of production machines based on level of automation, from manually operated to fully automated machines. It also discusses different types of manufacturing system layouts including single station cells, multi-station systems with fixed routing along an assembly line, and multi-station systems with variable routing to different workstations. The document provides examples and advantages of different manufacturing system configurations.
The document discusses manufacturing systems and lean manufacturing. It defines a manufacturing system as a collection of integrated equipment and human resources that perform processing and assembly operations on raw materials. It describes the typical input-transformation-output process. Examples of manufacturing systems include single station cells, machine clusters, and automated assembly lines. The key components of manufacturing systems are production machines, material handling systems, computer systems, and human resources. Lean manufacturing aims to eliminate waste from the manufacturing system, such as overproduction, waiting, inventory, transportation, and over-processing. It was pioneered by Toyota to increase efficiency and reduce costs.
Unit 3 Manufacturing Systems in automationrahulkatre9
This document provides an overview of single-station manufacturing cells. It discusses two types: single-station manned workstations where a worker operates or tends a single production machine, and single-station automated cells where a production machine can operate unattended for longer than one work cycle. Single-station cells are the most common and flexible manufacturing system due to their low cost and ease of implementation. Enablers for unattended operation include parts storage, automatic loading/unloading, and quick changeover capability for mixed model production.
Automation involves the use of technology and computers to automate production processes. There are different types of automation based on the level of flexibility, including fixed, programmable, and flexible automation. Flexible manufacturing systems (FMS) are highly automated systems that can produce different product varieties with minimal changeover time. An FMS uses a physical subsystem with workstations, material handling systems, and storage to process parts, along with a control subsystem. Common layout configurations for an FMS include line, loop, ladder, carousel, robot cell, and open field layouts. Benefits of FMS include reduced costs, lead times, and inventories, while limitations include high initial costs and need for skilled labor and pre-
The adjusted flow matrix is obtained as:
F = [[0, 40, 490, 250, 180],
[40, 0, 70, 200, 120],
[490, 70, 0, 280, 210],
[250, 200, 280, 0, 150],
[180, 120, 210, 150, 0]]
The heuristic algorithm provides the following sequence:
3 - 1 - 4 - 2 - 5
Hence, the recommended linear single row layout is:
3 1 4 2 5
This minimizes the total material handling cost by placing machines with highest flow between them closest. The clearance between machines must also be ensured as per the data provided.
The document describes three garment production systems: 1) Progressive Bundle System, where bundles of garment parts move sequentially between operations; 2) Unit Production System, which uses an overhead transport system to move individual garments between automated work stations; and 3) Modular Production System, where small teams of multi-skilled operators work together to complete full garments. The Modular Production System allows for flexibility, quick response times, and improved quality and teamwork compared to traditional bundle systems. It involves cross-trained workers organized into modules to collaboratively produce garments from start to finish.
Definition of Automation
Automated Manufacturing Systems
Types of Manufacturing Automation
Levels of Automation
Computerized Manufacturing Support Systems
Reasons for Automation
Automation Strategies-The USA Principle
Ten Strategies for Automation and Process Improvement
Automation Migration Strategy
Benefits of Automation
References
Concept of automation - mechanization and automation - Concept of automation in industry - mechanization and automation - classification, balancing of assembly line using available algorithms - Transfer line-monitoring system (TLMS) using Line Status - Line efficiency - Buffer stock Simulation in assembly line
advanced industrial automation and roboticsKunal mane
This document provides an overview of an advanced industrial automation and robotics course. It outlines the course prerequisites, outcomes, and covers topics like automated manufacturing systems, reasons for automating production, basic elements of automated systems, principles of automation, levels of automation, and classification of manufacturing systems. The key topics are automated manufacturing systems, basic elements of an automated system (power, program, control), and levels of automation (manual, semi-automated, automated).
The document discusses manufacturing systems and lean manufacturing. It defines a manufacturing system as a collection of integrated equipment and human resources that perform processing and assembly operations on raw materials. It describes the typical input-transformation-output process. Examples of manufacturing systems include single station cells, machine clusters, and automated assembly lines. The key components of manufacturing systems are production machines, material handling systems, computer systems, and human resources. Lean manufacturing aims to eliminate waste from the manufacturing system, such as overproduction, waiting, inventory, transportation, and over-processing. It was pioneered by Toyota to increase efficiency and reduce costs.
Unit 3 Manufacturing Systems in automationrahulkatre9
This document provides an overview of single-station manufacturing cells. It discusses two types: single-station manned workstations where a worker operates or tends a single production machine, and single-station automated cells where a production machine can operate unattended for longer than one work cycle. Single-station cells are the most common and flexible manufacturing system due to their low cost and ease of implementation. Enablers for unattended operation include parts storage, automatic loading/unloading, and quick changeover capability for mixed model production.
Automation involves the use of technology and computers to automate production processes. There are different types of automation based on the level of flexibility, including fixed, programmable, and flexible automation. Flexible manufacturing systems (FMS) are highly automated systems that can produce different product varieties with minimal changeover time. An FMS uses a physical subsystem with workstations, material handling systems, and storage to process parts, along with a control subsystem. Common layout configurations for an FMS include line, loop, ladder, carousel, robot cell, and open field layouts. Benefits of FMS include reduced costs, lead times, and inventories, while limitations include high initial costs and need for skilled labor and pre-
The adjusted flow matrix is obtained as:
F = [[0, 40, 490, 250, 180],
[40, 0, 70, 200, 120],
[490, 70, 0, 280, 210],
[250, 200, 280, 0, 150],
[180, 120, 210, 150, 0]]
The heuristic algorithm provides the following sequence:
3 - 1 - 4 - 2 - 5
Hence, the recommended linear single row layout is:
3 1 4 2 5
This minimizes the total material handling cost by placing machines with highest flow between them closest. The clearance between machines must also be ensured as per the data provided.
The document describes three garment production systems: 1) Progressive Bundle System, where bundles of garment parts move sequentially between operations; 2) Unit Production System, which uses an overhead transport system to move individual garments between automated work stations; and 3) Modular Production System, where small teams of multi-skilled operators work together to complete full garments. The Modular Production System allows for flexibility, quick response times, and improved quality and teamwork compared to traditional bundle systems. It involves cross-trained workers organized into modules to collaboratively produce garments from start to finish.
Definition of Automation
Automated Manufacturing Systems
Types of Manufacturing Automation
Levels of Automation
Computerized Manufacturing Support Systems
Reasons for Automation
Automation Strategies-The USA Principle
Ten Strategies for Automation and Process Improvement
Automation Migration Strategy
Benefits of Automation
References
Concept of automation - mechanization and automation - Concept of automation in industry - mechanization and automation - classification, balancing of assembly line using available algorithms - Transfer line-monitoring system (TLMS) using Line Status - Line efficiency - Buffer stock Simulation in assembly line
advanced industrial automation and roboticsKunal mane
This document provides an overview of an advanced industrial automation and robotics course. It outlines the course prerequisites, outcomes, and covers topics like automated manufacturing systems, reasons for automating production, basic elements of automated systems, principles of automation, levels of automation, and classification of manufacturing systems. The key topics are automated manufacturing systems, basic elements of an automated system (power, program, control), and levels of automation (manual, semi-automated, automated).
A flexible manufacturing system (FMS) uses numerically controlled machine tools connected by an automated material handling system and controlled by a central computer. An FMS can process multiple product styles simultaneously unlike an automated production line. It allows changes to production schedules to meet varying product demands. Key components of an FMS include workstations, an automated material handling system, computer control system, and human labor. Common FMS layouts are progressive, loop, ladder, open field, and robot-centered.
The document discusses different types of manufacturing systems. It defines a manufacturing system as a collection of integrated equipment and human resources that performs processing and/or assembly operations on raw materials or parts. There are several types of manufacturing systems classified based on factors like the type of operations, number of workstations, level of automation, and ability to handle product variety. Common types include single workstation systems, multiple workstation systems with variable or fixed routing between stations, and systems that are manually operated, semi-automated, or fully automated.
Process Selection and Facility layout.pptSandipanMaji3
This document discusses operations management processes including process selection, facility layout, and line balancing. There are five basic process types - job shop, batch, repetitive, continuous, and project - determined by required volume and variety. Facility layout objectives include efficient workflow and minimizing costs. Basic layout types are product, process, and combination. Line balancing aims to evenly distribute work tasks among stations to minimize idle time and maximize output. Key considerations for process design and layout include required output, standardization, automation, and worker specialization.
Cam 1 unit palanivendhan manufacturin systemspalanivendhan
This document discusses computer aided manufacturing. It defines manufacturing as the process of converting raw materials into products through design, material selection, and sequenced processes. It describes the types of manufacturing as continuous processes, mass production, and batch production. It also discusses trends in manufacturing like computer integrated manufacturing, lean manufacturing, and automation. Automation in manufacturing is classified as fixed, programmable, and flexible automation based on flexibility and production rates. Group technology is introduced as a manufacturing philosophy that groups similar parts into families to take advantage of their manufacturing similarities.
Top Storm group is extremely proud to introduce itself as an esteemed, Wholesale, exporters and manufacturers of apparels, textiles, hand madeup , handicraft, handloom, powerloom, brassware , home furnishing, accessories, fruits, pulp & juices and vegetables. We are also in the business of real state. Our one of the sister concerns, Buit Builders and Developers is engaged in construction and development sector. The group employs 200 people in its diversified sectors. Top Storm group began its journey from 1998 and is reputed names in the global market.We have expertise in the garment business as well as in the other businesses. Our ceaseless thrust for producing quality products has contributed excessively to our success.
This document provides an overview of flexible manufacturing systems (FMS). It discusses key components of automation including sensors, actuators, programmable logic controllers (PLCs), computer numerical control (CNC) machines, and industrial robots. It also describes various types of material handling equipment used in FMS like automated guided vehicles and conveyor systems. Traffic control and vehicle management are important aspects for coordinating the movement of automated vehicles within the manufacturing system.
Flowlines are the prevailing layout for high-volume manufacturing. There are several types of flowlines including synchronous transfer lines with integrated conveyors, and asynchronous flowlines using either push or pull control. Asynchronous transfer lines use discrete buffers between stations while KANBAN and CONWIP lines use pull control with target work-in-process levels to prevent congestion. Effective flowline design requires analyzing factors like throughput, cycle time, utilization, and the impact of operational variations and batching policies.
Digital manufacturing uses computer-based systems for product and process simulation, 3D visualization, and collaboration tools. This allows manufacturers to model processes virtually before physical implementation. As automation increases in plants, digital modeling and simulation optimize processes by analyzing machines, tooling, and materials. Key benefits include process optimization, seeing results before investment, and real-time analysis across manufacturing steps.
1. Automation is the use of control systems and information technologies to reduce human involvement in production processes. This involves integrating machines into self-governing systems.
2. A production system includes facilities, equipment, and procedures to accomplish manufacturing. Production systems can be categorized as job shop or mass production depending on quantity and variety.
3. Automation of manufacturing systems uses machines, robots, and computer-controlled equipment to perform production tasks. Computerization integrates all business and design functions.
An FMS is a highly automated manufacturing system consisting of CNC machine tools and an automated material handling system controlled by a distributed computer system. It is suited for mid-volume, mid-variety production between 5,000-75,000 parts per year. Advantages include increased efficiency and flexibility to process different part styles and respond to changing production needs. FMS can be classified based on the number of machines, level of flexibility, and type of operations performed.
A flexible manufacturing system (FMS) is an automated machine cell consisting of a group of processing workstations like CNC machine tools interconnected by an automated material handling and storage system and controlled by a distributed computer system. FMS allows manufacturers to produce a variety of different part styles simultaneously and adjust production mix in response to changing demand while maintaining good quality and low costs. It transfers workpieces between machining stations using automated equipment like conveyors.
This document discusses automated production lines, also called transfer lines or transfer machines. It provides three key points:
1. Automated production lines consist of multiple linked workstations that perform processing operations like machining on parts. Parts are transferred between stations by a mechanized material handling system.
2. Transfer lines are appropriate for high production demand of parts requiring multiple operations, with stable designs and long product lives. They provide benefits like low labor costs and high production rates.
3. Storage buffers between workstations can reduce the impact of breakdowns and allow production to continue. The effectiveness of buffers depends on their capacity, providing some protection even with small buffers but maximum benefits with unlimited capacity buffers.
Flexible manufacturing systems (FMS) provide the ability to produce a variety of parts at non-uniform rates with small batch sizes. An FMS consists of programmable machines interconnected by an automated material handling and storage system controlled by an integrated computer system. It is characterized by variety of products, small volumes, less lead time, high quality, and low cost. The core components of an FMS include the manufacturing system, tool handling/storage, material handling/storage, and computer control system. FMS offers benefits like flexibility, higher efficiency, reduced lead times and costs, and increased productivity.
Introduction ,FMS Equipment,FMS Layouts ,Analysis Methods for FMS,,advantages of fms,comparison of fms to conventional methods,applications.Benefits of fms.
Plant layout refers to the physical arrangement of equipment, machinery, workstations, and space in a manufacturing facility. The key types of layouts discussed are process layout, product layout, mixed layout, fixed layout, and group technology layout. Process layout groups similar processes together while product layout arranges machinery in a linear flow. Group technology layout clusters machines by part families to reduce setup times and material handling. Flexible manufacturing systems apply group technology and automation to allow production of different product styles simultaneously on the same system.
This document provides an introduction to flexible manufacturing systems (FMS). It defines an FMS as a highly automated manufacturing cell consisting of CNC machine tools and an automated material handling system controlled by a distributed computer system. An FMS is capable of processing different part styles simultaneously and adjusting production in response to demand changes. The document discusses what gives manufacturing systems flexibility, types of flexibility, components of an FMS including workstations, material handling systems, computer control, and human resources, and characteristics of single machine cells, flexible manufacturing cells, and flexible manufacturing systems.
This document discusses the automation of feed mill processes through a programmable logic control system. It describes the main components of an automated feed mill including material receiving, grinding, mixing, pelletizing, cooling and bagging. The automation provides benefits like increased efficiency and consistency while reducing costs. However, automated systems also require technical skills for maintenance and come with higher initial and maintenance costs compared to manual systems.
This document discusses different types of manufacturing systems. It defines a manufacturing system as a collection of integrated equipment and human resources that perform processing and/or assembly operations to transform raw materials into a finished product. Manufacturing systems involve input, transformation, and output processes. Key factors in selecting a manufacturing system include volume, capacity, flexibility, lead time, efficiency, and environmental impact. Examples of manufacturing systems provided include single station cells, machine clusters, manual assembly lines, automated transfer lines, and flexible manufacturing systems. Components of manufacturing systems are production machines, material handling systems, computer systems, and human resources. The document further classifies manufacturing systems as intermittent or continuous production systems based on whether production flows are started and stopped irregularly or operate
The document discusses various garment production systems including make through, progressive bundle, unit production, and modular production systems. It provides details on the operational principles, components, advantages, and disadvantages of each system. Project management tools like Gantt charts and software are also described which can help plan and schedule garment production. Finally, it concludes that the best system depends on factors like product type, company policies, and available resources.
The reason the FMS is called flexible is that it is capable of
processing a variety of different part styles simultaneously
at the various workstations, and the mix of part styles and
quantities of production can be adjusted in response to
changing demand patterns.
• The FMS is most suited for
the mid-variety, mid-volume
production range
Vehicle homologation is the process of approving a vehicle's components and systems to ensure safety, quality, and environmental standards before sale. In India, all vehicle components like lamps, mirrors, tires, and engines are tested. Then the fitting of components and various vehicle systems like braking and emissions are tested. Finally, a whole vehicle test is conducted to approve the vehicle for sale. The Automotive Research Association of India (ARAI) plays a key role in testing electric vehicles, batteries, motors, and chargers according to various AIS standards to ensure safety and performance. Standards are important for EVs to ensure safety as their use increases and provide quality and access to markets.
The document defines and describes the various types of brake systems used in automobiles. It discusses mechanical, disc, hydraulic, power-assisted, air, and hand brake systems. The hydraulic brake system is the most common, using fluid pressure to slow wheels. When the brake pedal is pressed, fluid pushes brake pads against a disc or drum, converting kinetic energy to heat and slowing the vehicle. Master cylinders control fluid pressure to wheel cylinders for balanced braking on all wheels. Power-assisted and air brakes use vacuum or compressed air to augment braking force. Hand brakes provide independent parking capability.
A flexible manufacturing system (FMS) uses numerically controlled machine tools connected by an automated material handling system and controlled by a central computer. An FMS can process multiple product styles simultaneously unlike an automated production line. It allows changes to production schedules to meet varying product demands. Key components of an FMS include workstations, an automated material handling system, computer control system, and human labor. Common FMS layouts are progressive, loop, ladder, open field, and robot-centered.
The document discusses different types of manufacturing systems. It defines a manufacturing system as a collection of integrated equipment and human resources that performs processing and/or assembly operations on raw materials or parts. There are several types of manufacturing systems classified based on factors like the type of operations, number of workstations, level of automation, and ability to handle product variety. Common types include single workstation systems, multiple workstation systems with variable or fixed routing between stations, and systems that are manually operated, semi-automated, or fully automated.
Process Selection and Facility layout.pptSandipanMaji3
This document discusses operations management processes including process selection, facility layout, and line balancing. There are five basic process types - job shop, batch, repetitive, continuous, and project - determined by required volume and variety. Facility layout objectives include efficient workflow and minimizing costs. Basic layout types are product, process, and combination. Line balancing aims to evenly distribute work tasks among stations to minimize idle time and maximize output. Key considerations for process design and layout include required output, standardization, automation, and worker specialization.
Cam 1 unit palanivendhan manufacturin systemspalanivendhan
This document discusses computer aided manufacturing. It defines manufacturing as the process of converting raw materials into products through design, material selection, and sequenced processes. It describes the types of manufacturing as continuous processes, mass production, and batch production. It also discusses trends in manufacturing like computer integrated manufacturing, lean manufacturing, and automation. Automation in manufacturing is classified as fixed, programmable, and flexible automation based on flexibility and production rates. Group technology is introduced as a manufacturing philosophy that groups similar parts into families to take advantage of their manufacturing similarities.
Top Storm group is extremely proud to introduce itself as an esteemed, Wholesale, exporters and manufacturers of apparels, textiles, hand madeup , handicraft, handloom, powerloom, brassware , home furnishing, accessories, fruits, pulp & juices and vegetables. We are also in the business of real state. Our one of the sister concerns, Buit Builders and Developers is engaged in construction and development sector. The group employs 200 people in its diversified sectors. Top Storm group began its journey from 1998 and is reputed names in the global market.We have expertise in the garment business as well as in the other businesses. Our ceaseless thrust for producing quality products has contributed excessively to our success.
This document provides an overview of flexible manufacturing systems (FMS). It discusses key components of automation including sensors, actuators, programmable logic controllers (PLCs), computer numerical control (CNC) machines, and industrial robots. It also describes various types of material handling equipment used in FMS like automated guided vehicles and conveyor systems. Traffic control and vehicle management are important aspects for coordinating the movement of automated vehicles within the manufacturing system.
Flowlines are the prevailing layout for high-volume manufacturing. There are several types of flowlines including synchronous transfer lines with integrated conveyors, and asynchronous flowlines using either push or pull control. Asynchronous transfer lines use discrete buffers between stations while KANBAN and CONWIP lines use pull control with target work-in-process levels to prevent congestion. Effective flowline design requires analyzing factors like throughput, cycle time, utilization, and the impact of operational variations and batching policies.
Digital manufacturing uses computer-based systems for product and process simulation, 3D visualization, and collaboration tools. This allows manufacturers to model processes virtually before physical implementation. As automation increases in plants, digital modeling and simulation optimize processes by analyzing machines, tooling, and materials. Key benefits include process optimization, seeing results before investment, and real-time analysis across manufacturing steps.
1. Automation is the use of control systems and information technologies to reduce human involvement in production processes. This involves integrating machines into self-governing systems.
2. A production system includes facilities, equipment, and procedures to accomplish manufacturing. Production systems can be categorized as job shop or mass production depending on quantity and variety.
3. Automation of manufacturing systems uses machines, robots, and computer-controlled equipment to perform production tasks. Computerization integrates all business and design functions.
An FMS is a highly automated manufacturing system consisting of CNC machine tools and an automated material handling system controlled by a distributed computer system. It is suited for mid-volume, mid-variety production between 5,000-75,000 parts per year. Advantages include increased efficiency and flexibility to process different part styles and respond to changing production needs. FMS can be classified based on the number of machines, level of flexibility, and type of operations performed.
A flexible manufacturing system (FMS) is an automated machine cell consisting of a group of processing workstations like CNC machine tools interconnected by an automated material handling and storage system and controlled by a distributed computer system. FMS allows manufacturers to produce a variety of different part styles simultaneously and adjust production mix in response to changing demand while maintaining good quality and low costs. It transfers workpieces between machining stations using automated equipment like conveyors.
This document discusses automated production lines, also called transfer lines or transfer machines. It provides three key points:
1. Automated production lines consist of multiple linked workstations that perform processing operations like machining on parts. Parts are transferred between stations by a mechanized material handling system.
2. Transfer lines are appropriate for high production demand of parts requiring multiple operations, with stable designs and long product lives. They provide benefits like low labor costs and high production rates.
3. Storage buffers between workstations can reduce the impact of breakdowns and allow production to continue. The effectiveness of buffers depends on their capacity, providing some protection even with small buffers but maximum benefits with unlimited capacity buffers.
Flexible manufacturing systems (FMS) provide the ability to produce a variety of parts at non-uniform rates with small batch sizes. An FMS consists of programmable machines interconnected by an automated material handling and storage system controlled by an integrated computer system. It is characterized by variety of products, small volumes, less lead time, high quality, and low cost. The core components of an FMS include the manufacturing system, tool handling/storage, material handling/storage, and computer control system. FMS offers benefits like flexibility, higher efficiency, reduced lead times and costs, and increased productivity.
Introduction ,FMS Equipment,FMS Layouts ,Analysis Methods for FMS,,advantages of fms,comparison of fms to conventional methods,applications.Benefits of fms.
Plant layout refers to the physical arrangement of equipment, machinery, workstations, and space in a manufacturing facility. The key types of layouts discussed are process layout, product layout, mixed layout, fixed layout, and group technology layout. Process layout groups similar processes together while product layout arranges machinery in a linear flow. Group technology layout clusters machines by part families to reduce setup times and material handling. Flexible manufacturing systems apply group technology and automation to allow production of different product styles simultaneously on the same system.
This document provides an introduction to flexible manufacturing systems (FMS). It defines an FMS as a highly automated manufacturing cell consisting of CNC machine tools and an automated material handling system controlled by a distributed computer system. An FMS is capable of processing different part styles simultaneously and adjusting production in response to demand changes. The document discusses what gives manufacturing systems flexibility, types of flexibility, components of an FMS including workstations, material handling systems, computer control, and human resources, and characteristics of single machine cells, flexible manufacturing cells, and flexible manufacturing systems.
This document discusses the automation of feed mill processes through a programmable logic control system. It describes the main components of an automated feed mill including material receiving, grinding, mixing, pelletizing, cooling and bagging. The automation provides benefits like increased efficiency and consistency while reducing costs. However, automated systems also require technical skills for maintenance and come with higher initial and maintenance costs compared to manual systems.
This document discusses different types of manufacturing systems. It defines a manufacturing system as a collection of integrated equipment and human resources that perform processing and/or assembly operations to transform raw materials into a finished product. Manufacturing systems involve input, transformation, and output processes. Key factors in selecting a manufacturing system include volume, capacity, flexibility, lead time, efficiency, and environmental impact. Examples of manufacturing systems provided include single station cells, machine clusters, manual assembly lines, automated transfer lines, and flexible manufacturing systems. Components of manufacturing systems are production machines, material handling systems, computer systems, and human resources. The document further classifies manufacturing systems as intermittent or continuous production systems based on whether production flows are started and stopped irregularly or operate
The document discusses various garment production systems including make through, progressive bundle, unit production, and modular production systems. It provides details on the operational principles, components, advantages, and disadvantages of each system. Project management tools like Gantt charts and software are also described which can help plan and schedule garment production. Finally, it concludes that the best system depends on factors like product type, company policies, and available resources.
The reason the FMS is called flexible is that it is capable of
processing a variety of different part styles simultaneously
at the various workstations, and the mix of part styles and
quantities of production can be adjusted in response to
changing demand patterns.
• The FMS is most suited for
the mid-variety, mid-volume
production range
Vehicle homologation is the process of approving a vehicle's components and systems to ensure safety, quality, and environmental standards before sale. In India, all vehicle components like lamps, mirrors, tires, and engines are tested. Then the fitting of components and various vehicle systems like braking and emissions are tested. Finally, a whole vehicle test is conducted to approve the vehicle for sale. The Automotive Research Association of India (ARAI) plays a key role in testing electric vehicles, batteries, motors, and chargers according to various AIS standards to ensure safety and performance. Standards are important for EVs to ensure safety as their use increases and provide quality and access to markets.
The document defines and describes the various types of brake systems used in automobiles. It discusses mechanical, disc, hydraulic, power-assisted, air, and hand brake systems. The hydraulic brake system is the most common, using fluid pressure to slow wheels. When the brake pedal is pressed, fluid pushes brake pads against a disc or drum, converting kinetic energy to heat and slowing the vehicle. Master cylinders control fluid pressure to wheel cylinders for balanced braking on all wheels. Power-assisted and air brakes use vacuum or compressed air to augment braking force. Hand brakes provide independent parking capability.
The document discusses different types of vehicle suspension systems. It describes how suspension systems like leaf springs, independent suspension, wishbone suspension, and air suspension work to isolate passengers from road vibrations and maintain vehicle stability. It also covers types of tires, factors that affect tire life, and the purpose of wheel alignment in directing the wheels for stability and smooth rolling.
The document provides an overview of electric vehicles including their history and development. It discusses the key components of EVs such as batteries, motors, and motor controllers. It also covers charging methods for electric vehicles including conductive, inductive, and battery swapping technologies. The document compares combustion engines with electric motors and outlines the environmental and economic benefits of electric vehicles.
This document discusses crystal structures, material properties, and deformation. It begins by examining common crystal structures like BCC, FCC, and HCP. It then reviews various material properties including physical, chemical, thermal, and mechanical. Finally, it analyzes different types of deformation mechanisms such as elastic/plastic deformation, slip/twinning, work hardening, and fracture modes.
Charging electric vehicles can be done through various methods like Level 1, Level 2, and DC fast charging. Level 1 uses a standard 120V outlet while Level 2 uses a 240V outlet, providing faster charging. DC fast charging uses direct current to charge over 80 miles of range in 30 minutes. Wireless charging systems allow charging through induction coils in static parking spots or while driving on special roadways. Battery swapping provides an alternative to charging by exchanging depleted batteries for fully charged ones. Vehicle-to-grid technology enables electric vehicles to export stored energy back to the power grid. Battery management systems monitor battery health and safety through functions like temperature regulation, voltage balancing between cells, and protection from overcharging.
The document discusses the history and development of electric vehicles. It begins with the pre-electric car age in the 1820s through early experimentation. The golden age from 1880-1920 saw improvements to batteries and motors leading to electric taxis. However, the 1920-1970 period was a dark age as oil became prevalent. Renewed interest has occurred since the 1970s due to environmental concerns. Issues like emissions, oil dependence, and global warming are reducing as electric vehicles grow in popularity. The document outlines the technology of electric vehicles and compares them to internal combustion engines.
The document discusses the key components and working principles of electric vehicle batteries and motors. It provides information on:
1) The main components of lithium-ion batteries used in EVs including the cathode, anode, electrolyte, and separator. It also discusses battery parameters like storage capacity, energy density, and cycle life.
2) The types of motors used in EVs like AC induction motors and brushed vs brushless DC motors. It provides a basic overview of how motors work using electromagnetic induction to convert electrical energy from batteries into mechanical energy.
3) The function of motor controllers to precisely control the motor based on driver input and convert battery power into vehicle motion using components like sensors and power electronics.
Brakes work by converting the kinetic energy of a moving vehicle into heat energy via friction. When the brake pedal is pressed, hydraulic pressure is applied to the brake pads or shoes, causing them to squeeze a disc or drum attached to the wheel. This slows the wheel's rotation through friction. Most modern vehicles have a hydraulic brake system where brake fluid in a master cylinder transfers pressure to disc brakes on the front wheels and sometimes drum brakes on the rear wheels. The brake system is designed with safety redundancies like dual hydraulic circuits to prevent total braking failure.
The document discusses the key components and classifications of automobile chassis. It describes how the chassis contains major parts like the frame, axles, steering system, suspension system and engine. It classifies chassis based on control type, engine placement, and number of wheels/driving wheels. The frame is the main structure that supports all other chassis components and the body. Different types of frames include conventional, semi-integral and integral frames. The document also provides a brief overview of the automobile body, its connection to the chassis, and how it is typically constructed from welded steel pressings.
The document discusses anti-lock braking systems (ABS). It provides an overview of ABS, including its history, components, principles of operation, types, and advancements like electronic stability control. ABS prevents wheel locking under heavy braking, allowing the driver to steer and maintain vehicle control. It modulates brake pressure to keep wheels rotating at an optimal slip rate for maximum braking force. ABS improves safety by reducing skidding and keeping vehicles stable during emergency stops on slippery surfaces.
This document lists and describes 6 types of metals: white cast iron, grey cast iron, malleable cast iron, chilled cast iron, nodular cast iron, and low carbon steel and medium carbon steel. It provides an overview of different metal alloys without going into detail about the specific properties or uses of each.
The document provides guidelines for preparing metal specimens for microscopic examination. Key steps include carefully selecting and cutting a representative sample, mounting it, grinding it with successively finer grit paper to create a flat surface, polishing it to remove scratches, and sometimes etching it to reveal microstructural features. Proper preparation helps facilitate clear examination and accurate interpretation of grain structure, phases, inclusions and other microscopic characteristics of the material.
The document discusses three main topics: crystal structure, material properties, and deformation. It provides in-depth information on crystal structures like BCC, FCC, and HCP. It describes various material properties including physical, chemical, thermal, and mechanical properties. It also discusses different types of deformation mechanisms like elastic and plastic deformation, slip and twinning, work hardening, and fracture behaviors.
Plastic deformation can occur through two main mechanisms in metals: slip and twinning. Slip occurs when one plane of atoms slides over another within the crystal structure. Twinning involves mirroring part of the atomic lattice next to the undeformed part. Cold working increases the strength and hardness of metals by obstructing the movement of dislocations through mechanisms like strain hardening. Annealing can be used to relieve stresses from cold working and modify mechanical properties by allowing recovery, recrystallization and grain growth processes. Hot working deforms metals above the recrystallization temperature to avoid strain hardening.
This document summarizes various material properties including physical, chemical, thermal, mechanical, optical, electrical, and magnetic properties. It describes key properties such as density, melting point, strength, conductivity, permeability, and more. For each property, it outlines what the property is, how it is measured or defined, and examples of factors that influence the property. The document also briefly summarizes the main internal components of electric vehicles such as the electric motor, inverter, drivetrain, batteries, and charging system.
Mechanical engineers play an important role in the design, manufacturing, and quality control of electric vehicles. Their responsibilities include designing mechanical parts like the vehicle body, chassis, suspension, and steering while considering factors like aerodynamics, loads on motors, and thermal management of batteries. They are also involved in simulation of crashes and heat transfer, manufacturing process optimization, and ensuring quality control. Mechatronics knowledge is useful for controller design and sensor/actuator automation. Materials engineering expertise helps with battery and powertrain component research and development using lightweight metals and composites. After gaining experience, mechanical engineers can work with EV companies or pursue higher education and research opportunities.
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1. Introduction
Manufacturing System
• Manufacturing systems consist of human workers, automation,
and various material handling technologies, configured in
ways that create specific manufacturing system typologies.
• Our focus in this unit is upon manufacturing systems that are
said to be automated, and so concentration will be put upon the
types of integrated equipment that is used and arranged in a
manufacturing cell.
2. Cont…
• This can range from production machines and tools, material
handling and work positioning devices, to the use of various
computer systems that facilitate automation in the production
environment.
• A manufacturing system is a collection of integrated
equipment and human resources, whose function is to perform
one or more processing and/or assembly operations on a
starting raw material, part, or set of parts.
3. Cont…
• The manufacturing system is where value-added work is
performed to parts and/or products.
• in system of production it is supported by:
• quality control,
• material handling,
• automation control.
4. Cont..
• Single station cell—one worker tends one production machine
that operates on semi-automatic cycle
• Machine cluster—one worker tends a group of semi-
automated machines
• Automated transfer line—production line consisting of a series
of automated workstations that perform processing operations
• Automated assembly system—performs a sequence of
automated or mechanized assembly operations
• Flexible manufacturing system (FMS)—a highly automated
machine cell that produces part or product families; often
consists of workstations comprising CNC machine tools
5. Components of Manufacturing
• A manufacturing system consists of the following components:
• production machines (plus tools, fixtures, and other related
hardware);
• A material handling system;
• a computer system to co-ordinate and/or control the preceding
components;
• human workers to operate and manage the system.
6. Production Machine
• Machines can be classified according to worker participation
in the task, as:
• manually-operated
• semi-automated
• fully automated.
7. Manual Operated Machine
• Controlled or supervised by a worker or operator,
there is a clear division of labour, whereby the
machine provides the power for the operation and the
worker provides the control.
• Conventional machine tools (such as lathes, milling
machines, drill presses etc.) fit this category.
• The worker must attend the machine continuously
during the work cycle.
9. Semi-automated machines
• This performs a portion of the work cycle under
programme control, and then a worker assumes
control for the remainder of the cycle.
• An example of a machine in this capacity is a CNC
lathe, where the CNC machine performs its
processing operation as per the programme, and then
the worker unloads and reloads the machine for the
next work cycle.
• The worker must attend the machine every cycle, but
need not be continuously present.
13. Material Handling
• For most processing and assembly operations the following
material handling actions can be distinguished:
• Loading work units at each station
• Positioning work units at the station
• Unloading work units from the station after processing
• Transporting work units between stations;
• Performing temporary storage, if necessary
14. Cont…..
• There are, in general, two types of work transport:
• fixed routing, and variable routing
• Fixed routing uses the same sequence of workstations to
process identical work units as they passed through the
system;
• whereas, with variable routing, work units are transported
through a variety of different station sequences to allow for
variable processing to be performed on transported work units
15.
16. Computer Control System
• Computer systems are an integral part of automated
manufacturing, as they are required to control fully-automated
and semi-automated equipment and participate in overall co-
ordination and management of the manufacturing system.
17. Cont..
• Computer functions utilised in automated manufacturing
include:
• The communication of instructions to workers
• The downloading of workpart programmes
• The control of the material handling system
• The scheduling of production
• The diagnosis of failures
• The monitoring of safety
• The maintenance of quality control
• The management of operations.
18. Human Resources
• Humans also have a role to play, even if it is only in a
supervisory capacity.
• In cases where humans perform some value-added work on
work units, the work done is called direct labour—that is,
physical labour that results in an increase in value of the
processed work unit.
• This generally includes direct work done on work units or
work done to control the machines that are processing the
workpart.
19. Cont….
• Human workers are also required to:
• manage and support the system as computer programmers;
• operate and direct computer activities;
• maintain and repair the automated manufacturing system,
20. Classification of manufacturing System
• Types of operations performed
• Number of workstations
• System layout
• Automation and manning level
• Product or part variety.
21. Types of operations performed
• Type of material processed
• Size or weight of the part or product
• Part or product complexity
• Part geometry
22. Number of Workstations
• The number of workstations in a manufacturing system exerts
a strong influence on the performance of the manufacturing
system, in terms of its workload capacity, production rate, and
reliability.
• As the number of workstations increases, the more work can
be performed by the system, which may translate into a higher
production rate
23. Cont…
• The use of multiple workstations can also produce a
synergistic benefit, when compared against single workstation
systems.
• The total amount of work performed on the part or product is
too complex to accomplish at a single workstation; instead the
task is divided among a multiple of stations, thus simplifying
the complexity of the task into simpler work elements.
24. Cont…
• However, the more workstations developed in a system
generally means that the system itself becomes more complex,
and harder to manage and maintain.
• The system consists of more workers, machines, and parts to
be handed.
• Reliability and maintenance problems also begin to surface on
a more frequent basis.
25. System Layout
• System configuration, or the layout of the manufacturing
system’s workstations, is also an important factor. This applies
mainly, of course, to systems with multiple workstations.
• Workstation layouts for fixed routing are usually arranged
linearly, as in a production line.
• variable routing layouts can have multiple configurations.
System layout is an important factor for the design of the
material handling system.
26. Automation and Manning Levels
• The level of automation deployed is an important
characteristic of the manufacturing system.
• Workstation machines may be manually-operated,
semiautomated, or fully-automated.
• This factor allows us to define the amount of time
that a human operator is required to be in attendance
at a workstation as the manning level (Mi) of the
workstation
27. Part or Product Variety
• This factor examines the manufacturing system’s flexibility for
dealing with variations in the parts or products it produces.
• Part or product variations that could occur in manufacturing
systems include:
• variations in type, or colour of plastic or moulded parts;
• variations in electronic components placed on circuit boards;
• variations in the size of printed circuit boards handled;
• variations in part geometry;
• variations in parts
30. Overview of the Classification Scheme
• single-station cells.
• multi-station systems with fixed routing.
• multi-station systems with variable routing.
32. Multi-station Systems with Fixed Routing
• Single workstations are widespread, but typically come in one
of two forms:
• manned workstations—where a worker is in attendance
continuously or for a portion of each work cycle
• automated stations—where worker attention is required less
frequently than the set work cycle.
• Both systems are used for assembly. Single-station cell
systems are popular because they are relatively inexpensive to
implement.
• They are highly flexible, and they are easy to convert to
automation when required
34. Multi-station Systems with Fixed Routing
• A multi-station system with fixed routing is
essentially a production line, which consists of a
series of workstations laid-out so that the part/product
moves from one station to the next, while a value-
adding work element is performed at each
workstation along the way.
36. A multiple-station system with variable routing
• is a group of workstations organised to achieve
some special purpose. It usually handles
medium-sized production quantities
37. Single-Station Automated Cells
• The single-station automated cell consists of a fully
automated machine that can operate unattended for a
time period longer than one machine cycle.
• The operator must load and unload the machine, and
otherwise tend it, but is not required to be at the
machine except periodically.
38. . Advantages of single-station automated cells
• Reduced labour costs
• Relatively inexpensive to implement and maintain.
• Production rates are higher than manned machines
39. Manual Assembly Lines
• A production line that consists of a sequence of
workstations where assembly tasks are performed by
human workers.
• Products are assembled as they move along the line.
• At each station a portion of the total work content is
performed on each unit
40. Manual Assembly Lines
• Work systems consisting of multiple workers
organized to produce a single product or a limited
range of products
• Assembly workers perform tasks at workstations
located along the line-of-flow of the product
41. Manual Assembly Lines
Factors favoring the use of assembly lines:
• High or medium demand for product
• Products are similar or identical
• Total work content can be divided into work elements
• To automate assembly tasks is impossible
42. Why Assembly Lines are Productive
Specialization of labor
• When a large job is divided into small tasks and each
task is assigned to one worker, the worker becomes
highly proficient at performing the single task
Interchangeable parts
• Each component is manufactured to sufficiently close
tolerances that any part of a certain type can be
selected at random for assembly with its mating
component.
43. Cont…
• Base parts are launched onto the beginning of the line
at regular intervals (cycle time)
• Workers add components to progressively build the
product
44. Assembly workstation:
• A designated location along the work flow path at
which one or more work elements are performed by
one or more workers
45. Assembly Workstation
• A designated location along the work flow path at
which one or more work elements are performed by
one or more workers