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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
CHAPTER 15
Computer-Integrated
Manufacturing
Systems
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Computer-
IntegratedManufacturing
System
FIGURE 15.1 Aschematic illustration of acomputer-integrated
manufacturing system.Source: U. Rembold etal., Computer-Integrated
Manufacturing andEngineering, Addison-
Wesley, 1993.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Modeling for CAD
FIGURE 15.2 Various types of modeling for CAD.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Types of Splines
FIGURE 15.3 Types of splines. (a) A Bezier curve passes through the first and last controlpoint and generates a curve from the other points. Changing a control point modifies theentire curve. (b) A B-spline is constructed piecewise, so that changing a vertex affects thecurve only in the vicinity of the changed control point. (c) Third-order piecewise Beziercurve constructed through two adjacent control points, with two other control pointsdefining the curve slope at the end points. A third-order piecewise Bezier curve iscontinuous, but its slope may be discontinuous.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Boundary Representation of Solids
FIGURE 15.4 (a) Boundary representation of solids, showing the enclosing surfaces and
the generated solid model. (b) A solid model represented as compositions of solidprimitives. (c) Three representations of the same part be CAD. Source: P. Ranky.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Parametric Design
FIGURE 15.5 An example of parametric design. Dimensions of part features can be easily
modified to quickly obtain an updated solid model.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Octree Representation of a Solid Object
FIGURE 15.6 The octree representation of a solid object. Any volume can be broken downinto octants, which are then identified as solid, void, or partially filled. Shown is two-dimensional, or quadtree, version, for representation of shapes in a plane.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Skeleton Data Structure for Solid Objects
FIGURE 15.7 (a) Illustration of the skeleton data structure for solid objects. The skeleton isthe dashed line in the objects interior. (b) A skeleton model used for kinematic analysis of aclamp. Source: S. D. Lockhart and C. M. Johnson,Engineering Design Communication,
Prentice Hall, 2000, p. 299.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Simple Routing Sheet
FIGURE 15.8 An example of asimple routing sheet. These
operation sheets may include
additional information on
materials, tooling, estimated
time for each operation,processing parameters (such as
cutting speeds and feeds), and
other details. The routing sheet
travels with the part from
operation to operation. Thecurrent trend is to store all
relevant data in computers and
to affix to the part a bar code
that serves as a key into the
database of parts information.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Robotic Welding Station
FIGURE 15.9 Simulation ofa robotic welding station. A
collision has been detected
that production engineers
can rectify before building
the assembly line, therebyreducing development time
and cost. Source: Mechanical
Engineering, March 2001.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Grouping of Parts
FIGURE 15.10 Groupingparts according to theirgeometric similarities.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Machine Tools in a
Traditional Plant
FIGURE 15.11 Functional layout of
machine tools in a traditional plant.
Arrows indicate the flow of materialsand parts in various stages of
completion. (b) Group-technology
(cellular) layout. Legend: L= lathe; M=
milling machine; D= drilling machine;
G= Grinding machine; A= assembly.Source: M. P. Groover.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Decision-Tree Classification
FIGURE 15.12 Decision-tree classification for a sheet-metal bracket. Source: G. W. Millar.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Classification and Coding System
FIGURE 15.13
A classification
and coding
system using the
Opitz system,consisting of five
digits and a
supplementary
code of four
digits.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Multiclass Code for a Machined Part
FIGURE 15.14 Typical MultiClass code for a machined part. Source: Organization for
Industrial research.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
System for Rotational Components
FIGURE 15.15 The structure
of a KK-3 system for
rotational components. Source:
Japan Society for the
Promotion of MachineIndustry.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Flexible Manufacturing Cell
FIGURE 15.16Schematic view
of a flexible
manufacturing
cell, showing two
machine tools,and automated art
inspection
system, and a
central robot
serving thesemachines.
Source: P. K.
Wright.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Flexible Manufacturing System
FIGURE 15.17 Ageneral view of aflexiblemanufacturingsystem, showingseveral machinetools and anautomated guidedvehicle. Source:Courtesy ofCincinnati
Milacron, Inc.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Comparison of Transfer Lines and Flexible
Manufacturing SystemsCharacteristic Transfer line FMS
Types of parts made Generally few InfiniteLot size > 100 150Part changing time 1/2 to 8 hr 1 minTool change Manual AutomaticAdaptive control Difficult AvailableInventory High LowProduction during breakdown None PartialEfficiency 6070% 85%
J ustification for capital expenditure Simple Difficult
TABLE 15.1 Comparison of the characteristics of transfer lines and flexible manufacturing
systems.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Topology for a Local Area Network
FIGURE 15.18 Three basic types of topology for a local area network (LAN). (a) the startopology is suitable for situations that are not subject to frequent configuration changes. Allmessages pass through a central station. Telephone systems in office buildings usually have thistype of topology. (b) In the ring topology, all individual user station are connected in a continuousring. The message is forwarded from one station to the next until it reaches its assigned destination.Although the wiring is relatively simple, the failure of one station shuts down the entire network.
(c) In the bus topology, all stations have independent access to the bus. This system is reliable andis easier than the other two to service. Because its arrangement is similar to the layout of themachines in the factory, its installation is relatively easy, and it can be rearranged when themachines are rearranged.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Reference Model for Open Communication
FIGURE 15.19 The ISO/OSI reference model for open communication. Source: U.Rembold et al., Computer Integrated Manufacturing and Engineering, Addison-Wesley,
1993.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Expert System Structure
FIGURE 15.20 The basic structure ofan expert system. The knowledge base
consists of knowledge rules (general
information about the problem) and
inference rules (the way conclusions are
reached). The results may becommunicated to the user through the
natural-language interface. Source: K.
W. Goff, Mechanical Engineering,
October 1985.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Vision Guided Robot
FIGURE 15.21 Expert system as applied to an industrial robot guided by machine vision.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Solid Model of an Engine Compartment
FIGURE 15.22 Every vehiclecomponent, from body panels
to knobs on the instrument
panel, has a solid model
associated with it. Source:
Ford Motor Company.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Instrument-Panel Concept
FIGURE 15.23 A clay sculptor working on an instrument-panel concept. Source: Ford
Motor Company.
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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid
Prentice Hall, 2003
Flange and Fillet
FIGURE 15.24 First flange and fillet.